Textured surface articles and method of making

Abstract

An article having a textured surface and a method for manufacturing such an article is provided. The article comprises a polymeric layer coated on at least a portion of the article, a plurality of cavities formed in the polymeric layer, wherein each cavity in the plurality of cavities have a size between about 50 microns to about 2000 microns, and wherein a majority of the plurality of cavities have encircling perimeter ridges, and a plurality of channels formed in the polymeric layer between the encircling perimeter ridges.

1 . A textured polymeric layer having an outer surface comprising:
 a plurality of cavities, each cavity having a perimeter, wherein the perimeter of each cavity is defined by a ridge circumscribing substantially an entire perimeter of each cavity; and   a plurality of channels located between the ridges, wherein the cavities have interior cavity shapes of diameter in a range of about 50 microns to about 2000 microns.   
     
     
         2 . The layer of  claim 1 , wherein the polymeric layer is made from an unfoamed polymer, and wherein the ridges have substantially the same height measured from the base of the textured polymeric layer. 
     
     
         3 . The textured polymeric layer of  claim 1 , wherein the textured polymeric layer is disposed at least partially on another polymeric layer. 
     
     
         4 . The textured polymeric layer of  claim 1 , wherein the textured polymeric layer is disposed at least partially on fabric. 
     
     
         5 . The textured polymeric layer of  claim 4 , wherein the fabric is a knitted fabric. 
     
     
         6 . An article having a textured polymeric surface comprising:
 a polymeric layer coated on at least a portion of the article;   a plurality of cavities formed in the polymeric layer, wherein each cavity in the plurality of cavities have a size between about 50 microns to about 2000 microns, and wherein a majority of the plurality of cavities have encircling perimeter ridges; and   a plurality of channels formed in the polymeric layer between the encircling perimeter ridges.   
     
     
         7 . The article of  claim 6 , wherein the encircling perimeter ridges have substantially the same height relative to a base of the polymeric layer. 
     
     
         8 . The article of  claim 6 , wherein the polymeric layer comprises a foamed polymer. 
     
     
         9 . The article of  claim 6 , wherein the article is a fabric. 
     
     
         10 . The article of  claim 9 , wherein the fabric is a knitted fabric. 
     
     
         11 . A textured surface covering at least a portion of an article, the surface made by a process comprising:
 applying a coagulant to a portion of the article;   applying a foamed or an unfoamed polymer to the coagulant-applied portion of the article to form an ungelled layer of the foamed or the unfoamed polymer on the coagulant-applied portion;   applying particles of salt to the ungelled layer, wherein the particles of salt have a size between about 50 microns to about 2000 microns, and wherein the salt particles coagulate at least partially the ungelled layer where the salt particles contact the ungelled layer;   exposing the ungelled layer to a solvent for removing the particles of salt and at least some material from the ungelled layer between the particles of salt; and   curing the ungelled layer to form a textured surface comprising cavities that are reverse impressions of the salt particles and channels between the reverse impressions.   
     
     
         12 . The textured surface of  claim 11 , wherein exposing the ungelled layer to the solvent comprises washing the ungelled layer with the solvent, which removes the salt particles and the at least some material from the ungelled layer between the salt particles. 
     
     
         13 . The textured surface of  claim 11 , wherein the textured surface is disposed at least partially on another polymeric layer. 
     
     
         14 . The textured surface of  claim 11 , wherein the article is a fabric. 
     
     
         15 . The textured surface of  claim 14 , wherein the fabric is a knitted fabric.