U.S. patent application number 17/324450 was filed with the patent office on 2021-11-25 for protective composite fabrics and methods of manufacture and use.
This patent application is currently assigned to Transhield, Inc.. The applicant listed for this patent is Transhield, Inc.. Invention is credited to Seckin Ozol, Na Qi, Gregory L. Todt.
Application Number | 20210362465 17/324450 |
Document ID | / |
Family ID | 1000005638665 |
Filed Date | 2021-11-25 |
United States Patent
Application |
20210362465 |
Kind Code |
A1 |
Ozol; Seckin ; et
al. |
November 25, 2021 |
PROTECTIVE COMPOSITE FABRICS AND METHODS OF MANUFACTURE AND USE
Abstract
A composite fabric includes a film, a first fibrous layer, a
fabric layer, and a second fibrous layer. The film has a first side
and a second side. The first fibrous layer has a first side
connected to the second side of the film and a second side. The
fabric layer has a first side connected to the second side of the
first fibrous layer and a second side. The second fibrous layer has
a first side connected to the second side of the fabric layer and a
second side. The film can be a non-heat shrinking film. The
composite fabric may also include one or more retaining members for
contacting a surface on which the composite fabric is placed and
resisting movement of the composite fabric relative to the
surface.
Inventors: |
Ozol; Seckin; (South Bend,
IN) ; Todt; Gregory L.; (Union, MI) ; Qi;
Na; (Granger, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Transhield, Inc. |
Elkhart |
IN |
US |
|
|
Assignee: |
Transhield, Inc.
Elkhart
IN
|
Family ID: |
1000005638665 |
Appl. No.: |
17/324450 |
Filed: |
May 19, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
63028814 |
May 22, 2020 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 7/12 20130101; B32B
2307/752 20130101; B32B 27/38 20130101; B32B 5/26 20130101; B32B
2307/71 20130101; B32B 3/16 20130101; B32B 27/12 20130101 |
International
Class: |
B32B 5/26 20060101
B32B005/26; B32B 3/16 20060101 B32B003/16; B32B 27/38 20060101
B32B027/38; B32B 27/12 20060101 B32B027/12; B32B 7/12 20060101
B32B007/12 |
Claims
1. A composite fabric, including: a film having a first side and a
second side; a first fibrous layer having a first side connected to
the second side of the film and a second side; a fabric layer
having a first side connected to the second side of the first
fibrous layer and a second side; a second fibrous layer having a
first side connected to the second side of the fabric layer and a
second side; and a plurality of retaining members for contacting a
surface on which the composite fabric is placed and resisting
movement of the composite fabric relative to the surface, the
retaining members connected to and extending from the second side
of the second fibrous layer.
2. The composite fabric of claim 1, wherein the film is a non-heat
shrinking film.
3. The composite fabric of claim 1, wherein the retaining members
include a corrosion inhibitor.
4. The composite fabric of claim 3, wherein the corrosion inhibitor
is a vapor corrosion inhibitor.
5. The composite fabric of claim 1, wherein the plurality of
retaining members form at least one pocket between one or more of
the plurality of retaining members, the second side of the second
fibrous layer, and the surface, and further including a vapor
corrosion inhibitor at least a portion of which collects in one or
more of the pockets.
6. The composite fabric of claim 1, wherein the retaining members
are constructed from epoxy.
7. The composite fabric of claim 1, wherein the retaining members
are constructed from polyurethane.
8. The composite fabric of claim 1, further including a pH
modifier.
9. The composite fabric of claim 1, further including an adhesive
between the film and the first fibrous layer.
10. The composite fabric of claim 9, further including a vapor
corrosion inhibitor in the adhesive.
11. The composite fabric of claim 9, wherein the adhesive adheres
the film to the first fibrous layer and the water saturated bond
strength adhesion between the film and the first fibrous layer in
the machine direction is at least 1,000 g/cm.
12. The composite fabric of claim 9, wherein the adhesive adheres
the film to the first fibrous layer and the water saturated bond
strength adhesion between the film and the first fibrous layer in
the cross direction is at least 1,000 g/cm.
13. The composite fabric of claim 1, wherein the film is a
multilayer film.
14. The composite fabric of claim 1, further including
electromagnetic shielding.
15. A composite fabric, including: a non-heat shrinking film having
a first side and a second side; a first fibrous layer having a
first side connected to the second side of the film and a second
side; a fabric layer having a first side connected to the second
side of the first fibrous layer and a second side; and a second
fibrous layer having a first side connected to the second side of
the fabric layer and a second side.
16. The composite fabric of claim 15, further including a plurality
of retaining members for contacting a surface on which the
composite fabric is placed and resisting movement of the composite
fabric relative to the surface, the retaining members connected to
and extending from the second side of the second fibrous layer.
17. The composite fabric of claim 16, wherein the retaining members
include a corrosion inhibitor.
18. The composite fabric of claim 17, wherein the corrosion
inhibitor is a vapor corrosion inhibitor.
19. The composite fabric of claim 16, wherein the plurality of
retaining members form at least one pocket between one or more of
the plurality of retaining members, the second side of the second
fibrous layer, and the surface, and further including a vapor
corrosion inhibitor at least a portion of which collects in one or
more of the pockets.
20. The composite fabric of claim 16, wherein the retaining members
are constructed from epoxy.
21. The composite fabric of claim 16, wherein the retaining members
are constructed from polyurethane.
22. The composite fabric of claim 15, further including a pH
modifier.
23. The composite fabric of claim 15, further including an adhesive
between the film and the first fibrous layer.
24. The composite fabric of claim 23, further including a vapor
corrosion inhibitor in the adhesive.
25. The composite fabric of claim 23, wherein the adhesive adheres
the film to the first fibrous layer and the water saturated bond
strength adhesion between the film and the first fibrous layer in
the machine direction is at least 1,000 g/cm.
26. The composite fabric of claim 23, wherein the adhesive adheres
the film to the first fibrous layer and the water saturated bond
strength adhesion between the film and the first fibrous layer in
the cross direction is at least 1,000 g/cm.
27. The composite fabric of claim 15, wherein the film is a
multilayer film.
28. The composite fabric of claim 15, further including
electromagnetic shielding.
29. A composite fabric, including: a first film having a first side
and a second side; a first fibrous layer having a first side
connected to the second side of the first film and a second side; a
fabric layer having a first side connected to the second side of
the first fibrous layer and a second side; a second fibrous layer
having a first side connected to the second side of the fabric
layer and a second side; a second film having a first side
connected to the second side of the second fibrous layer and a
second side; and a plurality of retaining members for contacting a
surface on which the composite fabric is placed and resisting
movement of the composite fabric relative to the surface, the
retaining members connected to and extending from the second side
of the second film.
30. A method of producing a composite fabric, including: providing
a film; connecting a first fibrous layer to the film; connecting a
fabric layer to the first fibrous layer; connecting a second
fibrous layer to the fabric layer; and forming a plurality of
retaining members on the second fibrous layer.
Description
[0001] This application claims priority to U.S. Provisional
application No. 63/028,814, filed on May 22, 2020.
[0002] The present invention relates to protective composite
fabrics and methods of manufacturing and using protective composite
fabrics.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] Protective fabrics and other constructs can be used to
prevent corrosion, scratches and other damage to surfaces and
objects that can result from contact with other objects, rain,
wind, sunlight, the elements and other sources of harm. Examples of
such fabrics and constructs are described in U.S. Pat. Nos.
6,696,120, 7,074,288, 8,828,487 and 8,883,284.
[0004] In one embodiment of the present invention, a composite
fabric includes a film, a first fibrous layer, a fabric layer, a
second fibrous layer, and a plurality of retaining members. The
film has a first side and a second side. The first fibrous layer
has a first side connected to the second side of the film and a
second side. The fabric layer has a first side connected to the
second side of the first fibrous layer and a second side. The
second fibrous layer has a first side connected to the second side
of the fabric layer and a second side. The retaining members are
connected to and extend from the second side of the second fibrous
layer. The retaining members are for contacting a surface on which
the composite fabric is placed and resisting movement of the
composite fabric relative to the surface.
[0005] In one embodiment, the film is a non-heat shrinking
film.
[0006] In other embodiments, the retaining members include a vapor
corrosion inhibitor. In certain embodiments, the retaining members
include a contact corrosion inhibitor.
[0007] In another embodiment, the plurality of retaining members
form at least one pocket between one or more of the plurality of
retaining members, the second side of the second fibrous layer, and
the surface, and the composite fabric includes a vapor corrosion
inhibitor, at least a portion of which collects in one or more of
the pockets.
[0008] In certain embodiments, the retaining members are
constructed from epoxy. In other embodiments, the retaining members
are constructed from polyurethane.
[0009] In another embodiment, the composite fabric further includes
a pH modifier.
[0010] In one embodiment, the composite fabric includes an adhesive
between the film and the first fibrous layer. In some embodiments
the composite fabric includes a vapor corrosion inhibitor in the
adhesive. In another embodiment, the adhesive adheres the film to
the first fibrous layer and the water saturated bond strength
adhesion between the film and the first fibrous layer in the
machine direction is at least 1,000 g/cm. In yet another
embodiment, the adhesive adheres the film to the first fibrous
layer and the water saturated bond strength adhesion between the
film and the first fibrous layer in the cross direction is at least
1,000 g/cm.
[0011] In one embodiment, the film is a multilayer film.
[0012] In another embodiment, the composite fabric includes
electromagnetic shielding.
[0013] In one embodiment of the present invention, a composite
fabric includes a non-heat shrinking film, a first fibrous layer, a
fabric layer, and a second fibrous layer. The film has a first side
and a second side. The first fibrous layer has a first side
connected to the second side of the film and a second side. The
fabric layer has a first side connected to the second side of the
first fibrous layer and a second side. The second fibrous layer has
a first side connected to the second side of the fabric layer and a
second side.
[0014] In one embodiment, the composite fabric includes a plurality
of retaining members connected to and extend from the second side
of the second fibrous layer. The retaining members are for
contacting a surface on which the composite fabric is placed and
resisting movement of the composite fabric relative to the
surface.
[0015] In other embodiments, the retaining members include a vapor
corrosion inhibitor. In certain embodiments, the retaining members
include a contact corrosion inhibitor.
[0016] In another embodiment, the plurality of retaining members
form at least one pocket between one or more of the plurality of
retaining members, the second side of the second fibrous layer, and
the surface, and the composite fabric includes a vapor corrosion
inhibitor, at least a portion of which collects in one or more of
the pockets.
[0017] In certain embodiments, the retaining members are
constructed from epoxy. In other embodiments, the retaining members
are constructed from polyurethane.
[0018] In another embodiment, the composite fabric further includes
a pH modifier.
[0019] In one embodiment, the composite fabric includes an adhesive
between the film and the first fibrous layer. In some embodiments
the composite fabric includes a vapor corrosion inhibitor in the
adhesive. In another embodiment, the adhesive adheres the film to
the first fibrous layer and the water saturated bond strength
adhesion between the film and the first fibrous layer in the
machine direction is at least 1,000 g/cm. In yet another
embodiment, the adhesive adheres the film to the first fibrous
layer and the water saturated bond strength adhesion between the
film and the first fibrous layer in the cross direction is at least
1,000 g/cm.
[0020] In one embodiment, the film is a multilayer film.
[0021] In another embodiment, the composite fabric includes
electromagnetic shielding.
[0022] In one embodiment of the present invention, a composite
fabric includes a first film, a first fibrous layer, a fabric
layer, a second fibrous layer, a second film, and a plurality of
retaining members. The first film has a first side and a second
side. The first fibrous layer has a first side connected to the
second side of the first film and a second side. The fabric layer
has a first side connected to the second side of the first fibrous
layer and a second side. The second fibrous layer has a first side
connected to the second side of the fabric layer and a second side.
The second film has a first side connected to the second side of
the second fibrous layer and a second side. The retaining members
are connected to and extend from the second side of the second film
layer. The retaining members are for contacting a surface on which
the composite fabric is placed and resisting movement of the
composite fabric relative to the surface.
[0023] In one embodiment of the present invention, a method of
producing a composite fabric includes providing a film, connecting
a first fibrous layer to the film, connecting a fabric layer to the
first fibrous layer, connecting a second fibrous layer to the
fabric layer, and forming a plurality of retaining members on the
second fibrous layer.
[0024] These and other features of the present invention will be
apparent to those of skill in the art from the following detailed
description of embodiments of the invention and the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a cross sectional view of a protective composite
fabric according to one embodiment of the present invention.
[0026] FIG. 2 is a partially exploded view of the protective
composite fabric shown in FIG. 1.
[0027] FIG. 3 is a side view of a vehicle with a protective cover
constructed from protective composite fabric according to one
embodiment of the present invention applied thereto and shown in
cross section.
[0028] FIG. 4 is a detail of area 4 in FIG. 3.
[0029] FIG. 5 is a cross sectional view of a protective composite
fabric according to another embodiment of the present
invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0030] FIG. 1 is a cross-sectional view of a protective composite
fabric 10 according to one embodiment of the present invention. In
the embodiment shown composite fabric 10 generally includes a film
20, adhesive 30, a first fibrous layer 40, a fabric layer 50, a
second fibrous layer 60 and a plurality of retaining members
70.
[0031] Film 20 in the embodiment shown includes a first layer 21, a
second layer 22, and a third layer 23. Film 20 is produced from a
non-heat shrinking thermoplastic material. In certain embodiments
of the invention, first layer 21 is a polyurethane film, and in
some embodiments, is a high yield strength, thermoplastic
polyurethane film. Examples of materials suitable for film 20 in
certain embodiments of the invention include, but are not limited
to, ESTANE.RTM. 58277 TPU available from Lubrizol Advanced
Materials, Inc. of Cleveland, Ohio. In the embodiment shown, second
layer 22 of film 20 is a polyurethane film. Second layer 22 can be
constructed from the same material as first layer 21 or from a
different material. Third layer 23 of film 20 in the embodiment
shown is also a polyurethane film. In certain embodiments, third
layer 23 is a high yield strength polyurethane film. In certain
embodiments, first layer 21 and third layer 23 are produced from
the same material. Film 20 may be produced, for example, by
coextruding first layer 21, second layer 22 and third layer 23
together. Film 20 can be produced by extruding cast film and and/or
blown film. In one embodiment of the present invention, first layer
21, second layer 22 and third layer 23 are coextruded to form film
20.
[0032] In certain embodiments of the invention, second layer 22 of
film 20 is thicker than first layer 21 and third layer 23. In one
embodiment, second layer 22 constitutes approximately 60% of the
total thickness of film 20 and first layer 21 and third layer 23
each constitute approximately 20% of the total thickness of film
20. In another embodiment, second layer 22 constitutes
approximately 70% of the total thickness of film 20 and first layer
21 and third layer 23 each constitute approximately 15% of the
total thickness of film 20.
[0033] First layer 21 and/or third layer 23 may optionally include
a pH modifier 24. Relatively higher pH levels (i.e., a more
alkaline environment) help prevent the growth of mold and mildew
and help protect metal surfaces from corrosion. In use, first layer
21 faces outward from the surface to be protected and inhibits mold
and mildew growth on the surface of covers or other constructs made
from composite fabric 10 and on fabric layer 50. Third layer 23
inhibits mold and mildew growth on fabric layer 50. In various
embodiments of the present invention, pH modifiers 24 are utilized
in an amount effective to produce a pH level between the composite
fabric 10 and the object being protected of between about 8 and
about 13. In certain embodiments of the invention, pH modifier 24
is selected to produce a pH of at least 8. Suitable pH modifiers 24
include, but are not limited to, sodium acetate, wollastonite,
calcium oxide and/or calcium hydroxide. pH modifiers 24 can be
added directly to the layers of film 20 or as a pH modifying
component in the form of a masterbatch including one or more pH
modifiers 24.
[0034] Film 20, in the embodiment shown, is an essentially
waterproof construct with a high water vapor transmission rate.
Film 20 thereby prevents liquid water from migrating through film
20 to the object protected by composite fabric 10, while at the
same time permitting moisture vapor to pass from near the object
through composite fabric 10. In certain embodiments of the
invention, the water vapor transmission rate of film 20 is from
about 50 g/m.sup.2/day to about 200 g/m.sup.2/day at 7.5 mils
thickness. In one embodiment, the water vapor transmission rate of
film 20 is at least 50 g/m.sup.2/day. Utilizing thinner films 20
can result in even greater water vapor transmission rates,
including water vapor transmission rate of at least 500
g/m.sup.2/day.
[0035] Adhesive 30 joins film 20 to first fibrous layer 40.
Adhesive 30 may be any adhesives sufficient to bond film 20 to
first fibrous layer 40 in a manner that prevents delamination and
unacceptable degradation of composite fabric 10 in use,
particularly in hot, humid and/or wet environments. Examples of
acceptable adhesives include, but are not limited to, polyurethane
adhesives and hot melt styrene ethylene butadiene styrene (SEBS)
adhesives. In one embodiment of the invention, AL1262 adhesive with
a vapor corrosion inhibitor ("VCI") is utilized. In another
embodiment of the invention, AL34-149-1 adhesive with VCI is
utilized. These adhesives can be obtained from Adherent
Laboratories, Inc. of St. Paul, Minn.
[0036] Various types of VCI's can be utilized in connection with
embodiments of the present invention. These VCI's can be amines,
nitrites, natrates, triazoles, and other volatile compounds.
Certain chemistries are more effective at inhibiting corrosion of
certain metals. For example benzotriazole is a more effective VCI
for copper, whereas cyclohexylamine carbonate is more effective for
use with steel. Non limiting examples of vapor corrosion inhibitors
useful in connection with embodiments of the present invention
include: primary, secondary and tertiary aliphatic amines;
aliphatic diamines; cycloaliphatic and aromatic amines;
polymethylimines; long chain ethanolamines; imidazolines; amine
salts, for example those of carbonic, carbamic, acetic, benzoic,
oleic, nitrous and chromic acids; acetylenic alcoauric alcohol;
alkyl chromates; organic esters of nitrous acid; organic esters of
phthalic acid; organic esters of carbonic acid; nitronaphthalene;
nitrobenzene; amides; mixtures of nitrites with urea, urotropine,
or ethanolamines; naphthols; thiourea derivatives; heterocyclic
compounds 65 such as benzotriazole, tolyltriazole, and
mercaptobenzothiazole and their respective salts; nitrated or
sulfonated petroleum derivatives; and organic acid derivatives.
[0037] First fibrous layer 40 in certain embodiments of the
invention is a spun-laced non-woven material. Acceptable materials
for first fibrous layer 40 can be natural or synthetic and include
organic and inorganic fibers and bioplastic materials. Examples
include, but are not limited to, cotton, viscose, rayon, acetate,
polyamid, nylon, polyester, acrylic, polyethylene terephthalate
("PET"), polypropylene ("PP"), polyethylene ("PE"), polylactic acid
("PLA"), polyurethane, glass and/or other fibers suitable for
producing spun-laced nonwoven material. In certain embodiments of
the invention, the staple fibers used to produce first fibrous
layer 40 are crimped staple fibers suitable for carding,
hydroentangling, and heat drying. Denier of the fibers utilized can
vary depending on the production method. In one embodiment of the
invention, the fibers have a denier of less than 3. In certain
embodiments, the fibers have a denier between 0.5 and 1.5. The
basis weight of first fibrous layer 40 can vary based on the
intended use of composite fabric 10. In one embodiment of the
invention, the basis weight of first fibrous layer 40 is between 10
g/m.sup.2 and 100 g/m.sup.2. In one embodiment of the invention,
the basis weight of first fibrous layer 40 is 25 g/m.sup.2.
[0038] Multiple samples were prepared to test the level of adhesion
between films 20 and first fibrous layers 40 according to
embodiments of the present invention. The samples were prepared by
applying an adhesive 30 to a film 20 and laminating film 20 to a
fibrous layer 40. One set of samples was prepared using AL34-149-1
adhesive ("Embodiment 1") and another set of samples was prepared
using AL1262 adhesive ("Embodiment 2"). Both adhesives included a
vapor corrosion inhibitor. The samples were prepared using the
following production specifications:
TABLE-US-00001 Adhesive Air Pressure Fibrous Hopper, Applied Air
Roller Film Layer Sample Amount of Line Hose and Adhesive Spray Nip
Material Material Width Adhesive Speed Head T Exiting Head T
Pressure Polyurethane Polyester 20.32 cm 30 g/m.sup.2 22.86 m/min
168.33.degree. C. 4.83 N/cm.sup.2 190.56.degree. C. 51.71
N/cm.sup.2
[0039] Because film 20 is produced from a non-heat shrinking
thermoplastic material, it will not distort when it comes into
contact with the hot adhesive.
[0040] The samples of the present invention were submerged in water
for 24 hours and their saturated bond strength adhesion was tested
by using a tensile testing machine and compared to their dry bond
strength adhesion. The same test was performed on a prior art
composite fabric product that utilizes a heat shrinkable film. The
average results for five samples of the prior art and five samples
of each of two embodiments of the present invention are set forth
in the table below, in which "MD" indicates adhesion in the machine
direction (i.e., along the length of the sample) and "CD" indicates
adhesion in the cross direction (i.e., across the width of the
sample). The adhesion results are reported in g/cm.
TABLE-US-00002 Prior Art Embodiment 1 Embodiment 2 MD CD MD CD MD
CD Dry Bond Strength 774.80 714.96 1,101.18 1,227.95 1,114.96
1,202.36 Adhesion Wet Bond Strength 24.80 15.75 1,220.87 1,427.95
1,198.03 1,188.58 Adhesion % Adhesion Loss or Gain -96.81% -97.82%
10.88% 16.27% 7.48% -1.15%
[0041] As shown in the table above, the bond strength adhesion of
the prior art product degraded considerably after soaking in water.
In contrast the bond strength adhesion of Embodiment 1 increased
significantly. Furthermore, the bond strength adhesion of
Embodiment 2 increased significantly in the machine direction and
showed only minimal degradation in the cross direction.
[0042] Fabric layer 50 may be joined to first fibrous layer 40 by a
hydroentanglement process, such as those used in known spunlaced
production methods. Unlike prior art devices that utilize a scrim,
fabric layer 50 is a continuous membrane of material. Fabric layer
50 is, in certain embodiments of the invention, a non-woven fabric
material. Examples of suitable fabric materials for fabric layer 50
include, but are not limited to, knitted fabrics and spunbond
fabrics made from polyamid, nylon, polypropylene, polyester,
polyamide, PLA and/or polyurethane. Fabric layer 50 in certain
embodiments of the invention includes vapor corrosion inhibitors
51. The VCI's discussed above in connection with adhesive 30 are
examples of VCI's suitable for incorporation into fabric layer
50.
[0043] Second fibrous layer 60 may be made from the same materials
and in the same manners as discussed above in connection with first
fibrous layer 40, and may have the same physical properties. In
certain embodiments of the invention, second fibrous layer 60 is
identical to first fibrous layer 40. In other embodiments of the
present invention, second fibrous 60 and first fibrous layer 40 are
different. Second fibrous layer 60 may be joined to fabric layer 50
by a hydroentanglement process.
[0044] As noted above, in certain embodiments of the invention,
first fibrous layer 40, fabric layer 50, and/or second fibrous
layer 60 may be constructed in whole or in part from PLA, such as
PLA that is produced from corn or another renewable resource.
Because PLA is biodegradable, composite fabrics 10 that include PLA
are environmentally friendly.
[0045] Retaining members 70, in the embodiment shown, are connected
to and extend from one side of second fibrous layer 60. Retaining
members 70 function to resist movement, including sliding movement,
of composite fabric 10 across the surface of the object being
protected by cover 10. Retaining members 70 are produced from a
material that will provide sufficient frictional engagement with
the surface of the object being protected by composite fabric 10.
In one embodiment of the invention, retaining members 70 are made
of polyurethane. In certain embodiments of the invention, retaining
members 70 are constructed from formulation FL2030 available from
Key Polymer Corporation of Lawrence, Mass. In other embodiments,
retaining members 70 are made from epoxy. Retaining members 70 may
be produced by utilizing a thermoset or a thermoplastic ink that is
printed onto second fibrous layer 60. The ink used to produce
retaining members 70 preferably has a viscosity of 30,000
centipoise or higher at ambient temperature, which assists
formation of raised retaining members 70. Certain samples of
embodiments of the present invention were partially produced at
Spectro Coating Corp. of Leominster. Mass. on equipment that primed
and dried retaining members 70 on second fibrous layer 60.
Retaining members 70 may be printed onto second fibrous layer 60
either before or after laminating to film 20.
[0046] Retaining members 70 may include corrosion inhibitors 71,
which may be VCI's or contact corrosion inhibitors. Contact
corrosion inhibitors resist metal corrosion via contact with the
metal. In embodiments of the invention that utilize corrosion
inhibitors 71, the ink used to produce retaining members 70 has a
pH of about 8 or higher, which results in better corrosion
inhibition. The VCI's discussed in connection with vapor corrosion
inhibitors 51 above are also suitable for use as corrosion
inhibitors 71. Corrosion inhibitors 71 need not be the same as
vapor corrosion inhibitors 51. If contact corrosion inhibitors are
used, they can be located on or near the outer surface of retaining
members 70.
[0047] Composite fabric 10 can be formed in any one of a number of
manners. In one embodiment of the invention, first fibrous layer
40, fabric layer 50, and second fibrous layer 60 are joined
together as, for example, by a hydroentanglement process as
described above. Retaining members 70 are then applied to second
fibrous layer 60, such as by printing as described above. Film 20
is then laminated to first fibrous layer 40 as described above.
Alternatively, first fibrous layer 40, fabric layer 50, and second
fibrous layer 60 are first joined together, followed by laminating
film 20 to first fibrous layer 40. Retaining members 70 are then
applied to second fibrous layer 60.
[0048] Composite fabric 10 can be formed into any desired
configuration. For example, as shown in FIG. 3, composite fabric 10
can be formed into a custom fit cover 100 that is specially
configured to protect a vehicle 110 having a surface 111. In use,
retaining members 70 contact surface 111 of vehicle 110 (FIG. 4),
thereby holding the remainder of cover 100 away from surface 111.
In this manner, should second fibrous layer 60 become wet,
retaining members 70 hold it away from surface 111, thereby keeping
surface 111 drier and resisting corrosion. This configuration also
creates pockets in which the VCI can collect. The pockets also
assist with evaporation of condensation. Retaining members 70 also
help secure cover 100 to vehicle 110, such as when high winds push
cover 100 toward or relative to vehicle 110 and the friction
between retaining members 70 and surface 111 resists movement of
cover 100. In certain embodiments of the invention, retaining
members 70 are capable of retaining cover 100 on vehicle 110 under
wind speed conditions of from about 119 km/h to about 252 km/h.
Furthermore, frictional heat generated by movement between
retaining members 70 and surface 111 will facilitate the release of
vapor corrosion inhibitors 71, which helps prevent corrosion of
vehicle 110 and surface 111. Over time, some of the vapor corrosion
inhibitors 51 will also migrate from fabric layer 50 toward surface
111 of vehicle 110 and help prevent corrosion.
[0049] FIG. 5 is a cross sectional view of a composite fabric 200
according to another embodiment of the present invention. Like the
embodiment of FIGS. 1 and 2, this embodiment includes film 20,
adhesive 30, first fibrous layer 40, fabric layer 50, second
fibrous layer 60, and retaining members 70. However, composite
fabric 200 also includes a second film 20A between second fibrous
layer 60 and retaining members 70. Second film 20A can be connected
to second fibrous layer 60 by a second adhesive 30A in the same
manner as described above for connecting film 20 to first fibrous
layer 40. Second film 20A can be constructed in the same manners
and from the same materials discussed above in connection with film
20. The pH modifiers 24 discussed above can also be utilized as pH
modifiers 24A in connection with second film 20A. Note, however,
that film 20 and film 20A (as well as pH modifiers 24 and 24A) of a
particular fabric 200 do not have to be constructed in the same
manner or from the same materials. Any of the adhesives discussed
above that are suitable for use as adhesive 30 are also suitable
for use as adhesive 30A. However, different adhesives can be used
as adhesive 30 and adhesive 30A in any given composite fabric 200.
In an another embodiment of the invention, retaining members 70 are
attached to both film 20 and second film 20A. Retaining members 70
may be printed onto film 20 and/or second film 20A either before or
after laminating the films to first fibrous layer 40 and second
fibrous layer 60.
[0050] Composite fabric 200 can be formed in any one of a number of
manners. In one embodiment of the invention, first fibrous layer
40, fabric layer 50, and second fibrous layer 60 are first joined
together, followed by laminating film 20 to first fibrous layer 40.
Retaining members 70 are then applied to second film 20A, which is
then laminated to second fibrous layer 60. Alternatively, first
fibrous layer 40, fabric layer 50, and second fibrous layer 60 are
first joined together, followed by laminating film 20 to first
fibrous layer 40 and laminating second film 20A to second fibrous
layer 60. Retaining members 70 are then connected to second film
20A.
[0051] In other embodiments of the invention, infrared ("IR")
shielding, radio frequency ("RF") shielding, electromagnetic pulse
("EMP") shielding, high-powered microwave ("HPM") shielding,
directed-energy weapons ("DEW") shielding, and/or electromagnetic
interference ("EMI") shielding can be incorporated into fabrics and
covers of the present invention. As used in this application, the
terms "electromagnetic shielding" and "EMI shielding" include all
of the forgoing types of shielding and all other types of shielding
designed to block, inhibit, reduce or otherwise disrupt infrared,
electronic, radio, microwave, static, magnetic and other similar
forms of interference. Shielding electronics and other sensitive
equipment from such interference helps isolate electrical devices
from the surroundings and may protect equipment from electronic
attacks, such as RFID virus attacks in which a malicious code is
inserted into an RFID tag to alter or corrupt data in an RFID
system or equipment.
[0052] EMI shielding can be incorporated into composite fabric 10
in a number of ways. For example, conductive modifiers, such as
carbon or metal, can be incorporated into one or more layers of
composite fabric 10 to lower the surface and volume resistivity of
the layers so that they can dissipate electrostatic charges and
attenuate electromagnetic signals. The shielding materials can be
incorporated into film, fibrous layers, fabric layer, and/or
retaining members of embodiments of the present invention. The EMI
shielding materials can be used to construct the film, fibrous
layers, fabric layer, and/or retaining members of composite fabric
10, can be incorporated as a component of those parts of composite
fabric 10, and/or can be applied to those parts of composite fabric
10 as a coating. In certain embodiments of the present invention,
EMI shielding material is incorporated into adhesive 30. In other
embodiments, a separate layer, such as a fabric layer with EMI
shielding functionality, is included in composite fabric 10 as an
additional layer.
[0053] For example, in certain embodiments of the present
invention, EMI shielding is provided by incorporating carbon
modifiers into components of the present invention in amounts of 5
to 25%. Carbon modifiers in the form of fibers can be derived from
polyacrylonitrile ("PAN"). In certain embodiments of the present
invention, PAN carbon fibers are incorporated in amounts up to 10%
by weight of composite fabric 10. EMI shielding values of 30 dB to
50 dB can be achieved by incorporating approximately 50% by weight
PAN carbon fibers into composite fabric 10. Microcarbon fibers may
achieve similar EMI shielding values at amounts as low as 3% by
weight of composite fabric 10. Other effective EMI shielding
materials include nickel coated carbon fibers, stainless steel
fibers (at levels of 5% to 10% by weight of composite fabric 10),
copper and aluminum.
[0054] In certain embodiments of the invention, EMI shielding
effectiveness of between about 1 dB and about 100 dB or more can be
achieved by utilizing different coatings that include aluminum,
silver, nickel, copper or combinations of these materials. The
coatings utilized can be solvent based or water based systems. One
embodiment of the invention utilizes a water based silver coating,
such as Series 599-Z6098-01 from PPG Industries, Inc. of
Pittsburgh, Pa. The coating may be applied to the surface of the
film, the surface of the fibrous layers, and/or the surface of the
fabric layer. It can also be used to coat the individual strands of
the fibrous and fabric layers. The coating system can also be added
to the retaining members, used to coat the retaining members,
and/or incorporated into the VCI system of the retaining
members.
[0055] In certain embodiments of the present invention, one or more
components of composite fabric 10 is constructed to form a Faraday
cage or Faraday shield. This construction is particularly useful
for blocking electromagnetic pulses, which can disrupt, degrade the
performance of, and/or damage electronic components.
[0056] Covers made from composite fabrics 10 of the present
invention can be manufactured by sewing, welding (such as, for
example, impulse bar welding, ultrasonic welding, and RFID welding)
and/or other methods. However, welded cover seams may result in
better EMI shielding capabilities.
[0057] Although the present invention has been shown and described
in detail, the same is by way of example only and should not be
taken as a limitation on the invention. Numerous modifications can
be made to the embodiments disclosed without departing from the
scope of the present invention. For example, the protective cover
can be formed into configurations other than those shown and
described and can be used to protect objects other than vehicles.
Also, vapor corrosion inhibitors could be incorporated into
adhesive 30. Other modifications and variations are also within the
scope of the invention.
* * * * *