Thin film lamination delamination process to create very thin film on fabric

Abstract

A process for transferring a thin polymeric film to either woven or non-woven fabrics by first coextruding the thin polymeric film with a plastic support layer, then adhesively laminating the polymeric film to a fabric, followed by delaminating the support layer. The thin base layer remaining on the fabric imparts desired properties to the fabric while maintaining the soft feel, or drapeability, of the fabric, as opposed to lamination of thicker polymeric films to fabrics.

1 . A thin film lamination-delamination process comprising the steps of: 
 a) providing a plastic support layer having first and second surfaces;    b) applying at least one thin plastic base layer, having first and second surfaces, onto at least one surface of said support layer, with the first surface of said at least one thin base layer in contact with a surface of said support layer;    c) applying an adhesive layer onto the second surface of said second base layer;    d) attaching the base layer to a fabric via the adhesive layer; and    e) separating the support layer from the base layer, such that the base layer remains attached to the fabric.    
     
     
         2 . The process of  claim 1  further comprising conducting steps b) through e) on the second surface of said support layer.  
     
     
         3 . The process of  claim 1  wherein the adhesive bond strength between said base layer and said fabric is at least 3 times the interlayer bond strength between said base layer and said support layer.  
     
     
         4 . The process of  claim 1  wherein the interlayer bond strength between said base layer and said support layer is about 35 g/cm or less.  
     
     
         4 . The process of  claim 1  wherein said support layer comprises a material selected from the group consisting of polyolefins, polyamides, polyesters, polyvinyl chloride, ethylene vinyl acetate, cyclo olefin polymers, and blends thereof.  
     
     
         5 . The process of  claim 1  wherein said base layer comprises a polyethylene.  
     
     
         6 . The process of  claim 1  wherein said base layer comprises a polyamide.  
     
     
         7 . The process of  claim 1  wherein said base layer comprises a material selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polycarbonates, thermoplastic elastomers, high temperature polymers, and blends thereof.  
     
     
         8 . The process of  claim 1  further comprising metallizing said second surface of said base layer prior to applying said adhesive.  
     
     
         9 . The process of  claim 1  wherein said adhesive layer comprises a material selected from the group consisting of polyurethanes, epoxies, polyesters, acrylics, anhydride modified polyolefin and blends thereof.  
     
     
         10 . The process of  claim 1  wherein said fabric comprises a non-woven fabric.  
     
     
         11 . The process of  claim 1  wherein said base layer has a thickness of from about 1 μm to about 10 μm and said support layer has a thickness of from about 25 μm to about 50 μm.  
     
     
         12 . The process of  claim 1  wherein said base layer has a thickness of from about 4 μm to about 7 μm.  
     
     
         13 . The process of  claim 1  wherein said base layer is applied to said support layer by coextrusion.  
     
     
         14 . A multilayered film comprising: 
 a) a plastic support layer having first and second surfaces;    b) at least one thin plastic base layer, having first and second surfaces, on at least one of said surfaces of said support layer, with the first surface of said at least one thin base layer in contact with a surface of said support layer;    c) an adhesive layer on said second surface of said thin base layer; and    d) a fabric attached to said thin base layer via said adhesive layer.    
     
     
         15 . The multilayered film of  claim 14  further comprising an additional thin base layer on the second surface of the support layer, and an additional fabric attached to the second surface of the support layer via a second adhesive layer.  
     
     
         16 . The multilayered film of  claim 14  wherein the adhesive bond strength between said base layer and said fabric is at least 3 times the interlayer bond strength between said base layer and said support layer.  
     
     
         17 . The multilayered film of  claim 16  wherein the interlayer bond strength between said base layer and said support layer is about 35 g/cm or less.  
     
     
         18 . The multilayered film of  claim 14  wherein said support layer comprises a material selected from the group consisting of polyolefins, polyamides, polyesters, polyvinyl chloride, ethylene vinyl acetate, cyclo olefin polymers, and blends thereof.  
     
     
         19 . The multilayered film of  claim 14  wherein said base layer comprises a material selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes, polycarbonates, thermoplastic elastomers, high temperature polymers, and blends thereof  
     
     
         20 . The multilayered film of  claim 19  wherein said base layer comprises a polyethylene.  
     
     
         21 . The multilayered film of  claim 14  wherein said base layer has a metallized surface.  
     
     
         22 . The multilayered film of  claim 14  wherein said adhesive layer comprises a material selected from the group consisting of polyurethanes, epoxies, polyesters, acrylics, anhydride modified polyolefin and blends thereof.  
     
     
         23 . The multilayered film of  claim 14  wherein said fabric comprises a non-woven fabric.  
     
     
         24 . The multilayered film of  claim 14  wherein said base layer has a thickness of from about 1 μm to about 10 μm and said support layer has a thickness of from about 10 μm to about 80 μm.  
     
     
         25 . The multilayered film of  claim 14  wherein said base layer has a thickness of from about 4 μm to about 7 μm.  
     
     
         26 . A multilayered film comprising: 
 a) a fabric having a surface; and    b) a thin plastic base layer attached to the surface of said fabric; wherein said base layer has a thickness of from about 1 μm to about 10 μm, and wherein said thin base layer is adhesively attached to the fabric.    
     
     
         27 . A multilayered film produced by the process of  claim 1.