Laminated composite material

Abstract

The invention is directed to a stain-resistant and fluid-barrier composite fabric material that exhibits a good hand while maintaining intimate adhesion between the base fabric and the polymeric barrier material. The laminated composite material comprises three layers, a first or outer layer comprising a base fabric; a second layer of a thin waterproof film to provide the primary waterproof characteristics to the composite material; and a third or protective backing layer, to provide protection to the thin film during manufacturing and subsequent use of the composite material, such as for example as upholstery fabric. The composite fabric material of the invention is substantially water-proof.

1 . A multi-layered laminated composite material comprising: 
 a first layer comprising a base fabric of a woven, knitted or nonwoven fabric substrate treated with a fluoropolymer or a fluorochemical stain-resistant agent;    a second or fluid barrier layer comprising a thin waterproof film; and    a third layer spaced from the first layer by the second layer and comprising a protective backing material;    wherein the laminated composite material exhibits flexibility, durable stain resistance and durable fluid barrier properties.    
     
     
         2 . A multi-layered laminated composite material according to  claim 1  wherein the base fabric is treated with a fluorochemical stain-resistant agent.  
     
     
         3 . A multi-layered laminated composite material according to  claim 1  wherein the thin waterproof film is selected from the group consisting of polyethylenes, polyurethanes and polyamides.  
     
     
         4 . A multi-layered laminated composite material according to  claim 3  wherein the thin waterproof film is a polyethylene.  
     
     
         5 . A multi-layered laminated composite material according to  claim 1  wherein the base fabric is further treated with an antimicrobial agent, the laminated composite material further exhibiting durable antimicrobial properties.  
     
     
         6 . A multi-layered laminated composite material according to  claim 1  wherein the protective backing material is a fire barrier material, the laminated composite material further exhibiting fire retardancy.  
     
     
         7 . A multi-layered laminated composite material according to  claim 1  wherein the base fabric is treated with a fluorochemical stain-resistant agent and the thin waterproof film is a polyethylene.  
     
     
         8 . A multi-layered laminated composite material according to  claim 7  wherein the base fabric is further treated with an antimicrobial agent, the laminated composite material further exhibiting durable antimicrobial properties.  
     
     
         9 . A multi-layered laminated composite material according to  claim 7  wherein the protective backing material is a fire barrier material, the laminated composite material further exhibiting fire retardancy.  
     
     
         10 . A product made from or upholstered in the multi-layered laminated composite material according to  claim 1 .  
     
     
         11 . A product according to  claim 10  which is upholstered furniture.  
     
     
         12 . A product according to  claim 10  which is a mattress.  
     
     
         13 . A process for preparing a multi-layered laminated composite material, the method comprising: 
 bonding a base fabric of a woven, knitted or nonwoven fabric substrate to a fluid barrier material comprising a thin waterproof film; and    bonding the fluid barrier material to a protective backing material;    wherein the laminated composite material exhibits flexibility and durable fluid barrier properties.    
     
     
         14 . A process according to  claim 13  which comprises the further step of treating the base fabric with a fluoropolymer or a fluorochemical stain-resistant agent prior to bonding the base fabric to the fluid barrier material, wherein the laminated composite material exhibits flexibility, durable stain resistance and durable fluid barrier properties.  
     
     
         15 . A process according to  claim 13  which comprises the further step of treating the base fabric with an antimicrobial agent prior to bonding the base fabric to the thin waterproof film, the laminated composite material further exhibiting durable antimicrobial properties.  
     
     
         16 . A process according to  claim 13  wherein the protective backing material is a fire barrier material, the laminated composite material further exhibiting fire retardancy.  
     
     
         17 . A process for preparing a multi-layered laminated composite material, the method comprising: 
 preparing a multi-layered composite by superposing a base fabric of a woven or knitted or nonwoven fabric substrate, a fluid barrier material comprising a thin waterproof film integral with an adhesive, and a protective backing material; and    laminating the multi-layered composite in a laminating machine;    wherein the laminated composite material exhibits flexibility and durable fluid barrier properties.    
     
     
         18 . A process according to  claim 17  which comprises the further step of treating the base fabric with a fluoropolymer or a fluorochemical stain-resistant agent prior to bonding the base fabric to the fluid barrier material, wherein the laminated composite material exhibits flexibility, durable stain resistance and durable fluid barrier properties.  
     
     
         19 . A process according to  claim 17  which comprises the further step of treating the base fabric with an antimicrobial agent prior to preparing the multi-layered composite, the laminated composite material further exhibiting durable antimicrobial properties.  
     
     
         20 . A process according to  claim 17  wherein the protective backing material is a fire barrier material, the laminated composite material further exhibiting fire retardancy.