Extendable Self-Supporting Material Composites and Manufacture Thereof

Abstract

Specific composite materials described herein are based on the discovery that certain selections of materials and manufacturing conditions and processes provide unexpectedly improved self-supporting thin-film composite materials. It has been discovered that certain combinations of backing materials, shrink film materials, and manufacturing conditions provide improved composites having highly controllable, readily repeatable, and stable arc shaped cross-web curled structures. In general, the composite materials described herein comprise a dimensionally alterable film such as a polyester shrink film having a first surface and a second surface, and a polyester backing material having a first surface and a second surface, wherein the second surface of the backing material is laminated to the first surface of the dimensionally alterable film. Upon activation of the alterable film, for example upon exposing the composite material comprising the polyester heat shrink film to heat, the composite material can be imparted with an arc shaped cross-web curled structure along it longitudinal width, resulting in resistance to bending in its axial length, and a self-supporting material.

What is claimed is: 
     
         1 . A method of reducing deformation of an article during webbing process manufacturing, comprising:
 attaching a stabilizing layer to the article such that the stabilizing layer provides stabilization against deformation caused by the webbing process, wherein the stabilizing lawyer comprises a self-supporting composite having an axial length and a longitudinal width, the composite comprising:   a backing having a first surface and a second surface;   a heat activated shrink film comprising a first surface and a second surface;   an adhesive disposed between the second surface of the backing and the first surface of the shrink film;   the shrink film being oriented within the composite wherein, upon activation, the shrink film contracts greater along the longitudinal width of the composite than the axial length; and the axial length of the composite has a curvature about the longitudinal width of the composite induced by heat activation of the shrink film, wherein the curvature is in the shape of an arc and which curvature imparts stiffness to the composite;   performing the webbing process with the article while the stabilizing layer is attached to the article.   
     
     
         2 . The method of  claim 1 , wherein the stabilizing layer is removed following the webbing process. 
     
     
         3 . The method of  claim 1 , wherein the backing is a polyester thin film. 
     
     
         4 . The method of  claim 1 , wherein the shrink film is a polyester shrink film. 
     
     
         5 . The method of  claim 1 , wherein the adhesive is a heat cure adhesive. 
     
     
         6 . The method of  claim 1 , wherein the adhesive is a polyurethane adhesive. 
     
     
         7 . A composition comprising an article prone to deformation attached to a stabilizing layer, wherein the stabilizing layer has an axial length and a longitudinal width comprising:
 a backing having a first surface and a second surface;   a heat activated shrink film comprising a first surface and a second surface;   an adhesive disposed between the second surface of the backing and the first surface of the shrink film;   the shrink film being oriented within the stabilizing layer wherein, upon activation, the shrink film contracts greater along the longitudinal width of the stabilizing layer than the axial length; and the axial length of the stabilizing layer has a curvature about the longitudinal width of the stabilizing layer induced by heat activation of the shrink film, wherein the curvature is in the shape of an arc and which curvature imparts stiffness to the stabilizing layer, and   wherein the stabilizing layer reduces deformation to the article prone to deformation.   
     
     
         8 . The article of  claim 7 , wherein the backing is a polyester thin film. 
     
     
         9 . The article of  claim 7 , wherein the shrink film is a polyester shrink film. 
     
     
         10 . The article of  claim 7 , wherein the adhesive is a heat cure adhesive. 
     
     
         11 . The article of  claim 7 , wherein the adhesive is a polyurethane adhesive. 
     
     
         12 . A cylindrical tubular container comprising a composite having an axial length with an opposing first side and second side, and a longitudinal width, the composite comprising:
 a backing having a first surface and a second surface;   a heat activated shrink film comprising a first surface and a second surface;   an adhesive disposed between the second surface of the backing and the first surface of the shrink film,   the shrink film being oriented within the composite wherein, upon activation, the shrink film contracts greater along the longitudinal width of the composite than the axial length; and the axial length of the composite has a curvature about the longitudinal width of the composite induced by heat activation of the shrink film, wherein the curvature is in the shape of an arc and which curvature imparts stiffness to the composite, wherein the composite when extended is self-supporting,   and wherein the opposing first side and second side of the axial length of the composite are joined and form a cylindrical tube having opposing open ends.   
     
     
         13 . The cylindrical tubular container of  claim 12 , wherein the opposing ends of the cylindrical tube are sealed. 
     
     
         14 . The cylindrical tubular container of  claim 12 , wherein one of the opposing ends of the cylindrical tube is adhered to an apparatus that serves as a bottom of the cylindrical tubular container. 
     
     
         15 . The cylindrical tubular container of  claim 12 , wherein the backing is a polyester thin film. 
     
     
         16 . The cylindrical tubular container of  claim 12 , wherein the shrink film is a polyester shrink film. 
     
     
         17 . The cylindrical tubular container of  claim 12 , wherein the adhesive is a heat cure adhesive. 
     
     
         18 . The cylindrical tubular container of  claim 12 , wherein the adhesive is a polyurethane adhesive. 
     
     
         19 . A method of manufacturing a cylindrical tubular container comprising:
 providing a self-supporting composite having an axial length with an opposing first side and second side, and a longitudinal width, the composite comprising:   a backing having a first surface and a second surface;   a heat activated shrink film comprising a first surface and a second surface;   an adhesive disposed between the second surface of the backing and the first surface of the shrink film,   the shrink film being oriented within the composite wherein, upon activation, the shrink film contracts greater along the longitudinal width of the composite than the axial length; and the axial length of the composite has a curvature about the longitudinal width of the composite induced by heat activation of the shrink film, wherein the curvature is in the shape of an arc and which curvature imparts stiffness to the composite, and wherein the composite when extended is self-supporting;   joining the opposing first side and second side of the axial length of the composite to form a cylindrical tube having opposing open ends.   
     
     
         20 . The method of  claim 19 , further comprising sealing the opposing ends of the cylindrical tube. 
     
     
         21 . The method of  claim 19 , further comprising adhering an apparatus that serves as a bottom of the cylindrical tubular container to one of the opposing ends of the cylindrical tube. 
     
     
         22 . The method of  claim 19 , wherein the backing is a polyester thin film. 
     
     
         23 . The method of  claim 19 , wherein the shrink film is a polyester shrink film. 
     
     
         24 . The method of  claim 19 , wherein the adhesive is a heat cure adhesive. 
     
     
         25 . The method of  claim 19 , wherein the adhesive is a polyurethane adhesive.