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.

Description

This application is a continuation of International patent application No. PCT/US2003/028970, filed on Sep. 17, 2003 and designating the United States of America, which claims the benefit of U.S. Provisional patent applications Ser. No. 60/411,302, filed Sep. 17, 2002, and Ser. No. 60/446,222, filed Feb. 10, 2003, the disclosures of all of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

In the past, a number of approaches have been taken to make fabrics both cleanable and liquid-resistant so as to be more useful in environments where liquid staining is likely to occur. Vinyl-coated fabrics have been most broadly accepted for these purposes due to relatively easy cleanability and fairly low cost. However, such vinyl-coated fabrics are typically rather stiff to the touch and thereby lack the desired appearance and feel for use in environments such as homes, restaurants, vehicles, and the like where pleasing tactile and visual perceptions by the user are considered important. Surface-laminated fabrics have been utilized to enhance the aesthetic characteristics of the fabrics, but due to the generally disjunctive adherence between the laminate film and the fabric itself, these products tend to peel, crack, and delaminate after long periods of use. Such laminated products also tend to be thick and to lack the generally desirable feel of standard upholstery products. Adherence of a liquid barrier film or coating to a fabric substrate is made all the more difficult when fluorochemical stain-resistant treatments are applied, since such compositions by their nature tend to repel an applied coating.

SUMMARY OF THE INVENTION

The present invention is directed to an improved composite material for use in applications such as furniture upholstery or mattress ticking, the improved material possessing desirable flexibility, cleanability, and fluid resistance properties. More particularly, the material of the invention is a multi-layered laminated composite comprising a first layer which defines an outer facing layer of a woven, knitted, or nonwoven fabric substrate, which is preferably (but not required to be) treated with a fluoropolymer or a fluorochemical stain-resistant agent (the “base fabric”); a second layer adjacent to the first layer, the second layer acting as a fluid barrier layer and comprising a thin waterproof film (the “polymeric fluid barrier material”); and a third layer spaced from the first layer by the second layer, the third layer serving as the backing (the “protective backing material”). A process for forming the fluid- and stain-resistant composite fabric material according to the present invention is also provided. The composite fabric material of the invention possesses both stain resistance (when the base fabric is treated with a fluoropolymer or a fluorochemical stain-resistant agent) and fluid barrier properties, both of which properties are durable. In one embodiment of the invention, the composite fabric material is, in addition, fire-retardant. The composite fabric material also exhibits a soft fabric hand as in traditional noncomposite upholstery fabric, where “soft fabric hand” is used herein to mean flexibility and/or lack of stiffness in the fabric itself. Optionally, the composite fabric material may further be treated with an antibacterial or antimicrobial substance, the resulting fabric exhibiting durable antibacterial/antimicrobial properties in addition to its other properties, without sacrificing a soft hand.

DETAILED DESCRIPTION OF THE INVENTION

As used herein and in the appended claims, “a” and “an” mean one or more, unless otherwise indicated.

A stain-resistant and fluid-barrier composite fabric material is provided wherein the material 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, to provide stain resistance and to also contribute to water repellency; a second layer of thin waterproof film, preferably polyethylene film, to provide the primary waterproof characteristics to the composite material; and a third or protective backing layer, to provide protection to the polyethylene film (which can easily be torn) during manufacturing and subsequent use of the composite material, such as for example as commercial upholstery material. By “laminated” is meant that the three layers are bonded together by adhesive means. The composite fabric material of the invention will be substantially water-proof; that is, it will generally be 90 cm minimum in a Suter test.

The base fabric of the first layer of the composite material of the invention may be chosen from woven, knitted or non-woven fabric and textile substrates, which substrates have preferably been treated with a fluoropolymer or a fluorochemical stain-resistant agent. Such base fabrics exhibit a greatly improved, durable water and soil repellency. By “durable water and soil repellency” is meant that the fabric will exhibit a repellency or resistance to water and oily soils even after multiple cleanings. By “greatly improved” is meant that the substrate will exhibit a repellency or resistance that is more durable after multiple cleanings than the repellency or resistance exhibited by a substrate treated with a prior art fluorinated polymer textile finish.

The fabric substrate of the base fabric of the first layer includes fibers, woven and non-woven fabrics derived from natural or synthetic fibers and blends of such fibers. They can comprise fibers in the form of continuous or discontinuous monofilaments, multifilaments, staple fibers, and yarns containing such filaments and/or fibers, and the like, which fibers can be of any desired composition. The fibers can be of natural, manmade, or synthetic origin. Mixtures of natural fibers and synthetic fibers can also be used. Included with the fibers can be non-fibrous elements, such as particulate fillers, binders, sizes, dyes, and the like. The fabrics and textiles of the first layer may be a sheet-like structure [woven (including jacquard woven for home furnishings fabrics) or non-woven, knitted (including weft inserted warp knits), tufted, or stitch-bonded] comprised of fibers or structural elements. Examples of natural fibers include cotton, wool, silk, jute, linen, and the like. Examples of manmade fibers derived primarily from natural sources include regenerated cellulose rayon, cellulose acetate, cellulose triacetate, and regenerated proteins. Examples of synthetic fibers include polyesters (including polyethyleneglycol terephthalate), polyamides (including nylon, such as Nylon 6 and 6.6), acrylics, olefins, aramids, azlons, modacrylics, novoloids, nytrils, spandex, vinyl polymers and copolymers, vinal, vinyon, vinylon, and the like, and hybrids of such fibers and polymers.

The fluoropolymer or the fluorochemical stain-resistant agent is applied to the fabric substrate prior to assembly of the multi-layer composite material, to give the base fabric of the first layer. In a presently preferred embodiment, the fluorochemical stain-resistant agent is chosen to provide durable water and soil repellency to the fabrics without the production of formaldehyde. More particularly, the fluorochemical preparations improve the oil and water repellency of a fluorinated polymer textile finish. In a preferred embodiment, the fluorochemical stain-resistant agent imparts desirable durable water and oil repellency to the fabrics treated therewith without adversely affecting other desirable properties of the substrate, such as soft hand (or feel). The preferred fluorochemical stain-resistant agents allow for binding to cotton and other fabrics.

A preferred fluorochemical stain-resistant agent preparation comprises, in a suitable solvent, a fluoropolymer, an extender, a wetting agent, and, optionally, other components such as a surfactant, an antioxidant, an anti-microbial, a softener, and/or other additives. In a presently preferred embodiment, the preparation comprises from about 0.5 wt % to about 10 wt % of fluoropolymer; from about 0.01 wt % to about 10 wt % of extender; and from about 0.001 wt % to 2 wt % of wetting agent. The solvent is preferably water.

By “fluorinated polymer” or “fluoropolymer” is meant that the polymer will contain some perfluorinated or partially fluorinated alkyl chains to impart water and oil repellency to coated objects. It has now been found that the stain-resistant agent formulation of the present invention improves the performance of several commercially available proprietary fluoropolymers including Nuva® DCP and Nuva® HCP (Clariant A G, Basel, Switzerland), Freepel® FX-1202 and Freepel® 1225 (BF Goodrich Specialty Chemicals, Charlotte, N.C.), Zonyl® 8787 and Zonyl® 8300 (Ciba Specialty Chemicals Chemicals, High Point, N.C.), Repearl® F-4210, Repearl® F-8040, and Repearl® F-35 (Mitsubishi International Corporation, NY, N.Y.), Unidyne® TG470, Unidyne® TG-571, Unidyne® TG-590, Unidyne® TG-591, Unidyne® TG-991 (Daikin America, Inc., Orangeburg, N.Y. In a presently preferred embodiment of the invention, the fluoropolymer is the commercially available proprietary fluoropolymer, Nuva® DCP (Clariant A G, Basel, Switzerland). The resulting final fluorochemical stain-resistant agent is preferably NANO-PEL™, a commercially available proprietary composition from Nano-Tex, LLC (Emeryville, Calif.). However, any fluoropolymer or fluorochemical stain-resistant agent may be used in the practice of the present invention.

The fluorochemical stain-resistant agent is applied as a solution or dispersion/emulsion to the fabric substrate by methods known in the art such as by soaking, spraying, dipping, fluid-flow, padding, and the like. Curing can take place either before or after the treated textile is removed from the solution and dried, although it is generally preferred that the cure occur after the drying step. The fabric substrate may then be rinsed in water to remove any excess catalyst and polymer and dried to give the durable water- and soil-repellent base fabrics for use in the present invention.

In applying the fluoropolymer or the fluorochemical stain-resistant agent composition to the fabric substrate to be treated, the pH range should be chosen to be compatible with the reactants. The process temperature can vary widely. However, the temperature should not be so high as to decompose the reactants or so low as to cause inhibition of the reaction or freezing of the solvent. Unless specified to the contrary, the processes described herein take place at atmospheric pressure over a temperature range from ambient temperature to an elevated temperature that is below the boiling point of the solvent used, preferably from about 10° C. to about 110° C., more preferably from about 20° C. to about 60° C., and most preferably at 20° C. Conveniently, the processes will be at ambient temperature. The process (cure) temperature can also vary widely, depending on the reactivity of the reactants. Unless specified to the contrary, the curing process described herein takes place at atmospheric pressure over a temperature range from about 110° C. to about 250° C. The time required for the processes herein will depend to a large extent on the temperature being used and the relative reactivities of the starting fibrous substrate and water-repellent polymeric preparation. Therefore, the time of exposure of the textile to the catalyst and the polymers in solution can vary greatly, for example from about a few seconds to about two hours. Normally, the exposure time will be from a few seconds to ten minutes. Unless otherwise specified, the process times and conditions are intended to be approximate.

In one embodiment of the invention, an antibacterial and/or antimicrobial substance (encompassed herein under the term “antimicrobial”) is applied to the base fabric of the first layer of the composite material of the invention. The antimicrobial may be applied to the substrate of the base fabric prior to treatment with a fluorochemical stain-resistant agent, or the antimicrobial may be combined into and applied in conjunction with the fluorochemical stain-resistant agent. In a presently preferred embodiment, the antimicrobial substance is applied both prior to and together with the fluorochemical stain-resistant agent. Such base fabrics exhibit greatly improved, durable antimicrobial properties. By “durable antimicrobial properties” is meant that the fabric will exhibit antimicrobial activity even after multiple launderings. The total amount of antimicrobial substance on the base fabric is from about 0.01% to 5.0% of the weight of the base fabric, preferably from about 0.1 to about 2% of the weight of the fabric, and more preferably from about 0.19% to about 1.15% of the weight of the fabric.

When applied to the base fabric substrate prior to treatment with a fluorochemical stain-resistant agent, the antimicrobial substance may be applied to the fibers from which the fabric is woven, knitted or constructed, or it may be applied to the finished fabric. Preferably, the antimicrobial substance is applied to the fibers prior to weaving. More preferably, it is applied to warp yarns on a slasher or warper or similar coating or finish application device before the warp ends are rolled up onto a loom or section beam. The warp yarns are then woven with fill yarns (which fill yarns are not treated with the antimicrobial) into the base fabric, following the procedures described in U.S. Pat. No. 6,430,789, the disclosure of which is incorporated herein by reference.

When applied to the base fabric in conjunction with a fluorochemical stain-resistant agent, the antimicrobial substance is conveniently added to the stain-resistant agent preparation prior to application onto the fabric substrate. The amount of antimicrobial added to the stain-resistant agent is generally from about 0.1 wt % to about 1.0 wt %, preferably from about 0.3 wt % to about 0.7 wt %.

The choice of antimicrobial agent depends on the type or types of odor-causing or textile fabric discoloring/degrading microbes encountered where the laminated composite material is used. The antimicrobial preferably has both bacterostatic and fungistatic properties and thus imparts to the finished material resistance to bacterial growth and fungal growth sufficient to inhibit the growth of mildew and associated deterioration and discoloration as well as inhibiting microbial odor development. Suitable antimicrobial compositions are available to the textile industry from various suppliers and are approved for use on textiles by the Environmental Protection Agency. Agents active against dust mites may also be considered, and are encompassed within the term “antimicrobial agent”.

The polymeric barrier material comprising the second layer of the laminated composite material of the invention is a thin waterproof film, which may be selected from but is not limited to polyethylenes, polyurethanes and polyamides. Polyethylenes are presently preferred. By “thin” is meant that the film will have a thickness of between about 1.8 mil and about 3.2 mil, preferably between about 2.0 mil and about 3.0 mil, more preferably about 2.2 mil. The weight of the film may range from about 44 grams/sq yd to about 74 grams/sq yd. The presently preferred polyethylene film is of 2.2 mil thickness and weighs 54.2 grams/sq yd. In a presently preferred embodiment, a suitable adhesive is integral with the thin waterproof film. By “integral with” is meant that the adhesive may be coated onto each face of the film for bonding the film to both the base fabric first layer and the protective backing third layer; or alternatively, and preferably, that the adhesive may be admixed into the film prior to extrusion of the film; or both. In other embodiments, the adhesive may be applied to the base and the barrier layers, for adhering the film to each. Combinations of these adhesive application methods are possible. In a presently preferred embodiment, the adhesive is ethyl vinyl acetate (EVA).

Because the barrier film is very thin, it is very light, pliable and soft, and it imparts these characteristics to the resulting laminated composite material. However, also because of its thinness, the barrier film tends to be fragile and can be easily torn during manufacturing and subsequent use. To alleviate this problem, the composite material of the invention further comprises a third or backing layer of a protective backing material. This protective material may be selected from any fabric, woven or non-woven, as long as it is capable of protecting the barrier film while allowing the final composite material to have a soft hand. In a presently preferred embodiment, the backing material is selected from polyesters. The protective backing material is preferably light and thin, thus also contributing to the soft hand of the resulting composite fabric material. In addition, because the backing material covers the polymeric barrier film, it further gives the composite material a more cloth-like feel. The backing material will normally have a weight of from about 15 grams/sq yd to about 35 grams/sq yd, but is not limited thereto.

In one-embodiment of the invention, the protective backing layer comprises a fire barrier material. In addition to protecting the fluid barrier film, the fire barrier backing material provides Cal TB 133 fire retardancy to the composite fabric. California Technical Bulletin 133 (CAL TB 133) is a full-scale fire test for a complete piece of furniture. The test is as follows: A finished piece of furniture is placed in a 10×12×8 foot fire chamber and tested by applying a gas flame for 80 seconds. Then measurements are taken for the rate and amount of heat generated, temperature of the testing room at ceiling and at 4 feet off floor while the furniture is burning. Measurements are also taken for smoke opacity at the ceiling and 4 feet off the floor, the amount of carbon monoxide generated and mass loss for one hour or until the fire is completely extinguished. There are two categories for passing: 1) A temperature increase of 200 F or greater at the ceiling thermocouple; A temperature increase of 50 F or greater at the 4 ft. thermocouple; Greater than 75% obscuration at the 4 ft. room smoke opacity monitor; Concentration of carbon monoxide in the room of greater than 1000 ppm for a continuous period of 5 minutes; A mass loss of 3 pounds or greater in the first 10 minutes of the test. 2) A maximum rate of heat release of 80 kW or greater; A total heat release of 25 MJ or greater in the first 10 minutes of the test; Greater than 75% obscuration at the 4 ft. room smoke opacity monitor; Concentration of carbon monoxide in the room of greater than 1000 ppm for a continuous period of 5 minutes. If any one of the criteria in either category 1 or category 2 is exceeded, that category has been failed. Passing either category 1 or category 2 means a successful test. When the backing material is a fire barrier material, the fire barrier backing material will normally have a weight of from about 100 grams/sq yd to about 175 grams/sq yd, but is not limited thereto.

In the practice of the present invention, a fabric substrate is treated with a polymer or a fluorochemical stain-resistant agent and is thereafter bonded to a polymeric barrier film, which in turn is bonded to a protective backing material to give a final laminated composite material that exhibits durable fluid- and stain-resistant properties and a soft fabric hand. Lamination techniques and equipment are well-known in the textiles art. In the process of the invention, a multi-layered composite is prepared by superposing the the three materials. That is, the treated fabric substrate is placed face-down on a conveyor belt, the polymeric barrier film is placed on the back of the fabric, and the barrier film is covered with a protective backing material. The conveyor transports the composite through a nip, an oven, then through a second nip. The completed composite is then allowed to cool. The oven temperature and dwell time in the oven will be chosen to be compatible with the particular materials used while providing sufficient bonding of the materials to form a durable laminated fabric composite material. Production laminators typically use infrared, electric, or gas-fired ovens, any of which are suitable for use in the process of this invention. Most laminating lines also include some sort of cooling section, usually cooling cans or an air knife to cool the composite after the lamination is complete. Production lamination speeds are usually 5 to 25 yards per minute, although any speed that gives the resulting composite material of this invention its desirable properties is suitable.

The stain-resistant and fluid-barrier laminated composite material of the invention is useful in environments where liquid staining is likely to occur. Thus, the present invention is further directed to products made from or upholstered in the laminated composite material. Such products include, but are not limited to, upholstered furniture, such as chairs and sofas; mattresses; coverings, such as tablecloths; draperies and curtains; and the like.

EXAMPLES

Test Procedures:

Suter Test

Samples of materials were tested for water resistance using the Hydrostatic Pressure Tester from Alfred Suter, test method AATCC 127, which is a low water entry pressure challenge. The test consists of forcing water against one side of a test piece, and observing the other side of the test piece for indications of water penetration through it.

The sample to be tested is clamped and sealed with a rubber gasket in a fixture that holds the test piece horizontally. The outer surface of the test piece faces downward and is open to the atmosphere, and to close observation by using a mirror to see the bottom of the sample. Air is removed from inside the fixture and pressure is applied to the inside surface of the test piece, over an area of 114 mm (4.5 inches) diameter, as water is forced against the test piece from the top. The water pressure on the test piece was increased at a rate of 10±0.5 mm/sec by a rising column of water. As the water column rises, pressure is increased on the surface of the sample. The units of measure are in centimeters. One psi is equal to every 70.4 cm the water column rises.

The outer surface of the test piece is watched closely for the appearance of water forced through the material. When three drops of water are observed on the surface, then the test is stopped and the water column height is recorded.

While there are no official standards for waterproofness in the U.S., 90 cm is generally accepted as the benchmark in the textiles industry.

Oil Repellency Test

In these tests, oil rating was carried out by AATCC Test Method 118-1983. The higher the number, the better the oil repellency.

Water Spray Test

In these tests, water repellency was tested using AATCC Test Method 22. A higher number indicates greater water repellency.

Long-Term Adhesion Tests

1. The Wyzenbeek Abrasion Resistance Test ASTM D3597, 30,000 double rubs, was used to determine long-term adhesion of the laminated layers of the composite material. Also used was the Colorfastness to Light Test AATCC 18-1993 Option A, 40 hours.

2. Test ASTM D751 was used to measure the bond strength of the polymeric water barrier film to the base fabric. The film layer is peeled from the back of the base fabric a few inches by hand. The film is then placed in one jaw of an Instron or similar machine. The base fabric is placed in the other jaw. The fabric specimens are 2 inches (5 cm) wide and approx. 10 inches (25 cm) long. The Instron pulls the adhesion apart for 3 inches (7.5 cm) at a speed of 12 in (30 cm) per minute. The maximum amount of force required to pull the adhesion apart is measured in ounces. Multiple samples are pulled in each fabric direction (machine (warp) and cross (fill)), and the results are averaged. The average pull strength should be 19 oz or higher.

Example 1

Base Fabric: Dyed 100% polyester flat-woven commercial upholstery fabric (H5868, Burlington Industries, Greensboro, N.C.) was treated with NANO-PEL™ water and soil repellent.

Polymeric barrier material: A five-layer composite polyethylene film extruded with and coated with ethyl vinyl acetate (EVA) adhesive (6314G, Hollingsworth & Vose, Floyd, Va.). The film is 2.2 mil (0.002 in.) thick, weighs 1.91 oz/sq. yd (65 g/sq. meter), and is pigmented white. It could, if desired, be dyed to any color.

Protective barrier material: A specialty low-melt polyester thermal-bonded non-woven (TR3109A, Hollingsworth & Vose). The nonwoven is 4.43 mil thick, weighs 0.53 oz/sq. yard (18 g/sq. meter), and has a machine direction strength of 1.84 oz. and a cross direction strength of 0.23 oz.

The base fabric was placed face-down on the conveyor belt of a Kannegiesser laminating machine. The polyethylene film was placed on the back of the fabric and covered with the non-woven. The conveyor transported the composite through an electric oven having a temperature of 255° F. (124° C.), a speed of 21 ft/min. (giving a dwell time of 17 sec. in the oven), and 6.2 bar pressure on the exit-end pad. The sample was then allowed to air cool.

The resulting composite fabric material was tested for waterproofness in the Suter test and scored 120 cm.

The composite material was tested for water/oil repellency with the following results: 5 oil rating, 100 spray rating.

Example 2

Base Fabric: Dyed 100% polyester velvet upholstery fabric (MONET™, BH Upholstery, Belgium) was treated with NANO-PEL™ water and soil repellent.

Polymeric barrier material: A-five-layer composite polyethylene film extruded with and coated with ethyl vinyl acetate (EVA) adhesive (6314G, Hollingsworth & Vose, Floyd, Va.). The film is 2.2 mil (0.002 in.) thick, weighs 1.91 oz/sq. yd (65 g/sq. meter), and is pigmented white. It could, if desired, be dyed to any color.

Protective barrier material: A specialty low-melt polyester thermal-bonded non-woven (TR3109A, Hollingsworth & Vose). The nonwoven is 4.43 mil thick, weighs 0.53 oz/sq. yard (18 g/sq. meter), and has a machine direction strength of 1.84 and a cross direction strength of 0.23.

Following the procedures of Example 1, the base fabric, adhesive-treated polyethylene film and polyester non-woven layers were bonded together to give a laminated fabric composite material.

The resulting material was tested for waterproofness, scoring 106 cm in the Suter test.

The composite material was tested for water/oil repellency with the following results: 5 oil rating, 100 spray rating.

Example 3

Following the procedures of Example 1, a 93% polyester/7% nylon upholstery base fabric (flat woven, 9.95 oz/sq. yd., “Milestone” style #37315, Burlington) treated with NANO-PEL™ repellent, a polyethylene film extruded with and coated with ethyl vinyl acetate (EVA) adhesive (2;2 mil, 6314G, Hollingsworth & Vose), and a polyester thermal-bonded non-woven protective barrier material (7809, Hollingsworth & Vose) were bonded to produce a laminated composite material The resulting material was tested for adhesion in the ASTM D751 test; the average pull strength in the machine direction was 20.74 oz and in the cross direction, 31.09 oz.

In like manner, a laminated composite material identical to the above, except that the base fabric is “Messenger” (93% polyester/7% nylon, flat woven, 9.85 oz/sq. yd., style #37325, Burlington) was prepared and tested for adhesion in the ASTM D751 test. The average pull strength in the machine direction was 22.61 oz and in the cross direction, 31.39 oz.

Example 4

Laminated composite material identical to each of the two materials in Example 3, except that the polyethylene film was 3.0 mil thick in each, were prepared and were tested for adhesion in the ASTM D751 test.

For the composite material made with the Milestone base fabric, the average pull strength in the machine direction was 29.54 oz and in the cross direction, 33.26 oz.

For the composite material made with the Messenger base fabric, the average pull strength in the machine direction was 44.00 oz and in the cross direction, 28.90 oz. During the testing, two of these fabric specimens tore apart when pulled in the machine direction and one specimen tore apart when pulled in the cross direction, while the bonds between the base fabric and the polyethylene layer remained intact in each of these specimens.

Example 5

A base fabric exhibiting antimicrobial activity was prepared as follows. The antimicrobial product Sanitized T 96-21, containing the active ingredient triclosan (known as either 2,4,4′-trichloro-2′-hydroxydiphenyl ether or 5-chloro-2-(2,4-dichlorophenoxy) phenol), was applied to 100% polyester warp yarns by slashing, following the procedure described in U.S. Pat. No. 6,430,789, the disclosure of which is incorporated herein by reference. The treated warp yarns were then woven with 100% polyester fill yarns to provide a polyester fabric. The amount of triclosan applied to the warp yarn ranged from 0.5% to 4.0% of the weight of the warp yarn, resulting in a range of 0.1% to 0.8% of triclosan on the weight of the woven fabric (P2600 4C commercial upholstery, top of bed and drapery fabric; Burlington Industries, Greensboro, N.C.). This base fabric was then treated with NANO-PEL™ water and soil repellent, to which was added Sanitized XTX antimicrobial, which also contains triclosan as the active ingredient. 0.5% antimicrobial was added to the NANO-PEL mix, resulting in an additional 0.14% to 0.35% antimicrobial on the weight of the fabric.

Following the procedures of Example 1, the antimicrobial-treated base fabric, adhesive-treated polyethylene film and polyester non-woven layers were bonded together to give a laminated fabric composite material.

A swatch of the above base fabric was evaluated for antimicrobial efficacy against Klebsiella pneumoniae (ATCC 4352) and Staphylococcus aureus (ATCC 6538) using AATCC Test Method 147. The treated material showed excellent resistance and good zones of inhibition to both microbes, as shown in Table 1:

	TABLE 1
	Microbe	Growth	Halo (mm)
	S. aureus	nil	6
	K. pneumoniae	nil	2

Example 6

A stain-resistant and fluid-barrier composite fabric exhibiting fire retardancy was prepared as follows. The NANO-PEL™ repellent-treated base fabric and adhesive-treated polyethylene film barrier material of Example 1 were, following the procedures of Example 1, bonded together with a fire retardant protective barrier material obtained from Hollingsworth & Vose. The fire barrier material is a non-woven fabric of 70% rayon/30% polyester with an intumescent back coating of acrylic and various fire retardant additives (4 oz/sq. yd (113 g/sq. yd) fabric, 1 oz/sq. yd (28 oz/sq. yd) intumescent coating).

A chair was upholstered with the resulting laminated fabric composite material and was tested for fire retardancy in the Cal TB 133 procedure. The upholstered chair passed the test.

Claims

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.