US 11,958,273 B2
Decorative nonwoven laminates
Kenneth Mitchell Whitesell, Jr., Troy, NC (US); Sean Bracken Simmons, Concord, NC (US); Ernest Franklin Wilson, Albemarle, NC (US); Tyler M. Heath, Mt. Gilead, NC (US); Timothy J. Allison, Marion, NC (US); and Eric Staudt, Fletcher, NC (US)
Assigned to AURIA SOLUTIONS UK I LTD., London (GB)
Filed by AURIA SOLUTIONS UK I LTD, London (GB)
Filed on Sep. 6, 2019, as Appl. No. 16/563,244.
Prior Publication US 2021/0070023 A1, Mar. 11, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. B32B 27/12 (2006.01); B32B 5/02 (2006.01); B32B 5/26 (2006.01); B32B 38/00 (2006.01)
CPC B32B 27/12 (2013.01) [B32B 5/022 (2013.01); B32B 5/26 (2013.01); B32B 38/145 (2013.01); B32B 2255/02 (2013.01); B32B 2451/00 (2013.01); B32B 2605/003 (2013.01)] 3 Claims
OG exemplary drawing
 
1. A decorative, nonwoven laminate, comprising:
a first side of a first nonwoven affixed to
a first side of a polymeric sheet,
wherein said first nonwoven has a thickness in the range of 0.1 mm to 1.8 mm and exhibits a basis weight of 50 g/m2 to 200 g/m2 and said polymeric sheet has a thickness in the range of 0.1 mm to 1.0 mm and an areal density in the range of 30 g/m2 to 1000 g/m2; and
a colorant selected from an ink, paint or pigment dye deposited on a second side of said first nonwoven at a thickness of 0.01 mm to 0.3 mm;
a polyurethane topical coating applied on said colorant and said second side of said first nonwoven at a thickness of 0.25 mm to 0.60 mm at a weight of 300 grams per square meter to 650 grams per square meter;
a second nonwoven affixed to a second side of said polymeric sheet, wherein said second nonwoven has a thickness of 0.1 mm to 12.0 mm and an areal density of 15 g/m2 to 1200 g/m2 characterized by the feature that said first nonwoven, said polymer sheet and said second nonwoven are attached together and said decorative nonwoven laminate has a three-dimensional geometry including projections or depressions;
wherein said laminate with said colorant has a minimum fade resistance ranking of 4 in a xenon test system at 225 kJ/m2 to 451 kJ/m2 as measured by ISO 105-A02/AATCC evaluation Procedure 1 and a Taber abrasion of 15,000 cycles using an H18 wheel and 1000 gm weight according to ASTM D3884 or SAE J1530 and said laminate with said three-dimensional geometry is an automotive vehicle interior component.