(1) Field of the Invention
The present invention relates to embossed vinyl membranes and their manufacture. The invention relates more particularly to embossed awnings that are backlit for business use.
(2) Prior Art
The majority of awnings used by businesses in the market place are either dyed acrylic fabric or vinyl. A weakness of cloth awnings is that they are water resistant, not waterproof, and fungus and mildew can penetrate into the interstices of the cloth and discolor the cloth. Many of the vinyl awnings are backlit (for instance, those used by Blockbuster Video and various pizza stores). Nearly all such vinyl awnings are smooth. The few vinyl awnings that are embossed are used strictly for front-lit applications, and the backside does not have the esthetic appeal of cloth, which is substantially similar in appearance on both sides. There is no known use of vinyl embossed awnings where both sides of the awnings look and feel exactly like cloth.
The invention is a textured waterproof membrane that is suitable for displays, awnings and other applications, where it is highly desired that the material looks like fabric, but has the weather, mold and mildew resistance, and an ease of cleaning that is only obtainable with certain polymeric membrane materials. The textured membrane is substantially a laminate, comprised of a flexible polymeric top layer having an embossed front side; a fabric layer; and a flexible polymeric bottom layer having a printed bottom side with a printed layer of ink. The laminate can be further comprised of: a coextensive adhesive, where the coextensive adhesive extends from the bottom layer through the fabric layer to the top layer. The coextensive adhesive bonds all the layers into a unified membrane. Generally speaking, if the membrane is extruded, then a coextensive adhesive is not needed to bond the top layer and the bottom layer. Additionally, the top layer is coated with a polymer having resistance to weathering, staining, and plasticizer, and the printed bottom layer has a coating to protect the printing, and provide additional resistance to weathering, staining, and plasticizer migration.
The printing and the embossing are selected to simulate cloth, in both appearance and feel, such that the membrane is visually, substantially indistinguishable from cloth. Typically, the simulated cloth mimics sailcloth or another woven cloth, where the cloth has historically been employed in outdoor applications. The top and bottom layers of the membrane can be comprised of any flexible polymeric material that can be laminated to, or through, the fabric. Exemplary polymeric materials are plasticized polyvinylchloride (PVC), polyurethane, polyester, polyamide, halogenated polyolefins, hydrogenated polyisoprene, hydrogenated polybutadiene, hydrogenated ethylene polybutadiene, hydrogenated styrene ethylene polybutadiene block copolymers, certain flexible grades of polyolefin, EVA, EVOH, certain grades of thermoplastic block copolymers, polycaprolactones, polyacrylates and the like compounded for color, weather resistance and flammability. The fabric layer is typically a reinforced fabric, preferably comprised of a polyester yarn, polyamide yarn, a polyimide yarn, a polyethylene yarn, an acrylic yarn, a glass yarn, an aramid yarn, a cotton yarn, and blends thereof, where the yarn is selected to impart a desired degree of reinforcement, flexibility and cost. The fabric layer is embedded in the laminated layers, and adds very little to the overall texture and appearance of the membrane. When the top and bottom layers are comprised of PVC, then the coextensive adhesive is preferably a PVC plastisol, which during processing is converted into a continuous PVC film by application of heat. When the top and bottom layers are comprised of polyurethane then the coextensive adhesive is preferably a curing urethane. The coextensive is selected to penetrate the fabric and to bond the top and bottom layers. The top and bottom layers can further more have tie coats, sometimes referred to as bond coats to improve the adhesion between the coextensive and top and bottom layers.
The membrane can be fitted with PSV (pressure sensitive vinyl) graphics or digitally inkjet printed for external decoration. In backlit applications, the top layer is clear or translucently colored, and the top layer is printed. If the printing covers the entire layer, then backlit graphics can be formed by eradicating the printed ink. The eradicated ink forms a graphic design, which when backlit is translucent. Application of a PSV can then optionally be added to change the color of the graphic, and still produce a backlit membrane.
The principal object of the present invention is to provide a textured membrane that has the look and feel of fabric.
Another object of this invention is to provide a waterproof material that has excellent weatherability, and resistance to staining, fungus, mildew and ultraviolet light.
Another object of this invention is to provide a textured material that has the strength, puncture resistance, and non-flammability to be suitable for an outdoor awning.
A further object of this invention is to provide a textured material that can be decorated using PS vinyl graphics, silk screen printing, digital printing, ink and templates, stitched graphics, graphics formed from the invented membrane, and free-hand painting.
The foregoing and other objects will become more readily apparent by referring to the following detailed description and the appended drawing in which:
The invention is a textured waterproof membrane 10 that is suitable for displays, awnings and other applications, where it is highly desired that the material looks like fabric, but has the weather, mold and mildew resistance, and cleanability that is only obtainable with certain polymeric membrane materials. The textured membrane 10 is substantially a laminate, and as shown in
Alternatively, as illustrated in
The invented textured and printed flexible membrane has a thickness of 2 to 50 mils, but preferably a thickness of 10 to 35 mils. The top layer of plasticized PVC contains a colorant to produce the desired color of the simulated cloth. If the membrane is to be used in backlit applications, then the color intensity is kept such that the top layer is translucent. The bottom layer is white or translucent vinyl, and can have a flame retardant package, such as antimony trioxide or brominated compounds, aluminum trihydrate, magnesium hydroxide, and the like incorporated therein. Both top and bottom layers typically contain heat stabilizers and PVC processing aids, and UV stabilizers for added protection.
The top layer of flexible polymeric material, PVC preferably, can have a protective topcoat 28 of a polymer having resistance to weathering, staining, and plasticizer migration, as illustrated in
The front of the membrane 10 can be fitted with graphics (lettering or design), such as a pressure sensitive vinyl (PSV) graphic.
The invented textured vinyl membrane has a composition, by weight percent, of:
In the following example the top layer comprises formulated PVC, having a plasticizer and UV stabilizers. Table 1 illustrates the properties of a typical awning material. The membrane is textured 16-ounce PVC composite without the intrinsic weaknesses of woven fabric. It is currently available in widths up to 76″, allowing for greater design flexibility and improved productivity during fabrication. It is easy to handle and durable throughout the fabrication process and it resists stretching and sagging.
The awning membrane of Table 1 is suitable for a variety of awning applications, including residential, retail, restaurant and hospitality, office buildings and other establishments. The textured waterproof membrane has stain-resistant properties not available in woven fabrics, yet the membrane looks like a woven cloth on both sides of the membrane.
The invented membrane offers excellent weatherability, resisting fungus and ultraviolet rays, and is digitally printable. In all applications, it keeps its new appearance with minimal care. It can meet fire specifications such as UL48 and UL94, California State Fire Marshal Title 19 Section 1237, NFPA 701 and/or ASTM E84. Cloth Awnings need to add a special flame resistant coating to pass these specifications.
From the foregoing, it is readily apparent that we have invented a reinforced vinyl membrane that has the look and feel of cloth, and yet still has the performance properties only achievable by certain filmic materials. The textured membrane has the strength of cloth, but unlike cloth which is water resistant, the membrane is waterproof, stain and fungus resistant, and has excellent weathering properties. The membrane can be decorated with graphics and fabricated using technology that is utilized for both cloth and vinyl materials. The cloth awnings can be dielectrically or thermally sealed when joining panels together. The membrane has a reinforced fabric that is selected to provide the level of strength suitable for awnings and other applications.
It is to be understood that the foregoing description and specific embodiments are merely illustrative of the best mode of the invention and the principles thereof, and that various modifications and additions may be made to the apparatus by those skilled in the art, without departing from the spirit and scope of this invention,
The application claims the benefit of the priority filing date of the Provisional Patent Application bearing Ser. No. 60/684,316, which was filed on May 25, 2005.
Number | Date | Country | |
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60684316 | May 2005 | US |