(19) United States
`(2) Patent Application Publication (10) Pub. No.: US 2006/0252320 A1
`(43) Pub. Date:
`Nov. 9, 2006
`Panse
`
`US 20060252320A1
`
`(54) METHOD OF FORMING A PVC SCRIM
`FABRIC LAMINATE HAVING SUPERIOR
`SCUFF AND ABRASION RESISTANCE
`
`(75) Inventor: Dattatreya Ramesh Panse, Warwick,
`RI (US)
`
`Correspondence Address:
`DOUGHERTY CLEMENTS
`1901 ROXBOROUGH ROAD
`SUITE 300
`CHARLOTTE, NC 28211 (US)
`
`(73) Assignee: Cooley, Incorporated
`
`(21) Appl. No.:
`
`11/123,799
`
`(22) Filed:
`
`May 6, 2005
`
`Publication Classification
`
`(51) Int. Cl.
`(2006.01)
`B32B 27/12
`(2006.01)
`B32B 27/04
`(52) U.S. Cl. ................. 442/38; 442/43; 442/40; 442/49;
`442/148
`
`ABSTRACT
`(57)
`The invention is a laminate and a method for making the
`laminate, where the laminate has good scuff resistance, good
`abrasion resistance, good low temperature properties, and
`excellent resistance to delamination. The laminate is con
`structed of a polyurethane primer coated scrim fabric that is
`laminated to a cast extruded compounded PVC film. The
`film composition is predominately polyvinyl chloride
`(PVC), a thermoplastic polyurethane polymer (TPU), and a
`polytetrafluoroethylene micronized wax. The method for
`forming the laminate is a) providing a compounded PVC
`and a primer coated scrim fabric; b) extruding the com
`pounded PVC forming a cast extruded compounded PVC
`film; and c) laminating the compounded PVC film to the
`primer coated scrim fabric.
`
`Bestway Exhibit 1016-0001
`PGR2017-00003
`
`

`

`Patent Application Publication Nov. 9, 2006 Sheet 1 of 4
`
`US 2006/0252320 A1
`
`
`
`30
`
`
`
`FIG. I.
`
`FIG. 2
`
`Bestway Exhibit 1016-0002
`PGR2017-00003
`
`

`

`Patent Application Publication Nov. 9, 2006 Sheet 2 of 4
`
`US 2006/0252320 A1
`
`14
`
`
`
`
`
`\, ZZZZZZZZZ,
`44-444-4444.
`44-444-444-4
`
`FIG. 3
`
`18
`
`ZZZZZZZZZT
`4.4.4.4.4.4.4.4.4.
`444 ZZZZZZ.
`
`
`
`It
`
`30
`
`FIG. 4
`
`Bestway Exhibit 1016-0003
`PGR2017-00003
`
`

`

`Patent Application Publication Nov. 9, 2006 Sheet 3 of 4
`
`US 2006/0252320 A1
`
`
`
`12
`
`- - - - -
`
`Z ZZZZZZ C
`
`4.4.4.4.4.4.4.4.4.
`
`
`
`FIG. 6
`
`Bestway Exhibit 1016-0004
`PGR2017-00003
`
`

`

`Patent Application Publication Nov. 9, 2006 Sheet 4 of 4
`
`US 2006/0252320 A1
`
`
`
`12
`
`20
`
`18
`
`444 ZZZZZZ.
`A44444444 - 6
`
`FIG. 7
`
`Bestway Exhibit 1016-0005
`PGR2017-00003
`
`

`

`US 2006/0252320 A1
`
`Nov. 9, 2006
`
`METHOD OF FORMING A PVC SCRIM FABRIC
`LAMINATE HAVING SUPERIOR SCUFF AND
`ABRASION RESISTANCE
`
`BACKGROUND OF THE INVENTION
`[0001] 1. Field of the Invention
`[0002] The invention relates generally to extrusion-coated
`fabrics, and more particularly to a PVC coated scrim having
`excellent scuff and abrasion resistance.
`[0003] 2. Prior Art
`[0004] The prior art of laminates having scuff resistance
`includes the following patents. U.S. Pat. No. 6,066,601 to
`Steckel teaches a coating additive for a coating composition
`where the coating additive is a polytetrafluoroethylene. In
`Example 2 of column 20, lines 20–23, the coating compo
`sition contains a blend of polytetrafluoroethylene (PTFE) in
`a polyester resin/isocyanate curative powder coating formu
`lation. The assignee, Lubrizol, manufactures micronized
`PTFE waxes.
`[0005] U.S. Pat. No. 4,499,137 to O'Dell et al. teaches a
`scuff-resistant laminate. While the patent reads principally
`on polyethylene waxes, the specification states in column 4,
`lines 60-67, that there are times when other lubricants may
`be preferred, and specifically mentions micronized fluoro
`carbon polymers (tetrafluoroethylene) in fine particular size,
`such as SST-2 manufactured by Shamrock Chemicals, or
`Poly Fluo 190 by Micropowders.
`[0006] U.S. Pat. No. 4,194,041 to Gore et al teaches a
`waterproof laminate. Gore discloses a PTFE sheet (column
`9, line 41) and a polyurethane (column 4 lines 19–22). PVC
`is not taught.
`[0007] U.S. Publication No. 2004/0116022 to Langley et
`al. teaches a durable waterproof composite sheet material.
`The fabric can be made from natural or synthetic fibers, such
`as nylon, polyester, acrylic, acetate, rayon, polyamides,
`polypropylene, polyethylene, flame-resistant fibers includ
`ing PBI fibers, meta-aramides and para-aramides, such as
`Kevlar® and Nomex8), cotton, jute, hemp, ramie, and
`blends of one or more of the foregoing (column 3, lines 1-8).
`These materials have a coating of a polytetrafluoroethylene,
`as was described by Gore initially in U.S. Pat. No. 4,194,
`041. In the Background of the Invention, Langley et al. teach
`that PTFE can be combined with a thermoplastic polyure
`thane on a fabric to make a waterproof breathable material
`(paragraph 9, page 1). The TPU cited is Estane R, formerly
`a product of BF Goodrich, now produced by Noveon.
`Langley et al. further teach a durable waterproof composite
`sheet material. The fabric, paragraph 24, can be made from
`natural or synthetic fibers, such as nylon, polyester, acrylic,
`acetate, rayon, polyamides, polypropylene, polyethylene,
`flame-resistant fibers including PBI fibers, and meta-ara
`mides and para-aramides such as Kevlar.R and Nomex R,
`cottons, or jute.
`[0008] U.S. Pat. No. 6,742,545 to Fisher et al. teaches a
`method of hose construction. In column 5 in lines 22-26, the
`thermal plastic material can be a polyolefin, polyester, a
`fluoropolymer, polyvinyl chloride, thermoplastic rubber, or
`polyurethane, or a polyamide such as Nylon. In column 6.
`lines 65-28, the list is further expanded to include EPDMs,
`NBRs, SBRs, and blends of them. These materials are all
`extruded.
`
`[0009] A problem with laminates that are comprised of a
`flexible PVC thin film (e.g. less than 6 mils) laminated to an
`open scrim fabric is that the laminate exhibits poor scuff and
`abrasion resistance. Generally speaking, in order to achieve
`the desired flexibility the Durometer of the film is from 80
`to 90A. The laminate typically has an uneven profile causing
`wear to be exacerbated on the high spots, and the low
`Durometer aggravates the wear problem, as the friction is
`higher. Typically, high durometer (greater than 50 D) mate
`rials are used in applications where high scuff resistance is
`required but these materials are not flexible and do not
`posses good low temperature properties. The open scrims
`typically are woven from polyester or Nylon fibers because
`of their superior strength, and relatively modest cost for a
`relatively good weathering product. Unfortunately, polyester
`or Nylon fibers are also somewhat difficult to adhere to using
`a plasticized PVC, and combined with the previously enu
`merated problem of scuff and abrasion resistance, the lami
`nate is subject to delaminating. Poor adhesion between film
`and fabric in turn manifests itselfin inferior scuff resistance.
`What is needed is a laminate comprised of a PVC coated
`scrim that in addition to having good scuff resistance also
`has good abrasion resistance, good low temperature prop
`erties, and resistance to delamination.
`SUMMARY OF THE INVENTION
`[0010] The invention is a laminate and a method for
`making the laminate, where the laminate has good scuff
`resistance, good abrasion resistance, good low temperature
`properties, and excellent resistance to delamination. The
`laminate is comprised of a scrim fabric having a polyure
`thane primer coating; and a cast extruded compounded PVC
`film, wherein said cast extruded compounded PVC film is
`comprised of a thermoplastic polyvinyl chloride polymer
`(PVC), a thermoplastic polyurethane polymer (TPU), and a
`fluoroethylene polymer. The fluoroethylene polymer is pre
`dominately polytetrafluoroethylene (PTFE), in the form of a
`micronized wax. The micronized PTFE can be cut or
`blended. The TPU is selected to have a low glass transition
`temperature, from about -10° C. to about —80° C., and to
`have excellent abrasion resistance. The TPU is preferably a
`thermoplastic elastomer comprised of an oligomeric block
`that is an aliphatic polyester or polyether. The scrim fabric
`is preferably an open scrim with pick count ranging from
`9x9 to 22×22 picks per inch in warp and fill direction. The
`fabric can be either woven or knitted.
`[0011] The method for forming the laminate is comprised
`of the steps of: a) providing a compounded PVC, where said
`compounded PVC comprises a thermoplastic polyvinyl
`chloride polymer (PVC), a thermoplastic polyurethane poly
`mer (TPU), and a fluoroethylene polymer; b) extruding the
`compounded PVC forming a cast extruded compounded
`PVC film; and c) laminating the compounded PVC film to
`a scrim fabric having a polyurethane primer coating. The
`method for forming the laminate is preferably further com
`prised of the steps of; d) annealing the laminate in an oven
`to reduce curl and minimize anisotropic distortions in the
`laminate; e) cooling the laminate; and f) winding the
`annealed laminate into a roll and/or sheeting the annealed
`laminate. The scrim fabric having the polyurethane primer
`coating is preferably formed by dip coating the scrim fabric
`with a polyurethane primer coating; and then drying the
`polyurethane primer coating. The primer coating imparts
`dimensional stability to the scrim and chemical affinity
`
`Bestway Exhibit 1016-0006
`PGR2017-00003
`
`

`

`US 2006/0252320 A1
`
`Nov. 9, 2006
`
`between scrim fabric and the extruded compounded PVC
`film. The drying is not necessarily designed to fully cure the
`polyurethane primer coating, but merely to remove the
`volatile carrier (e.g., dispersing medium or solvent), leaving
`some reactive moieties on the scrim fabric. These reactive
`moieties can further improve the bond of the film to the
`scrim fabric. In the case where the polyurethane primer
`coating is an emulsion or dispersion in water, the preferred
`drying process is with an Infrared oven. The freshly primed
`scrim fabric can either be wound for use in the future, or, as
`a web, be in tandem with the extruder for lamination to the
`extruded compounded PVC film. Lamination can be effected
`by adhesively combining the extruded compounded PVC
`film with the primed coated scrim fabric or by, substantially
`simultaneously, casting the extruded compounded PVC film
`on a cold roll and, in a proximal nip, laminating the
`compounded PVC film to the primer coated scrim fabric. In
`the first case, where the lamination utilizes an adhesive, the
`adhesive extrudate is preferably a mixture comprised of
`PVC and TPU. In the latter case, generally a heavier coating
`of the cast compounded PVC extrudate is applied. In a
`variation on the method, the PVC film and adhesive extru
`date are coextruded and laminated to the primer coated
`scrim fabric. In another variation on the method, the lami
`nate is laminated with a second extruded compounded PVC
`film.
`[0012] In the broadest sense, the invention is a laminate
`and a method for making the laminate, where the laminate
`is comprised of a scrim fabric having a primer coating and
`a cast extruded compounded PVC film, where the cast
`extruded compounded PVC film is comprised of PVC, TPU,
`and a fluoroethylene polymer. The method is particularly
`suitable for open scrim fabrics comprised of Nylon and
`polyester, as these materials are historically difficult to
`adhere.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`[0013] The foregoing and other objects will become
`readily apparent by referring to the following detailed
`description and the appended drawings in which:
`[0014] FIG. 1 is a perspective view of the invented
`laminate 10 of a primer coated scrim fabric and a com
`pounded PVC film.
`[0015] FIG. 2 is an exploded view of laminate 10 shown
`in FIG. 1, illustrating the primer coated scrim fabric and the
`compounded PVC film.
`[0016] FIG. 3 is a perspective view of the primer coated
`scrim fabric of FIGS. 1 and 2.
`[0017] FIG. 4 is an exploded diagrammatic view of the
`primer coated scrim fabric shown in FIG. 3, wherein the
`primer coating and scrim fabric are differentially shown.
`[0018] FIG. 5 is a perspective view of the invented
`laminate 10' of a primer coated scrim fabric, an adhesive and
`a compounded PVC film.
`[0019] FIG. 6 is an exploded view of the laminate shown
`in FIG. 5, illustrating the primer coated scrim fabric, the
`adhesive and the compounded PVC film.
`[0020] FIG. 7 is an exploded diagrammatic view of the
`laminate shown in FIG. 5, illustrating the scrim fabric, the
`primer coat, the adhesive, and the compounded PVC film.
`
`DETAILED DESCRIPTION
`[0021] The invention is a laminate 10 and a method for
`making the laminate, where the laminate has good scuff
`resistance, good abrasion resistance, good low temperature
`properties, and excellent resistance to delamination. The
`laminate, shown in FIG. 1 and FIG. 2, is comprised of a
`primer coated scrim fabric 14 having a polyurethane primer
`coating, and a cast extruded compounded PVC film 12. The
`cast extruded compounded PVC film 12 is comprised of a
`thermoplastic polyvinyl chloride polymer (PVC), a thermo
`plastic polyurethane polymer (TPU), and a fluoroethylene
`polymer, which is substantially polytetrafluoroethylene
`(PTFE). The PTFE is in a micronized wax form. The TPU
`is selected to have a low glass transition temperature, from
`about -10° C. to about —80° C., and to have excellent
`abrasion resistance. Preferred TPU have hardness between
`70 A-88 A. The TPU is preferably a thermoplastic elastomer
`comprised of an oligomeric component selected from the
`group consisting of polycaprolactone, polypropylene glycol,
`polypropylene glycol ethylene glycol, polytetramethylene
`glycol, polyisobutylene glycol, oligomeric aliphatic polyes
`ters, oligomeric polyacrylic hydroxyalkyl esters, hydroxy
`lated polybutadiene, and blends thereof. More preferably,
`the oligomeric component is selected from aliphatic poly
`esters and polyethers. Dow Chemical manufacturers a series
`of TPUs under the trade name of Pellethane R that have
`outstanding abrasion resistance and good low temperature
`flexibility. The 2102 series is a polyester (polycaprolactones)
`polyurethane having a Durometer Shore A hardness of 75 to
`90. 2102-75 A has a glass transition temperature of -39°C.,
`a hardness of 77 A, and a Taber Abrasion weight loss
`(ASTM D1044) of 20 mg/1000 cycles, using the coarse
`wheel, H-22. Having a slightly higher Durometer, 2102-80
`A has a hardness of 84 A, a glass transition temperature of
`–40°C., and a Taber Abrasion weight loss of 10 mg/1000
`cycles. The polyether series based on polytetramethylene
`glycol, 2103-70 A, has an even lower glass transition
`temperature —69° C., a hardness of 72 and an abrasion
`resistance of 3 mg/1000 cycles. Other commercially avail
`able TPU resins from Noveon sold under Estane trade name
`are also suitable. Examples of Estane grades suitable for this
`application are Estane 58213, Estane 54610, and Estane
`58315. Polyester as well as Polyether based grades of TPU
`are suitable for this application. Suitable TPU have an
`abrasion resistance as measured by ASTM D1044 of less
`than or equal to 75 mg per 1000 cycles using the H-22 coarse
`wheel.
`[0022] The PTFE is typically modified with polyethylene
`wax. A typical example is Lurizol R Lanco TF 1778. The
`PTFE enhances scratch resistance, resistance to scuffing,
`abrasion resistance, and improves anti-blocking properties.
`Another commercial grade of PTFE is Micro Powders Fluo
`series. These PTFE are high molecular weight, and provide
`long lasting properties, as they are very slow to bloom. In
`contrast, 3M’s Dyneon R. PTFE micropowders are low
`molecular weight polymers, and they are more prone to
`bloom. Dyneon R. PTFE micropowders provide non-stick
`and anti-friction properties, but are less effective for pro
`viding scratch resistance, resistance to scuffing, and abrasion
`resistance. Other examples of micronized PTFE include
`Zonyl MP1300, Zonyl MP1600 from DuPont and Fluoro
`T-707 and T-807 from Shamrock Technologies. Preferred
`grade of micronized PTFE should have mean particle size
`less than 25 microns.
`
`Bestway Exhibit 1016-0007
`PGR2017-00003
`
`

`

`US 2006/0252320 A1
`
`Nov. 9, 2006
`
`[0023] The PVC component of the compound is com
`prised of a suspension grade PVC resin, phthalate or adipate
`based monomeric plasticizers, flame retardants, antimicro
`bials, lubricants, heat stabilizers, mineral fillers, colorants
`and other common additives typically used in flexible PVC
`formulations. Examples of suspension grade PVC resin
`include OxyVinyls 240 and OxyVinyls 500 from Oxy
`Vinyls. Monomeric plasticizers can be linear or branched
`phthalate or adipate or a blend of adipates and phthalates.
`Examples of common plasticizers are DOP DIDP, DPHP,
`DINP. 711P L9P DOA and DINA. Flame retardants can be
`selected to meet the char length and afterflame requirements
`in application requiring NFPA 701, ASTM D6413 or other
`similar flammability requirements. Antimony trioxide can be
`used as synergistic flame retardant with PVC. Other
`examples of flame retardants include phosphate plasticizers,
`zinc borate, ammonium molybdate, alumina trihydrate,
`magnesium hydroxide and various brominated compounds.
`Heat stabilizers suitable for the application include calcium
`zinc, barium zinc, cadmium zinc complexes. Examples
`include stabilizers sold under Mark?R sold by Crompton
`Corporation, or Halstab R sold by OMG Corporation. Lubri
`cants can be external and/or internal type and may consist of
`fatty esters, montan waxes, polyethylene waxes. Mineral
`fillers such as calcium carbonate, calcium sulfate can be
`used to reduce cost. Titanium dioxide can be used as a filler
`as well as colorant in applications requiring whiteness and
`good weathering properties.
`[0024] The scrim fabric 16, as illustrated in FIG. 4, is an
`open scrim comprised of Nylon or polyester fibers 30 or a
`blend. Nylon is generally selected where greater flexibility
`and cost are not overriding considerations. The scrim fabric
`16 is coated with a primer coating 18 to improve the bond
`to the compounded PVC. An excellent bond is formed using
`a polyurethane dispersion sold by Bayer Material Science,
`such as DispercollK 53. Dispercoll R 53 is an anionic
`aqueous dispersion of a high molecular weight polyure
`thane. When dried, DispercollK 53 imparts dimensional
`stability to the scrim fabric 16, as well as improves the bond
`between scrim fabric 16 and the compounded PVC film 12.
`The solids of the dispersion are approximately 40% by
`weight, and the viscosity is 50-600 centipoise. Typically, the
`solids are lowered to reduce pickup. Suitable coating meth
`ods include dip and squeeze, knife and rod (i.e., Meyer rod)
`coaters, fountain coaters, flooded gravure, foam coaters and
`roll coaters, such as reverse roll coaters. Foam coaters have
`the advantage that dilution water is not required, but the
`disadvantage that saturation is less penetrating. The thermal
`stability and the resistance to plasticizers and oil can be
`increased by the addition of a cross-linker, such as a water
`emulsifiable polyisocyanate. An example of a suitable
`water-emulsifiable polyisocyanate is DesmodurºR DN,
`which is an aliphatic polyisocyanate based on hexamethyl
`ene diisocyanate (HDI). Generally, 2-5% on a dry weight
`basis of the DispercollK 53 of the cross-linker is admixed
`with the anionic aqueous dispersion shortly before coating,
`as the HDI does limit the usable pot life of the primer
`coating. Additional cross-linker can be added to improve the
`bond with the compounded PVC.
`[0025] The method for forming the laminate 10 is com
`prised of the steps of: a) providing a compounded PVC
`comprised of: a PVC, a TPU, and a fluoroethylene polymer
`that is substantially PTFE; b) extruding the compounded
`PVC forming a cast extruded compounded PVC film 12; and
`
`c) laminating the compounded PVC film 12 to a scrim fabric
`having a polyurethane primer coating 14. The compounded
`PVC is preferably compounded using a mix-extruder,
`wherein for every 100 parts of PVC there are 5 to 50 parts
`of TPU and 0.1 to 5.0 parts of PTFE. The PVC and the TPU
`are extrusion grade, and therefore are further comprised of
`the requisite processing aids, colorants, thermal and light
`stabilizers, plasticizers, oils, and fillers. The mix-extruder
`can be used to customize the compounded PVC by changing
`the ratio of the components, and adding other modifying
`components, such as additional processing aids, colorants,
`thermal and light stabilizers, plasticizers, oils, and fillers. In
`the method, the cast extruded compounded PVC film 12 is
`simultaneously formed and laminated with the primer coated
`scrim fabric, by extruding the compounded PVC through a
`die into a two roll nip, where the primer coated scrim fabric
`wraps a compression roll and the compounded PVC is in
`contact with an opposing steel roll. The steel roll has a finish
`that determines the surface of the film.
`[0026] FIG. 6 illustrates a variation on the method,
`wherein the laminate 10' is comprised of the compounded
`PVC film 12, the primer coated scrim 14 and an extruded
`adhesive 20. The extruded adhesive 20 bonds the film 12 to
`the scrim fabric 14. The adhesive is typically very similar to
`the compounded PVC, except without the fluoroethylene
`polymer—PTFE. PTFE is expensive and substantially not
`functional except on the surface of the compounded PVC
`film 12. A suitable extruded adhesive is comprised of an
`extrusion grade of PVC and an extrusion grade of TPU.
`Another potential advantage of using an extruded adhesive
`is that the finished laminate should have a more even profile
`for the same total weight of extruded material. The profile of
`the scrim 32', as shown in FIG. 5, illustrates that the scrim
`protrudes less than the profile of the scrim 32, as shown in
`FIG. 1. FIG. 7 is an exploded diagrammatic view of the
`invented laminate 10' shown in FIG. 5, illustrating the scrim
`fabric, the primer coat, the adhesive, and the compounded
`PVC film.
`[0027] The extruded adhesive 20 and the compounded
`PVC film 12 can be co-extruded into the two roll nip; or
`alternatively the compounded PVC film 12 can be pre-cast
`and then the pre-cast film 12 and the primer coated scrim
`fabric 14 can be brought together at a nip containing the
`extruded adhesive 20.
`[0028] Following lamination, the method is preferably
`further comprised of the steps of d) annealing the laminate
`in an oven to reduce curl and minimize anisotropic distor
`tions in the laminate; e) cooling the laminate; and f) winding
`the annealed laminate into a roll and/or sheeting the
`annealed laminate.
`[0029] In laminates where it is desired that both sides of
`the scrim fabric have a compounded PVC film, the scrim
`side of the laminate can be laminated with another layer of
`compounded PVC film using the method as previously set
`forth.
`[0030] The primer coated scrim fabric 14, preferably
`freshly prepared using a method that imparts dimensional
`stability, will still have some primer coat that is not fully
`cured. When the primer coat 18 is not fully cured it is a more
`effective primer because when it comes into contact with the
`extrudate, either the compounded PVC film 12 or the
`extruded adhesive 20, the primer will become tacky with
`
`Bestway Exhibit 1016-0008
`PGR2017-00003
`
`

`

`US 2006/0252320 A1
`
`Nov. 9, 2006
`
`application of heat and have better wetting and therefore
`higher adhesion; and the latent cross-linker (i.e., polymeric
`isocyanate) will be available to bond with the extrudate. The
`primer coated scrim fabric 14 is prepared using a saturation
`coating process, such as dip and squeeze, and then drying in
`an IR oven to remove the volatile carrier. As previously
`taught, the primer is a high molecular weight polyurethane,
`and the cross-linker is a polyisocyanate. To minimize dis
`tortion of the scrim fabric 16, after the fibers 30 are woven
`into the scrim fabric, and while still on a loom, the scrim
`fabric 16 is saturation coated with the primer coating 18,
`dried and wound into a roll.
`[0031] The following examples illustrate the formulations
`and properties of laminates:
`
`3. The laminate, as claimed in claim 1, wherein said PVC
`is an extrusion grade further comprised of the requisite
`processing aids, colorants, thermal and light stabilizers,
`plasticizers, oils, and fillers.
`4. The laminate, as claimed in claim 1, wherein said
`fluoroethylene polymer is predominately polytetrafluoroet
`hylene (PTFE).
`5. The laminate, as claimed in claim 4, wherein said PTFE
`is a micronized wax.
`6. The laminate, as claimed in claim 2, wherein said TPU
`is a polyurethane having an oligomeric component selected
`from the group consisting of polycaprolactone, polypropy
`lene glycol, polypropylene glycol ethylene glycol, polytet
`ramethylene glycol, polyisobutylene glycol, oligomeric ali
`
`Ingredients
`
`OXYVINYLS 500 RESIN
`ANTIMONY TRIOXIDE
`CALCIUM CARBONATE
`ANTIMICROBIAL
`EPOXIDIZED SOYABEAN OIL
`PHTHALATE PLASTICIZER
`PHOSPHATE PLASTICIZER
`HEAT STABILIZER 1
`HEAT STABILIZER2 + LUBRICANT
`BLEND
`Alumina Trihydrate
`TPU
`Micronized PTFE Wax
`Test Results
`
`Example 1 Example 2 Example 3 Example 4
`PHR
`PHR
`PHR
`PHR
`
`100.000
`8.300
`36.000
`1.000
`5.000
`35.000
`15.000
`2.200
`3.000
`
`100.000
`14.000
`25.000
`1.000
`5.000
`40.000
`5.000
`3.000
`2.200
`
`20.000
`14.000
`4.200
`
`100.000
`14,000
`25.000
`1.000
`5.000
`40.000
`5.000
`3.000
`2.200
`
`20.000
`18.000
`
`100.000
`14.000
`25.000
`1.000
`5.000
`45.000
`5.000
`3.000
`2.200
`
`20.000
`
`5.000
`
`Cycles To Exposed Fabric ASTM D3389
`Using H-18, 1000 gm load
`Fingernail Mar Resistance
`
`36
`
`120
`
`75
`
`60
`
`Poor
`
`Good
`
`Fair
`
`Fair
`
`[0032] The descriptions above and the accompanying
`drawings should be interpreted in the illustrative and not the
`limited sense. While the invention has been disclosed in
`connection with the preferred embodiment or embodiments
`thereof, it should be understood that there may be other
`embodiments which fall within the scope of the invention as
`defined by the following claims. Where a claim is expressed
`as a means or step for performing a specified function, it is
`intended that such claim be construed to cover the corre
`sponding structure, material, or acts described in the speci
`fication and equivalents thereof, including both structural
`equivalents and equivalent structures.
`
`What is claimed is:
`1. A laminate, comprising: a primer coated scrim fabric;
`and a cast extruded compounded PVC film, wherein said
`cast extruded compounded PVC film is comprised of a
`thermoplastic polyvinyl chloride polymer (PVC), a thermo
`plastic polyurethane polymer (TPU), and a fluoroethylene
`polymer.
`2. The laminate, as claimed in claim 1, wherein said TPU
`has a glass transition temperature of from about -10°C. to
`about —80° C.
`
`phatic polyesters, oligomeric polyacrylic hydroxyalkyl
`esters, hydroxylated polybutadiene, and blends thereof.
`7. The laminate, as claimed in claim 6, wherein said TPU
`is an extrusion grade of an aliphatic polyester or polyether
`urethane or a blend thereof.
`8. The laminate, as claimed in claim 6, wherein said TPU
`has a Taber Abrasion Resistance, as defined by ASTM
`D1044, of less than 75 mg per 1000 cycles using the H-22
`wheel.
`9. The laminate according to claim 1, wherein said cast
`extruded compounded PVC film is further comprised of at
`least one modifying component selected from the group
`consisting of processing aids, colorants, thermal and light
`stabilizers, plasticizers, oils, and fillers.
`10. The laminate, as claimed in claim 1, wherein said cast
`extruded compounded PVC film has, by weight, 5 to 50 parts
`of TPU per 100 parts of PVC.
`11. The laminate, as claimed in claim 4, wherein said cast
`extruded compounded PVC film has, by weight, 0.1 to 5.0
`parts of PTFE per 100 parts of PVC.
`12. The laminate, as claimed in claim 1, wherein said
`primer coated scrim fabric is an open scrim fabric coated
`with a high molecular weight polyurethane.
`13. The laminate, as claimed in claim 12, wherein said
`high molecular weight polyurethane has a polyisocyanate
`cross-linker.
`
`Bestway Exhibit 1016-0009
`PGR2017-00003
`
`

`

`US 2006/0252320 A1
`
`Nov. 9, 2006
`
`14. The laminate, as claimed in claim 12, wherein said
`high molecular weight polyurethane is an anionic polyure
`thane dispersion.
`15. The laminate, as claimed in claim 13, wherein said
`polyisocyanate cross-linker is based on hexamethylene
`diisocyanate.
`16. The laminate, as claimed in claim 1, wherein said
`laminate is further comprised of an extruded adhesive.
`17. The laminate, as claimed in claim 16, wherein said
`extruded adhesive is comprised of an extrusion grade of
`PVC and an extrusion grade of TPU.
`18. A method for forming a laminate having superior scuff
`and abrasion resistance, said method comprising the steps
`of:
`a) providing a compounded PVC, where said com
`pounded PVC comprises a thermoplastic polyvinyl
`chloride polymer (PVC), a thermoplastic polyurethane
`polymer (TPU), and a fluoroethylene polymer;
`b) extruding the compounded PVC forming a cast
`extruded compounded PVC film; and
`c) laminating the compounded PVC film to a scrim fabric
`having a polyurethane primer coating.
`19. The method, as claimed in claim 18, wherein said
`scrim fabric having the polyurethane primer coating is
`formed by steps comprised of:
`i) dip coating a scrim fabric with a polyurethane primer
`coating:
`ii) drying the polyurethane primer coating; and
`iii) winding the primer coated scrim fabric.
`20. The method, as claimed in claim 19, wherein said
`polyurethane primer coating is applied to the scrim fabric
`while it is being woven and is still on the loom.
`21. The method, as claimed in claim 19, wherein said
`polyurethane primer coating is an aqueous dispersion of an
`anionic polyurethane and an aliphatic polyisocyanate.
`22. The method, as claimed in claim 19, wherein said
`drying step is infrared drying.
`23. The method, as claimed in claim 18, wherein said
`fluoroethylene polymer is predominately polytetrafluoroet
`hylene (PTFE).
`24. The method, as claimed in claim 23, wherein said
`PTFE is a micronized wax.
`25. The method, as claimed in claim 24, wherein said
`compounded PVC is prepared by admixing the PVC, the
`TPU and the PTFE on a mix-extruder.
`
`26. The method, as claimed in claim 18, wherein said
`extruding step is further comprised of:
`extruding the compounded PVC through a die onto a two
`roll nip forming the compounded PVC film, where said
`die has a compression roll and a steel roll, and wherein
`said primer coated scrim fabric partially wraps the
`compression roll.
`27. The method, as claimed in claim 18, wherein said
`method further comprises the step of:
`d) annealing the laminate in an oven to reduce curl and
`minimize anisotropic distortions in the laminate.
`28. The method, as claimed in claim 27, wherein said
`method further comprises the steps of:
`e) cooling the laminate; and
`f) winding the annealed laminate into a roll.
`29. The method, as claimed in claim 18, wherein said
`extruding step further comprises:
`co-extruding compounded PVC through a die onto a two
`roll nip forming the compounded PVC film, and
`extruding an adhesive between said film and said
`primer coated scrim fabric, where said die has a com
`pression roll and a steel roll, and wherein said primer
`coated scrim fabric partially wraps the compression
`roll.
`30. A method for forming a laminate having superior scuff
`and abrasion resistance, said method comprising the steps
`of:
`a) providing a compounded PVC film, where said com
`pounded PVC film is comprised of PVC, TPU, and a
`fluoroethylene polymer;
`b) providing a scrim fabric with a polyurethane primer
`coating:
`c) providing an extrudable adhesive comprised of PVC
`and TPU;
`d) extruding the adhesive through a die onto a two roll nip
`to which is fed the compounded PVC film and the
`primer coated scrim fabric, where said die has a com
`pression roll and a steel roll, and wherein said primer
`coated scrim fabric partially wraps the compression
`roll; and
`e) laminating the compounded PVC film to the primer
`coated scrim fabric.
`
`Bestway Exhibit 1016-0010
`PGR2017-00003
`
`