United States Patent [19]
`Geiger
`
`[54] LAMINATED FABRIC
`[76] Inventor: David H. Geiger, 125 Grandview
`Dr., Toms River, N.J. 13905
`July 20, 1973
`Filed:
`Appl. No.: 381,065
`
`[22]
`[21]
`
`[52]
`
`[51]
`[58]
`
`[56]
`
`3,365,355
`3,369,774
`
`U.S. Cl................. 428/245; 428/268; 428/273;
`428/290; 428/336; 428/422
`Int. Cl.”....................... B32B 7/04; B32B 31/06
`Field of Search......... 16 1/88, 89, 93, 189, 203,
`161/175
`
`References Cited
`UNITED STATES PATENTS
`1/1968 Netsch............................ 16 1/189 X
`2/1968 Struble.............................. 161/93 X
`
`
`
`3,899,622
`[11]
`[45] Aug. 12, 1975
`
`3,542,633
`
`11/1970 Goldsmith......................... 16 1/93 X
`
`Primary Examiner—Marion E. McCamish
`Attorney, Agent, or Firm—Arthur V. Smith; Pasquale
`A. Razzano
`
`ABSTRACT
`[57]
`A composite sheet for use in membrane type roof con
`structions or the like comprises a foraminous web
`formed of a plurality of fibers coated with a plastic
`material and heat sealed to a compatible thin film of
`plastic sheet material. The thin film sheet material is
`preferably transparent, so that the composite sheet is
`transparent through the openings in the foraminous
`web.
`
`19 Claims, 6 Drawing Figures
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`INTEX EXHIBIT 2031, Pg. 1
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`PATENTEDAUGi 2,975
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`1
`LAMINATED FABRHC
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`The present invention relates to composite sheet ma
`terials and more particularly to a composite sheet of
`plastic film and reinforcing web which are adapted to
`be used in membrane constructions for building roofs,
`domes, air inflated structures and the like.
`In many types of building constructions flexible sheet
`material is used to form a portion of the roof of the
`structure. This occurs, for example, in lightweight tem
`porary building structures such as tents, geodesic
`domes, air inflated building constructions, and the like.
`Typically, such materials must have relatively high
`strength, particularly in air inflated structures wherein
`the membrane actually forms a structural element of
`the building.
`Although various types of membranes have been pre
`viously proposed for use in such structures, those mem
`branes have presented numerous problems, particu
`larly with respect to the fact that the previously pro
`20
`posed materials must be relatively heavy in order to
`have the necessary strength. Moreover, such previously
`proposed membranes are usually formed of tightly
`woven materials so that they are opaque, or at best
`translucent. As a result, it is not possible to use such
`materials in applications where it is desirable that the
`roof of material be transparent to provide visibility to
`the outside of the structure; moreover, such materials
`tend to trap infrared heat within the building since they
`are not transparent to such heat. As a result, excess air
`conditioning and air treatment systems are required in
`order to handle the trapped heat within building con
`structions using such previously proposed membranes.
`Accordingly, it is an object of the present invention
`to provide a relatively lightweight sheet material having
`high strength and being adapted for use as a membrane
`in building constructions.
`Yet another object of the present invention is to pro
`vide a sheet material which is adapted for use as a
`40
`membrane in building constructions and which is trans
`parent to infrared heat.
`Yet another object of the present invention is to pro
`vide a composite reinforced sheet material for use in
`building constructions wherein the reinforcing ele
`45
`ments of the sheet are protected against wear and expo
`sure to the elements.
`In accordance with one aspect of the present inven
`tion, a composite sheet material adapted to be used as
`a membrane material in a building construction, and in
`particular in an air inflated building construction, is
`formed from a thin relatively light weight film of plastic
`material such as for example polytetrafluoroethylene.
`The film is reinforced by a foraminous fiber inch, e.g.
`a fiberglass web, which is coated with a plastic coating
`material compatible to the plastic sheet material and
`secured thereto by heat sealing or the like so that the
`fiber web is bonded to the thin film. By this construc
`tion, the openings in the web form transparent windows
`in the film material so that when the composite sheet
`60
`material is used in a building construction, the occu
`pants of the building have relatively good visibility to
`the outside. In addition, the transparent film permits
`trapped infrared heat or radiation within the building
`to be radiated out of the building through these trans
`parent windows.
`The sheet material formed in accordance with the
`present invention is also relatively inexpensive since
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`3,899,622
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`only a single film or sheet of plastic material is required
`which, in turn, is reinforced by the fiberglass web. The
`web is securely bonded to the sheet by the plastic coat
`ing over the fibers of the web and the composite sheet
`formed in this manner has substantial strength.
`The above, and other objects, features and advan
`tages of the present invention, will be apparent in the
`following detailed description of an illustrative embodi
`ment thereof which is to be read in connection with the
`accompanying drawing wherein:
`FIG. 1 is a perspective view of a portion of a compos
`ite sheet material constructed in accordance with the
`present invention;
`FIG. 2 is a perspective view, with parts broken away,
`of composite sheet material constructed in accordance
`with another embodiment of the present invention;
`FIG. 3 is a schematic elevational view of the appara
`tus used for bonding the foraminous web to the sheet
`material;
`FIG. 4 is an enlarged end view of the sheet material
`shown in FIG. 1; and
`FIGS. 5 and 6 are end views, similar to FIG. 4, of
`other embodiments of the invention.
`Referring now to the drawing in detail, and initially
`to FIG. 1, it will be seen that a composite sheet material
`10, constructed in accordance with the present inven
`tion, is formed from a relatively thin film 12 of a trans
`parent plastic material, secured to a web 14 of fibers.
`Sheet material 12 may be formed of any suitable, pref
`erably transparent, plastic material; and it has been
`30
`found that polytetrafluoroethylene film is highly satis
`factory particularly for use in forming membrane mate
`rials for air inflated dome type structures and the like.
`Web 14 may be in the form of a woven foraminous
`layer, such as shown in FIG. 1, and preferably is formed
`of woven fiberglass fibers. The particular type of weave
`may be a simple over and under weave, as seen in FIG.
`1, or the more complex leno weave, or any type of
`weave which provides the desired strength characteris
`tics in the sheet material as are required for the particu
`lar use to which the sheet is to be placed. In any case,
`the weave is formed so that there are openings 16 be
`tween the fibers so that the web is foraminous and the
`composite sheet material formed by the web and sheet
`12 will be transparent. Alternatively, web 14 may be
`unwoven, as seen in FIG. 2, with the fibers thereof ar
`rayed in a regular or irregular pattern as desired.
`As seen most clearly in FIG. 4, fibers 18 of the web
`14, are coated with a plastic material 20 which is com
`patible to the plastic material of which the sheet or film
`12 is formed. This coating may be applied to the web
`or fibers by dispersion coating or coating in any other
`convenient manner prior to bonding of the web to the
`plastic film 12. After the coating 20 is sufficiently dried
`over fibers 18, web 14 and sheet 12 are brought to
`gether, as seen in FIG. 3, between a pair of pressure rol
`lers 22, one or both of which may be heated, so as to
`form a heat seal between sheet 12 and the coating 20.
`In this manner, the fiberglass fibers 18, which provide
`the reinforcing strength to the composite sheet 10, are
`securely bonded to the transparent film 12.
`It is noted that in previously proposed structures the
`fiberglass fibers 18 typically are embedded in plastic
`layer 12 to reinforce the same or are sandwiched be
`tween sheet 12 and another complementary sheet, in
`Order to be bonded by the additional sheet to the sheet
`12. However, such membrane constructions are rela
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`tively expensive and difficult to produce. Moreover,
`inside of the building generated as a result of the solar
`energy entering the building will be re-radiated out of
`such constructions render the sheet non-transparent
`because the two films of plastic which are bonded to
`the building as infrared radiation. The polytetraflu
`oroethylene film is substantially more transparent to
`gether lose their transparency at their interface-bonded
`surfaces. Accordingly, by the construction of the pres
`such infrared radiation than is glass; thus a substantially
`ent invention as shown in FIG. 4, the composite sheet
`larger amount of such infrared heat will be allowed to
`10 remains transparent in the window 16 formed be
`pass out of the building through the roof by this mate
`rial. This, accordingly, substantially reduces the
`tween the fibers 18, and the construction is also sub
`stantially less expensive since only a single sheet of
`amount of cooling or air conditioning equipment re
`plastic film is required.
`quired for use in the building construction utilizing the
`composite sheet material of the present invention.
`In the manufacture of the sheet material of the inven
`Another embodiment of the present invention is illus
`tion it is often desirable to coat the fibers 18 of the fi
`berglass web 14 with a layer 26 of silicon prior to the
`trated in FIG. 5 of the drawing wherein it is seen that
`application of the plastic coating 20 thereto. The sili
`the sheet 12 is heat sealed to glass fibers 18 of a web
`con layer 26 on the fiberglass fibers wets the surface of
`14, which has been coated with two types of plastic ma
`the fibers and protects the fiberglass against attack by
`terial. That is, the fibers 18 are first coated with the sili
`water. The fiberglass fibers are further protected there
`con layer 26, as described above, and then are coated
`after by the coating 20 of plastic or polytetraflu
`with an inner layer of plastic 28 and, after that layer has
`oroethylene which encases the silicon around the fiber
`solidified, with an outer layer 30. Preferably, inner
`glass fibers, thereby protecting the silicon and the glass
`layer 28 is formed of a plastic material having a melting
`20
`temperature which is substantially higher than the
`fibers, in addition to serving as a bonding material se
`curing the glass fibers to the film 12.
`melting temperature of the plastic material used to
`Preferably, sheet material 10, as shown in FIG. 4, is
`form sheet 12. On the other hand, the coating 30 is
`used in the building construction with the sheet 12
`formed of a plastic material which is the same as the
`thereof exposed to the exterior of the building, i.e. with
`material used to form sheet 12 or which is compatible
`the fiberglass web 14 located on the interior thereof. By
`to that material and has substantially the same melting
`this construction the fiberglass fibers have a double
`temperature. In this manner, when sheet 12 and web 14
`protection from the elements and the eroding charac
`are passed through the heating and compression rollers
`teristics thereof, i.e. by the sheet of material 12 and the
`22, the outer coating 30 of the web will be softened and
`coating 20 itself. Thus, there is a preferential protec
`30
`melted so as to be heat sealed to the softened sheet ma
`tion of the fiberglass with the sides thereof facing the
`terial 12. However, because of the higher melting tem
`elements being doubly protected while the interior
`perature of the inner layer 28, that layer will remain
`sides thereof, i.e. side facing the interior of the build
`substantially solid. In this manner, the fibers 18 are
`ing, is only protected by the coating 20.
`fully enclosed and encased in the protective plastic
`In one embodiment of the invention fiber coating 20
`coating 28 during the heating operation and are not ex
`may also be provided with a plurality of minute glass
`posed as a result of the melting of the outer layer 30.
`beads embedded therein to improve the abrasion or
`This embodiment of the invention is preferably formed
`wear characteristics of the coating against deterio
`with polytetrafluoroethylene plastic materials, and in
`ration by abrasion from air carried particles or the like.
`particular, the sheet 12 may be formed of a commeri
`As mentioned, the spacing between fibers 18 and
`cally available FEP Teflon material, while the fiberglass
`web 14 is selected so as to provide windows 16 between
`fibers 18 are coated first with a TFE Teflon material,
`the fibers to taken advantage of the transparency of
`to form layer 28, and then with FEP Teflon to form the
`film 12. Preferably, the web is formed such that the
`layer 30. As is well known, commerically available TFE
`openings 24 occupy at least 10% of the area of the film.
`Teflon has a substantially higher melting temperature
`This will let the light from the exterior of the bulding
`than the commerically available FEP Teflon.
`enter the building, and will permit individuals inside of
`Another embodiment of the invention is illustrated in
`the building to look out. In one embodiment of the
`FIG. 6 of the drawing. In this embodiment, the sheet 12
`present invention the sheet or film 12 is provided in the
`is formed of two separate sheet members 32, 34. The
`thickness of between 2 to 5 mils, with the windows 16
`inner sheet 34 has the web 14 bonded to the inner side
`having widths or dimensions of approximately 4 of an
`38 thereof, while the outer side 40 of the sheet 34 has
`inch. This is accomplished by providing the fiberglass
`a half-silvered metallic coating 42 applied thereto. This
`web formed from fibers having a diameter, when
`coating may, for example, be a vacuum metalized alu
`coated, of about ¥8'' and being spaced 98' center. Typi
`minum coating applied to the sheet material in the con
`cally, the coating on such fibers would be between 2 to
`ventional manner. This coating is used to form a “one
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`5 mils, or substantially the same thickness as the thick
`way” mirror effect in the sheet material. Typically, the
`ness of the sheet 12. In one embodiment formed in ac
`coating may be applied as half-tone dots so that sub
`cordance with this example, it was found that the ten
`stantially half of the surface area of the sheet material
`sile strength of the material was between 200 and 600
`is coated with metal while the remainder, in the form
`ps1.
`of openings between the metallized dots, remains trans
`Another advantage of the present invention, particu
`parent.
`larly with the use of a foraminous web 14 which renders
`After the metallic layer 42 is applied to the inner film
`the composite sheet transparent is that the polytetraflu
`34, the outer film 32 is secured to the sheet 34 by heat
`oroethylene sheet material 12 is also transparent to in
`sealing, thereby to protect the metallized layer 42. The
`frared heat or radiation. Thus, when the sheet material
`two sheets 32,34 are bonded to each other through the
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`of the present invention is used in a building construc
`Openings in the metallized surface. Thereafter, film 12
`tion solar energy and light will enter the building
`is secured by heat sealing to the coated web 14 in the
`through the windows 16; however, ground heat or heat
`manner described above. This web may be in the form
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`temperature and said coating material comprises an
`of the web shown in FIGS. 4 or 5, or alternatively, may
`inner coating of a polytetrafluoroethylene material sur
`be in the form shown in FIG. 6 wherein inner and outer
`rounding said fibers and having a melting temperature
`layers 28 and 30 are provided; but with the inner layer
`higher than said predetermined melting temperature
`28 having glass beads 44 embedded therein to improve
`and an outer coating of a polytetrafluoroethylene mate
`the abrasion resistance characteristics of the inner TFE
`rial having a melting temperature substantially equal to
`Teflon coating.
`:
`that of said sheet material and being heat sealed to said
`In any case, the vacuum metallized film 12 utilizes
`the advantage of the previously described embodi
`film.
`ments, in particular that the film of polytetraflu
`3. The sheet material as defined in claim 1 wherein
`oroethylene is substantially transparent to admit light
`said web is formed of fiberglass and has a silicon coat
`ing applied thereto prior to coating by said polytetra
`into the interior of the building, while the metallized
`fluoroethylene material.
`layer reflects solar heat and prevents a substantial por
`tion thereof from entering the building. At the same
`4. The sheet material as defined in claim 3 wherein
`said coating has a plurality of glass beads embedded
`time, the sheet material is transparent to infrared radia
`tion from the interior of the building so that infrared
`therein.
`solar heat entering the building through the transparent
`5. The sheet material as defined in claim 1 wherein
`layer can pass out of the building again. In addition, the
`said web comprises an unwoven foraminous scrim of
`fiberglass.
`half-silvered, or one-way mirror effect, of sheet 12 per
`mits occupants of the building to look out through the
`6. The sheet material as defined in claim 1 wherein
`said web comprises a woven foraminous sheet of fiber
`material but at the same time provides privacy from the
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`glass.
`outside. In one embodiment of the invention it is con
`templated that the layer of film 34 of the composite
`7. The sheet material as defined in claim 1 wherein
`said polytetrafluoroethylene coating comprises a first
`film 12 of FIG. 6 have a thickness of 1 mil while the
`inner coating of a first polytetraflurorethylene material
`outer layer 32 have a thickness of 3 mils. The greater
`having a melting temperature greater than the melting
`thickness in the outer layer is to provide protection for
`temperaure of said film and a second outer coating of
`the metallized layer 42 against the elements.
`Accordingly, it is seen that a relatively inexpensively
`a second polytetrafluoroethylene material having sub
`stantially the same melting temperature as said film,
`constructed composite sheet material is provided
`which is highly advantageous for use in building con
`whereby said film and second coating may be heat
`30
`structions and particularly in air inflated dome con
`sealed together to secure said web to said film without
`exposing the fibers of said web during the heat sealing
`structions. The material, being formed of polytetraflu
`operation.
`oroethylene, is air impervious and is highly suitable for
`the latter application. Moreover, since the material is
`8. The sheet material as defined in claim 7 wherein
`transparent, it will permit light to enter the building and
`said inner coating has a plurality of glass beads embed
`yet will also permit infrared heat and radiation to pass
`ded therein.
`out of the guiding, thereby reducing the amount of
`9. The sheet material as defined in claim 1 wherein .
`said film of polytetrafluoroethylene sheet material
`cooling equipment required therefore. In addition, the
`comprises inner and outer polytetrafluoroethylene
`fiberglass web secured to the Teflon or polytetraflu
`oroethylene sheet material provides a composite sheet
`films, said inner having a half-silvered metallic surface
`material having a tensile strength which is substantially
`formed thereon and being bonded to said outer film
`greater than that of the polytetrafluoroethylene sheet
`through said metallic surface, whereby said film of
`polytetrafluoroethylene sheet material is relatively
`alone. On the other hand, the Teflon sheet serves as a
`protective cover for the reinforcing scrim and is a bar
`transparent and will reflect solar heat.
`rier against wear of the fiberglass fibers as a result of
`10. A composite sheet material for use as a roof
`exposure to the elements and air carried dust particles
`membrane or the like in building constructions which
`comprises a foraminous web of fiberglass formed from
`or the like.
`a plurality of fibers defining a plurality of openings in
`Although illustrative embodiments of the present in
`the web, and a thin film of transparent polytetraflu
`vention have been described herein with reference to
`oroethylene having a pair of opposite sides, the fibers
`the accompanying drawings, it is to be understood that
`50
`in said fiberglass web being coated with polytetraflu
`the invention is not limited to those precise embodi
`oroethylene and said film being heat sealed on one side
`ments and that various changes and modifications may
`thereof to said coating thereby to extend across said
`be effected therein by one skilled in the art without de
`openings to form said composite sheet.
`parting from the scope or spirit of this invention.
`11. The sheet material as defined in claim 10 wherein
`What is claimed is:
`1. A composite sheet material comprising a forami
`said film of sheet material is formed of a polytetraflu
`oroethylene material having a predetermined melting
`nous web formed of a plurality of fibers defining a plu
`rality of openings in the web and a thin film of transpar
`temperature and said coating material comprises an
`ent polytetrafluoroethylene sheet material having a
`inner coating of a polytetrafluoroethylene material sur
`pair of opposite sides, said fibers being coated with
`rounding said fibers and having a melting temperature
`polytetrafluoroethylene,
`and said
`polytetraflu
`greater than said predetermined melting temperature,
`and an outer coating of a polytetrafluoroethylene mate
`oroethylene sheet being secured on one side thereof to
`rial having a melting temperature substantially equal to
`said polytetrafluoroethylene coating on said fibers and
`extending across said openings to form said composite
`that of said sheet and being heat sealed to said sheet.
`sheet and whereby said composite sheet is transparent.
`12. The sheet material as defined in claim 11 wherein
`said web is formed of fiberglass and has a silicon coat
`2. The sheet material as defined in claim 1 wherein
`ing applied thereto prior to coating with said inner
`said film of sheet material is formed of a polytetraflu
`coating.
`oroethylene material having a predetermined melting
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`said fiber is between 2 and 5 mils thick, and the spacing
`between fibers in said web is approximately 4".
`18. The sheet material as defined in claim 17 wherein
`said fibers are 's' in diameter and are spaced 9%" on
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`Center.
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`19. The sheet material as defined in claim 10 wherein
`said thin film of transparent polytetrafluoroethylene
`comprises inner and outer polytetrafluoroethylene
`films, said inner film being secured on one side thereof
`to said web and having a half-silvered metallic surface
`applied to the other side thereof, said inner and outer
`films being bonded together through said metallic sur
`face whereby said film of plastic sheet material remains
`relatively transparent to light and infrared heat and yet
`will reflect solar heat.
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`13. The sheet material as defined in claim 12 wherein
`said inner coating has a plurality of glass beads embed
`ded therein.
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`14. The sheet material as defined in claim 10 wherein
`said web comprises an unwoven foraminous scrim of.
`fiberglass.
`15. The sheet material as defined in claim 10 wherein
`said web comprises a woven foraminous sheet of fiber
`glass.
`16. The sheet material as defined in claim 10 wherein
`the openings in said foraminous web occupy at least
`10% of the area of said web whereby said composite
`sheet is transparent and wiil permit infrared heat to
`pass therethrough from the interior of said building
`construction.
`17. The sheet material as defined in claim 16 wherein
`said film is between 2 and 5 mils thick, said coating on
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