The coating stage 200, including the texturing process 200a and the coating process 200b, is configured to ensure the fabric is adequately prepared for optimal performance in subsequent stages. For example, after combining the substrate layer 110 and the fabric layer 120 (step 210 of FIG. 2), a printing material can be applied to the surface of the fabric layer 120 (step 220 of FIG. 2). The resulting uniform texture 300 of the textured fabric 400 not only enhances the aesthetic appeal but also serves as an optimized base for high-quality printing on the fabric's surface. Printing can add intricate designs and patterns to the textured fabric.

FIG. 5 illustrates an exemplary method of manufacturing a textured fabric according to the second example and FIG. 6 is a flowchart of exemplary steps of the method of FIG. 5. In this second example, the texturing of the fabric occurs after the coating stage and before the printing stage. This method generally comprises coating a surface 512 of a fabric 510 with a polymer (step 600 of FIG. 6). The fabric 510 may be any woven or non-woven fabric, or any laminated woven or laminated non-woven fabric. For example, the fabric 510 can be a polypropylene laminated woven fabric or an unlaminated non-woven fabric. The fabric 510 can be coated using an extruder similar to the first example above, or by other known coating methods. The coated fabric 510 can then be textured. That is, after the coating of the surface 512 of the fabric 510, a texture 700 (FIGS. 7A and 7B) can be applied to the surface 512 of the fabric 510 by feeding the fabric 510 between a textured roller 520 and a plain pressure roller 530 to form the textured fabric 500 (step 610 of FIG. 6). Similar to the first example, the textured roller 520 has an engraved pattern 522 that imprints the texture 700 onto the surface of the fabric. FIG. 7A is a view of an example of the texture or textured pattern 700 of the textured fabric 500 that can result from this method and FIG. 7B shows an enlarged view of the textured pattern 700 of FIG. 7A.

In an aspect, the coated fabric 510 can be unwound from a payoff roll 514 and fed between the textured roller 520 and the plain pressure roller 530. After the texture 700 is applied to the coated fabric 510, the resulting textured fabric 500 can be wound onto a wind-up roll 516.

Heat can be applied to the textured roller 520 and the plain pressure roller 530 (step 612 of FIG. 6) to apply heat to the fabric while applying the texture to the fabric (step 610 of FIG. 6). The heat can be applied via hot air drying, for example, that results in a working temperature of about 25° C. plus. The pressure and heat from the rollers imprint the pattern onto the fabric. In an aspect, the textured roller 520 can be uniformly heated to imprint the desired texture across the entire width W of the fabric 510, ensuring consistent txture pattern quality. In an aspect, the textured roller 520 is oil-heated. The textured roller 520 and the plain pressure roller 530 can operate at a speed to optimize processing of the fabric. For example, the textured roller 520 and the plain pressure roller 530 can operate at a speed of about 4 to 10 meter/minute. The pressure applied to the fabric by the textured roller 520 and the plain pressure roller 530 can be managed to optimize texture imprinting onto the fabric 510. For example, the textured roller 520 and the plain pressure roller 530 can operate at a pressure of about 450 psi to a maximum achievable pressure, e.g. about 850 psi. The temperatures of the textured roller 520 and the plain pressure roller 530 can also be managed to optize imprinting and processing of the farbic 120. For example, the textured roller 520 and the plain pressure roller 530 can operate at temperatures between about 120° C. to a maximum achievable temperature, e.g. about 140° C., to imprint the desired design onto the fabric's surface.

One or more guide rolls 540 may also be employed to facilitate the movement of the fabric 510 through the texturing stage and ultimately the winding of the textured fabric 500 on the wind-up roll 516. All of the rollers can be configured to maintain synchronization between the fabric's unwind and rewind rolls, allowing for steady fabric movement and consistent texturing throughout the process.

The texturing and heating at steps 610 and 612 are configured to ensure the fabric is adequately prepared for optimal performance in subsequent stages. For example, after step 610, a printing material can be applied to the surface 512 of the fabric 510 (step 620 of FIG. 6). The resulting uniform texture 700 of the textured fabric 500 not only enhances the aesthetic appeal but also serves as an optimized base for high-quality printing on the fabric's surface, such as for adding designs and patterns to the textured fabric.

The method of the second example allows for wide-width heat press texturing after coating. This enhances both efficiency and design flexibility, such as the following: uniform texturing across large surfaces of the fabric due to consistent pressure and heat distribution, allowing for seamless patterns and textures across wide-width materials; increased production efficiency because by accommodating larger widths, this method significantly reduces processing time, making it ideal for high-volume production in industries like textiles, flooring, and packaging; design versatility because wide-width texturing of the method enables intricate and large-scale patterns, expanding creative possibilities for new designs and manufacturing capabilities; enhanced material performance because the method adds functional benefits, such as drainage efficiency, improved grip, reduced slippage, or added durability, tailored for specific applications like residential, commercial and industrial textiles, membranes, and upholstery; and customization capability because the method offers the flexibility to switch between designs or textures quickly, catering to diverse customer requirements without extensive downtime and wastage.

FIG. 8 illustrates an exemplary method of manufacturing a textured fabric according to the third example and FIG. 9 is a flowchart of exemplary steps of the method of FIG. 8. In this third example, the texturing of the fabric occurs after the coating stage and during the printing stage (rather than before the printing stage as in the second example). That is, the texturing of the fabric is incorporated into the printing process of the fabric. This method generally comprises the steps of coating a surface 812 of a fabric 810 with a polymer (step 900 of FIG. 9), and after coating the surface 812 of the fabric 810, applying a texture and a printing material to the surface 812 of the fabric 810 (step 910 of FIG. 9). The fabric 810 can be coated using an extruder similar to the first example above, or by other known coating methods.

Step 910 includes a texturing process 910a and a printing process 910b applied together to the fabric surface 812. The combined texturing and printing processes 910a and 910b can be used to apply various designs, patterns, graphics, logos, and the like, directly onto the coated fabric 810. The texturing process 910a combined with the printing stage 900 integrates patterns, designs, and colors into the coated fabric 810, enhancing both aesthetic appeal and functional properties. This can be accomplished by applying a printing material 816 to a textured roller 820 and feeding the fabric 810 between the textured roller 820 and a plain pressure roller 830. Similar to the above examples, the textured roller 820 has an engraved pattern 824 that imprints a texture 1000 onto the surface 812 of the fabric 810 while also printing the printing material 816 on the surface 812 of the fabric 810.

Similar to the above examples, the textured roller 820 transfers the desired texture or pattern 1000 onto the fabric 810 through controlled pressure and heat, ensuring accurate replication of the design. The textured roller 820 and the plain pressure roller 830 can be tension controlled to ensure that the coated fabric 810 has consistent contact with the textured roller 820 when fed into the printing stage 900.

The method may include the step of inspecting the coated fabric 810 for surface uniformity before feeding the coated fabric 810 into the printing stage 900. Any inconsistencies in the coating can be corrected prior to texturing and printing to ensure optimal texturing.

As with the above examples, the fabric 810 may be any woven or non-woven fabric. The fabric 810 can be coated using an extruder similar to the first example above, or by other known coating methods. The printing material 816 may be, for example, high-quality inks chosen to ensure excellent adhesion, vibrancy, and long-lasting texture effects. UV-cured inks can provide superior durability in harsh conditions.

FIG. 10A is a view of an example of the texture or textured pattern 1000 of the textured fabric 800 that can result from this method and FIG. 10B shows an enlarged view of the textured pattern 1000 of FIG. 10A. The texture 1000 imprinted on the surface 812 of the coated fabric 810 can be, for example, simple geometric patterns or complex organic motifs or designs tailored to specific customer requirements. Base colors and patterns can be integrated into the texturing process using compatible printing materials, such as inks and dyes. The choice of ink, e.g. water-based, solvent-based, or UV-cured, can be selected to suit the fabric material and intended use. For multi-dimensional effects, layering of colors and textures can be achieved through repeated passes of the fabric 810 through the printing stage 900.

The textured roller 820 and the plain pressure roller 830 can operate at a speed that optimizes the processing of the fabric 810. For example, the rollers 820 and 830 can operate at a speed of about 30 to 70 meter/minute to match the texture complexity and ensure a smooth, uninterrupted process. Also, the temperature of the rollers 820 and 830 can be managed to optimize the processing of the fabric 810. For example, heating zones can be maintained at a temperature ranging from about 25° C. to 80° C. For example, a working temperature may be from about 25°C. plus due to in process hot air drying during imprint of the desired texture 1000 across the entire width W of the fabric 810, ensuring consistent pattern quality.

One or more guide rolls 840 may also be employed to facilitate the movement of the coated fabric 810 through the printing stage 900 and ultimately the winding of the processed textured fabric 800 on a wind-up roll 832. All of the rollers can be configured to maintain synchronization between the fabric's unwind and rewind rolls, allowing for steady fabric movement and consistent texturing throughout the process.

An anilox roller 826 can be used to transfer a desired amount of the printing material 816 to the textured roller 820, which then applies the printing material 816 to the fabric. As seen in FIG. 1, the anilox roller 826 can be positioned adjacent to the textured roller 820. The anilox roller 826 can have a surface covered with small, engraved cells which hold and release a controlled volume of the printing material 816. The anilox roller 826 can be in fluid communication with a reservoir 818 of the printing material 816 (e.g. ink or dye) to pick up the printing material 816 from the reservoir 818 and transfer the printing material 816 to the textured roller 820. The reservoir 818 may be positioned below the anilox roller 826. A fountain roller 828 can optionally be used in conjunction with the anilox roller 826 to facilitate transfer of the printing material 816 from the reservoir 818 to the anilox roller 826.

The method may further comprise a quality control check of the fabric 810 post-texturing and printing processes 910a and 910b. That is, after the printing stage 900, the fabric 810 can undergo quality checks for colourfastness, texture integrity, and adhesion strength.

The above methods of the present disclosure may include the preliminary steps of manufacturing the woven or non-woven fabric layers before texturing. For example, the methods may include the step of granules to tape manufacturing to convert raw materials into tapes (to be woven together) through extrusion and stretching. This may begin with the preparation of raw materials, such as polypropylene (PP) granules, fillers, UV stabilizers, and master batches. These material components can undergo quality control checks to ensure compliance with predefined standards for optimal performance. Once cleared, the material components can be mixed and preheated to a temperature of approximately 80° C. a maximum achievable temperature to ensure uniformity. The prepared mixture can be fed into an extruder, where barrel temperatures are controlled, typically ranging from 250° C. to a maximum achievable temperature, e.g. 300° C., depending on the formulation of the mixture. The extruder processes the mixture into a homogenous molten state. The molten material is then directed through a T-die at elevated temperatures of approximately 270° C. to a maximum achievable temperature, e.g. about 310° C. to produce a continuous, uniform film with consistent thickness.

The extruded film can then enter a quenching stage, where it is rapidly cooled and solidified in a water bath maintained at 30° C. to a maximum achievable temperature, e.g. about 40° C. This step ensures the material stabilizes quickly, retaining its shape and dimensional integrity. Post-quenching, the film can be split into tapes using precision cutting equipment. Adjustable spacers on the cutters allow control over the tape width, ensuring uniform dimensions. This assists with maintaining consistency throughout subsequent production stages.