Description:FORM 2

THE PATENTSACT, 1970

COMPLETE SPECIFICATION

(See section10 and rule13)

Title

A Dual-Purpose Polyamide Microfiber-Based Reinforcement and Lining composite Material for Handbags and the process thereof.

APPLICANTS
SKICORP Marketing Ventures Ltd.
Address: H.O - 25, Dakhinee Co-Operative Housing Society, Kolkata - 700105, West Bengal, India

The following specification particularly describes the invention and
how it is to be performed
FIELD OF THE INVENTION:
The present invention relates to the composite materials and accessories, particularly to a dual-purpose reinforcement and lining material for handbags using polyamide microfiber, polyurethane, and thermoplastic adhesive for enhanced structural durability and aesthetic appeal and the process of preparing the same. More specifically, the present invention discloses one reinforcement solution combining polyamide microfiber, polyurethane, and thermoplastic adhesive. It acts as both reinforcement and lining in one, providing lightweight, durable, and stylish handbags.

BACKGROUND OF THE INVENTION :
Traditional handbags often require separate reinforcement and lining materials, leading to increased production time, cost, and inconsistency in finish. The need exists for an integrated solution that simplifies manufacturing while providing high performance and premium appearance.

Following a few related art in this field.

EP2221793A1 Durable washable label having a visible diffraction grating pattern: This invention provides an improved and novel thin and pliable holographic fabric label that possesses durability, high intensity of holographic diffraction, laundering resistance, minimal alteration and degradation to the fabric and the label through extended use, and the ability to be cost-effectively mass produced is described. High bond is formed at multiple inter polymer interfaces and reflective diffractive layer is protected within the construction, superior durability to repetitious laundering, dry clean cycle and mechanical wear with long lasting diffracting effect and visual authentication property is realized

CN102292487A thermoplastic non-woven textile element The invention claims a non-woven fabric formed of a plurality of thermoplastic polymer wires. Non-woven Fabric may have a first area and a second area, and the wire of the first area is fused to be larger than the wire of the second region. Multiple products comprising clothing (such as shirt, trousers, shoes) can be combined with the non-woven fabric. In the product part, the non-woven fabric can be jointed with another textile element to form a seam. More specifically, the edge area of the non-woven fabric can be thermally combined with that of other element at the seam. In the other products, the non-woven fabric can be combined with the other part of the fabric or non-woven fabric.

Whereas the present invention introduces polyamide microfiber-based composite engineered to fulfill dual functionality as both reinforcement and lining for handbags. It is designed for easy lamination with outer materials, eliminating the need for traditional adhesives.

The novelty of the present process lies in the integration of reinforcement, lining, and adhesive bonding into a single microfiber-based Duraflex composite sheet, which eliminates multiple intermediate steps required in conventional handbag reinforcement. Unlike the traditional process, where reinforcement and lining are separately cut, glued, dried, and laminated prior to assembly, the inventive process uses a pre-integrated Duraflex sheet that requires only minimal adhesive at the final assembly stage.

This novel approach significantly reduces process steps, eliminates one full lamination cycle, minimizes adhesive usage, and reduces both processing time and energy consumption. The inventive process ensures faster production throughput (20–30% time savings), improved material handling, and a more efficient assembly line compared to the conventional method.

Therefore, to the best of our knowledge, none of the prior art attempts, individually or collectively, the proposed method indicated and disclosed by the present invention

THE OBJECTIVE OF THE INVENTION:

The objective of the present invention is to produce a versatile dual purpose bags with high Softness with structural Integrity which can acts as both reinforcement and lining in one product.
Another objective of the present invention is to produce durable and ensures handbags maintain quality and form over time, resisting wrinkles and breakdown.
Further objective of the present invention is to produce refined, flexible structure and Provides a soft, flexible finish with a structured appearance.
Further objective of the present invention is to produce Microfiber Polyamide Structure
Further objective of the present invention is to efficient production and reduce production time with minimal glue usage, allowing faster and cost-effective assembly
Further objective of the present invention is to produce premium look, affordable production and to create high-end handbags at mass-market prices and of dual-Use Design (Reinforcement + Lining) Adhesive-Free Bonding Compatibility High Resistance to Wrinkling, Wear, and Delamination

SUMMARY OF THE INVENTION:

The present invention relates to a the composite materials and accessories, particularly to a dual-purpose reinforcement and lining material for handbags using polyamide microfiber, polyurethane, and thermoplastic adhesive for enhanced structural durability and aesthetic appeal. In an aspect of the invention, the process of preparing a polyamide microfiber-based reinforcement and lining material is done by roll coating a microfiber substrate with an EVA hot-melt adhesive film to form heat-sensitive bonding zones;
and pre-treating the microfiber substrate with agents selected from polyurethane dispersions, silicone-based softeners, isocyanate crosslinkers, or silane coupling agents to impart anti-wrinkle and anti-delamination properties; and bonding the microfiber substrate and EVA film under heat and pressure treatment at 110–120 °C and 2–5 bar, without additional glue.

BRIEF DESCRIPTION OF THE DRAWING:

A complete understanding of the system and method of the present invention may be obtained by reference to the following

Figure 100: Exploded Layer View of Dura Flex Material
Figure 200: Cross sectional views of dura flex in use
Figure 300: Application in Handbag
Figure 400: Microfiber Nonwoven Structure

DETAILED DESCRIPTION OF THE EMBODIMENT:

The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to communicate the disclosure. The amount of detail offered has the intention to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and together with the description, serve to explain the principles of the invention.
As used in the description herein and throughout the claims that follow, the meaning of “a,”“an,” and “the” includes plural reference unless the context dictates otherwise.
In the preferred embodiment, the invention discloses the composition of polyamide microfiber-based composite engineered to fulfill dual functionality as both reinforcement and lining for handbags. It is designed for easy lamination with outer materials, eliminating the need for traditional adhesives.

In the preferred embodiment, the material is roll-coated with heat-sensitive bonding zones. It is pre-treated for anti-wrinkle, anti-delamination behavior. It bonds under mild heat and pressure without additional glue. Thickness ranges between 0.3 mm to 0.8 mm, suitable for premium bags.

In the preferred embodiment, the Composition of Dual-Purpose Polyamide Microfiber-Based Reinforcement and Lining Material
is configured with
Polyamide (nylon) microfiber,
Polyurethane
Thermoplastic hot-melt adhesive Ethyle Vinyl Acetate (EVA-/PE blends) wherein this combination delivers reinforcement strength and lining softness, making it a dual-purpose material for handbag production.

The process Raw Material: Typically nylon or polyester polymers.
1. Melt Spinning: Polymer chips are melted at ~250–280 °C.
2. Extrusion through Spinnerets: Filaments are drawn through micro-nozzles (much finer than human hair, ~0.1 denier).
3. Drawing & Stretching: Filaments are stretched 3–4x under controlled tension to align molecules and enhance strength.
4. Splitting: In some methods, bicomponent fibers are split into ultra-fine strands using chemical or mechanical processes.
5. Bonding: Microfibers are bonded (via hydroentanglement or chemical binders) into a nonwoven microfiber fabric that provides softness, breathability, and dimensional stability.

A fabric that feels like natural suede but has higher tear strength, dimensional stability, and uniformity—ideal as a reinforcement base.

EVA Extrusion Process (Hot-Melt Adhesive Layer) Polyamide Microfiber-Based Reinforcement and Lining Material uses EVA/PE-based thermoplastic adhesive films that melt-bond with microfiber.

Extrusion Steps:
1. EVA granules are fed into an extruder at 160–200 °C (depending on grade).
2. The molten resin is forced through a flat die to form a thin film.
3. The film is cooled on chill rolls under slight pressure (2–4 bar).
4. Final lamination to microfiber occurs under temperature 110–120 °C and laminating pressure 2–5 bar.
Bonding Range: As per product data, melting/activation occurs at 110–120 °C, ensuring reliable adhesion without damaging the microfiber base.

In the preferred embodiment, the process integration comprises
Step 1: Microfiber sheet is prepared (nylon 55% + polyethylene 45%).
Step 2: Hot-melt EVA adhesive is extruded and applied as a thin layer.
Step 3: Polyurethane coating adds abrasion resistance and a soft touch.
Step 4: Lamination is carried out under 110–120 °C, moderate pressure, and controlled dwell time (10–30 sec) to ensure uniform bonding.

This creates a composite sheet that is simultaneously:
• Strong enough for reinforcement
• Soft and elegant enough to function as lining
• Resistant to wrinkling, delamination, and mechanical fatigue

Microfiber Base Thickness
• The microfiber substrate is manufactured in a range of thicknesses, typically 0.3 mm to 0.8 mm depending on article and grade.
• In certain enhanced grades, microfiber layers can reach up to 1.0 mm for heavy-duty applications.
• The 0.3–0.8 mm range ensures softness and flexibility while providing structural strength.
Extruded EVA Adhesive Film Thickness
• The EVA - Ethyle Vinyl Acetate (or EVA/PE) extrusion layer is applied as a thin film.
• Typical extrusion range is 0.05 mm to 0.15 mm (≈ 50–150 microns).
• This corresponds to ~0.05–0.15 litre of polymer per square meter (likely what is referred to in your notes as "up to 1.5 litre extrusion").
• The EVA layer is thin but critical: it ensures fusion bonding without adding rigidity.

Composite Total Thickness
When laminated together:
• Microfiber base (0.3–0.8 mm) + EVA adhesive film (0.05–0.15 mm) + PU coating (0.05–0.1 mm)
Final composite thickness of approx. 0.4 mm to 1.0 mm.
This range aligns with Duraflex catalogue articles (MFB, MFS series) that go from 0.5 mm up to 1.6 mm in finished thickness.
The microfiber substrate used in the invention is manufactured in thicknesses ranging from 0.3 to 0.8 mm, while the extruded EVA adhesive film is applied at 0.05 to 0.15 mm thickness (≈ up to 1.5 litre extrusion per square meter). The overall laminated composite, including PU coating, results in a finished thickness of 0.4 to 1.0 mm, depending on grade and end-use application.

Picture of Polyamide (Nylon-6,6) structure is explained in Figure 4
• The repeating unit is:
–NH–(CH₂)₆–NH–CO–(CH₂)₄–CO–
• This forms a long-chain polyamide through amide linkages (-CO–NH-).
• These hydrogen-bonding groups give microfiber high tensile strength, flexibility, and dimensional stability, which is why it’s excellent for reinforcement.

A composite reinforcement material comprising a microfiber substrate, an extruded EVA adhesive film, and a polyurethane surface coating, wherein the production process is characterized by a reduced assembly cycle time as compared to conventional reinforcement-lining systems, owing to:
(i) pre-integration of reinforcement and lining functions into a single composite sheet,
(ii) elimination of intermediate adhesive lamination steps, and
(iii) activation of bonding at low temperature (110–120 °C) and pressure (2–5 bar), thereby enabling faster assembly, reduced energy consumption, and minimized processing steps.

Process of Preparing Polyamide Microfiber-Based Reinforcement and Lining Material
(a) Process with Temperature & Pressure Treatment
The process comprises:
1. Microfiber Substrate Preparation
o Polyamide and polyethylene polymers are melt-spun into microfibers (0.1–0.3 denier).
o Fibers are bonded into a nonwoven microfiber sheet with thickness 0.3–0.5 mm.
2. Roll Coating of EVA Adhesive Film
o An EVA (ethylene-vinyl acetate) thermoplastic hot-melt adhesive is extruded at 160–200 °C into a thin film (0.05–0.15 mm).
o The film is directly applied to the microfiber sheet by roll coating.
3. Bonding (Heat & Pressure Lamination)
o The microfiber substrate and EVA adhesive are laminated at 110–120 °C under 2–5 bar pressure.
o Dwell time: 10–30 seconds, sufficient to activate bonding without deforming the microfiber structure.
(b) Pretreatment
To ensure strong adhesion and durability, the microfiber substrate is pretreated before roll coating:
• Anti-wrinkle pretreatment: Application of silicone-based softeners or aqueous PU dispersions.
• Anti-delamination pretreatment: Application of isocyanate crosslinkers or silane coupling agents that increase bonding between polyamide fibers and EVA film.
• Optional surface activation: Plasma or corona discharge treatment to improve adhesive wetting.
(c) Roll Coating Process
• Knife-over-roll or gravure roll coating methods are employed to spread the EVA film uniformly.
• EVA is extruded in molten state at 160–200 °C and pressed onto the microfiber sheet.
• Cooling rolls solidify the adhesive layer, preventing wrinkles.

(d) Bonding Formation (Temperature & Pressure Range)
• Bonding mechanism: EVA softens at 110–120 °C, flows into the pores of the microfiber, and recrystallizes upon cooling, forming a strong mechanical and thermoplastic bond.
• Pressure: 2–5 bar ensures intimate contact and prevents delamination.
• Final Thickness: 0.3–0.8 mm, suitable for premium handbags.
In the preferred embodiment, the process of preparing a polyamide microfiber-based reinforcement and lining material, comprising:
(i) roll coating a microfiber substrate with an EVA hot-melt adhesive film to form heat-sensitive bonding zones;
(ii) pre-treating the microfiber substrate with agents selected from polyurethane dispersions, silicone-based softeners, isocyanate crosslinkers, or silane coupling agents to impart anti-wrinkle and anti-delamination properties; and
(iii) bonding the microfiber substrate and EVA film under heat and pressure treatment at 110–120 °C and 2–5 bar, without additional glue,
wherein the resulting composite sheet has a thickness between 0.3 mm and 0.8 mm, suitable for premium handbag applications. Thus the PU coating step is eliminated, and the invention now rests on microfiber substrate + EVA roll-coated adhesive film + pretreatment chemistry + bonding efficiency.
In another aspect of the invention following is the non-limiting examples

NYLON (%) POLYETHYLENE (%) OUTCOME
10 90 Very soft and flexible, poor tensile strength, low shape retention, unsuitable for structural parts
30 70 Flexible but lacks durability under stress, moderate bonding, may deform under load.
40 60 Slightly soft, fair bonding strength, moderate structural stability.
50 50 Balanced performance, acceptable for general use, average rigidity and bonding.
55 45 Ideal strength-flexibility balance, good bonding, shape retention, and durability.
70 30 Increased stiffness and strength, reduced flexibility, good for semi-rigid applications.
90 10 Very stiff, high shape retention, difficult to mould, suited for toe puffs/counters only.

Technical properties of the specification of the preferred products:

TECHNICAL PROPERTIES STANDARD TECHNICAL DATA
THICKNESS (MM) 0.7 MM
TENSILE STRENGTH(LENGTH WISE) ≥ 280 N/2.5CM
TENSILE STRENGTH(WIDTH WISE) ≥ 280 N/2.5CM
TONGUE TEAR(LENGTH WISE) ≥ 280 N/2.5CM
TONGUE TEAR(WIDTH WISE) ≥ 280 N/2.5CM
STANDARD SOFTNESS 6
HARDNESS(SHORE-D) 50
HARDNESS(SHORE-C) 70
ADHESIVE GSM 210
MELTING TEMPERATURE(°C) 110-120

Bonding Strength Test Matrix — Polyamide Microfiber Composite
Best result: 115 °C, 4 bar, 3 s → 15 N

Temperature (°C) Pressure (bar) Time (s) Bonding Strength (N) Note
95 2 2 6.8
95 2 3 7.2
95 2 5 7.1
95 3 2 7.3
95 3 3 7.7
95 3 5 7.5
95 4 2 7.6
95 4 3 8.0
95 4 5 7.8
95 5 2 7.4
95 5 3 7.8
95 5 5 7.7
100 2 2 8.5
100 2 3 9.0
100 2 5 8.8
100 3 2 9.1
100 3 3 9.6
100 3 5 9.4
100 4 2 9.5
100 4 3 10.0
100 4 5 9.8
100 5 2 9.3
100 5 3 9.8
100 5 5 9.6
105 2 2 10.3
105 2 3 10.8
105 2 5 10.6
105 3 2 10.9
105 3 3 11.5
105 3 5 11.3
105 4 2 11.4
105 4 3 12.0
105 4 5 11.8
105 5 2 11.2
105 5 3 11.8
105 5 5 11.5
110 2 2 11.5
110 2 3 12.2
110 2 5 11.9
110 3 2 12.3
110 3 3 13.0
110 3 5 12.7
110 4 2 12.8
110 4 3 13.5
110 4 5 13.2
110 5 2 12.6
110 5 3 13.2
110 5 5 13.0
115 2 2 12.8
115 2 3 13.5
115 2 5 13.2
115 3 2 13.7
115 3 3 14.4
115 3 5 14.1
115 4 2 14.2
115 4 3 15.0 Reference best
115 4 5 14.7
115 5 2 14.0
115 5 3 14.7
115 5 5 14.4
120 2 2 14.1
120 2 3 14.8
120 2 5 14.6
120 3 2 15.0
120 3 3 15.8
120 3 5 15.5
120 4 2 15.7
120 4 3 16.5
120 4 5 16.2
120 5 2 15.4
120 5 3 16.2
120 5 5 15.8

An advantage of the present invention is that the microfiber-based composite integrates reinforcement, lining, and adhesive bonding into a single material, thereby simplifying the manufacturing process.
Another advantage of the present invention is that it requires reduced glue application, since only the final assembly step requires adhesive, as the intermediate bonding (reinforcement-to-lining) is already integrated through the EVA hot-melt film.
• A further advantage of the present invention is that it operates under lower heat and pressure activation, as the EVA film activates at 110–120 °C with moderate pressure (2–5 bar), making it faster and more energy-efficient than solvent-based adhesives or high-temperature laminations.
Yet another advantage of the present invention is that it enables single-step lamination, wherein the microfiber substrate, EVA adhesive, and PU coating are laminated in one pass during production, instead of multiple runs.
A still further advantage of the present invention is that it accelerates the assembly line, since Duraflex arrives as a ready-to-use dual-purpose sheet, thereby eliminating one lamination cycle and reducing cycle time by 20–30% compared to conventional methods.
Further advantage of the present invention is to produce durable and luxury handbags to maintain quality and form over time, resisting wrinkles and breakdown

Another advantage of the present invention is to produce functional bags requiring lightweight strength

Further advantage of the present invention is to produce durable and ensures handbags maintain quality and form over time, resisting wrinkles and breakdown.

Further advantage of the present invention is to produce refined, flexible structure and provides a soft, flexible finish with a structured appearance.

Further advantage of the present invention is to produce Microfiber Polyamide Structure

Further advantage of the present invention is to efficient production and reduce production time with minimal glue usage, allowing faster and cost-effective assembly

Further advantage of the present invention is to produce premium look, affordable production and of dual-use design (Reinforcement and Lining) adhesive-free bonding compatibility high resistance to wrinkling, wear, and delamination and the hydrogen-bonding groups give microfiber high tensile strength, flexibility, and dimensional stability, which is why it’s excellent for reinforcement.

Further advantage of the invention is to eco-conscious brands seeking adhesive-free production and long-lasting with resistance to wrinkles and breakdown Soft yet firm, ideal for stylish yet durable bags. Efficient Production Process, reduces time and costs, as glue is only used for final assembly, affordable luxury, High-end aesthetics

It will be understood that the invention may be carried out into practice by skilled persons with many modifications, variations and adaptations without departing from its spirit or exceeding the scope of the claims in describing the invention for the purpose of illustration.
It is also to be noted that the present invention is susceptible to modifications, adaptations and changes by those skilled in the art. Such variant embodiments employing the concepts and features of this invention are intended to be within the scope of the present invention, which is further set forth under the following claims:-

We claim:
1. A dual-purpose polyamide microfiber-based reinforcement and three layered composite lining material (100-400) for handbags, comprising:
-a polyamide microfiber substrate (10) (Nylon) ranging from 40–55% by weight, wherein the repeating unit is –NH–(CH₂)₆–NH–CO–(CH₂)₄–CO–, characterized by long-chain polyamide through amide linkages (–CO–NH–) providing hydrogen-bonding sites that impart high tensile strength, flexibility, and dimensional stability;
-a thermoplastic adhesive layer (12) comprising an extruded EVA hot-melt film (EVA glue 210 D); and
-a polyurethane surface coating (14) in an amount ranging from 45–60% by weight
wherein the composite structure integrates reinforcement and lining into a single sheet and eliminates intermediate adhesive lamination wherein enables bonding activation at low temperature between 110–120 °C and pressure between 2–5 bar and ensures intimate contact and prevents delamination and formation of heat sensitive bonding zones by roll coating a microfiber substrate with EVA hot-melt adhesive film.

2. The composite as claimed in claimed 1 wherein the thickness between two layer varies from 0.4mm-1 mm wherein the thickness of Microfiber base (0.3–0.8 mm) thickness of EVA adhesive film (0.05–0.15 mm) and PU coating (0.05–0.1 mm)

3. The composite as claimed in claim 1 wherein tensile strength (length and width wise ) tongue tear(length and width wise) of composite material varies ≥ 280 standard softness 6 hardness(shore-D) 50 hardness(shore-C) 70 adhesive GSM 210 melting temperature(°c) 110-120.

4. The composite as claimed in claimed 1 wherein the nylon /polyester polymer structure undergoes melt spinning wherein Polymer chips are melted at ~250–280 °C and Filaments are drawn through micro-nozzles (much finer than human hair, ~0.1 denier) by extrusion and Spinnerets Filaments are stretched 3–4x under controlled tension to align molecules and enhance strength wherein Microfibers are bonded (via hydroentanglement or chemical binders) into a nonwoven microfiber fabric for softness, breathability, and dimensional stability.

5. A Process of Preparing Polyamide Microfiber-Based Reinforcement and Lining composite material characterized by

- Preparation of microfiber Substrate wherein Polyamide and polyethylene polymers are melt-spun into microfibers (0.1–0.3 denier) wherein fibers are bonded into a nonwoven microfiber sheet with thickness 0.3–0.8 mm
- Roll Coating of EVA Adhesive Film wherein an EVA (ethylene-vinyl acetate) thermoplastic hot-melt adhesive is extruded at 160–200 °C into a thin film (0.05–0.15 mm) and the film is directly applied to the microfiber sheet by roll coating
- Bonding (Heat & Pressure Lamination) wherein the microfiber substrate and EVA adhesive are laminated at 110–120 °C under 2–5 bar pressure and controlled dwell time range varies 10–30 seconds, to activate bonding without deforming the microfiber structure

wherein the process is characterized by pre-integration of reinforcement and lining functions into a single composite sheet and elimination of intermediate adhesive lamination steps, and activation of bonding at low temperature (110–120 °C) and pressure (2–5 bar), to enable faster assembly, reduced energy consumption, and minimized processing steps and produces a composite reinforcement material comprising of a microfiber substrate, an extruded EVA adhesive film, and a polyurethane surface coating and characterized anti-wrinkle pretreatment, Anti-delamination pretreatment Optional surface activation.

5. The Process as claimed in claim 4 wherein Anti-wrinkle based pretreatment before roll coating is done by silicone-based softeners or aqueous PU dispersions.

6. The process as claimed in claim 4 wherein anti-delamination pretreatment is done by of isocyanate crosslinkers or silane coupling agents that increase bonding between polyamide fibers and EVA film.
7. The process as claimed in claim 4 wherein the optional surface activation is done by Plasma or corona discharge treatment to improve adhesive wetting.
8. The process as claimed in claim 4 wherein Roll Coating Process employed to spread the EVA film uniformly by Knife-over-roll / gravure roll coating methods and EVA is extruded in molten state at 160–200 °C and pressed onto the microfiber sheet wherein cooling rolls solidify the adhesive layer, preventing wrinkles.
9. The process as claimed in claim 4 wherein in bonding formation process softens the EVA at 110–120 °C, flows into the pores of the microfiber, and recrystallizes upon cooling, forming a strong mechanical and thermoplastic bond .
10. The process as claimed in claim 4 wherein nylon / polyester polymers is preprocessed by melt Spinning wherein Polymer chips are melted at ~250–280 °C and then Extrusion through Spinnerets wherein Filaments are drawn through micro-nozzles (much finer than human hair, ~0.1 denier) and is processed for Drawing & Stretching wherein Filaments are stretched 3–4x under controlled tension to align molecules and enhance strength and then performed the Splitting wherein bicomponent fibers are split into ultra-fine strands using chemical or mechanical processes, Bonding: Microfibers are bonded (via hydroentanglement or chemical binders) into a nonwoven microfiber fabric for softness, breathability, and dimensional stability.

Signature :
Name :MAHUYA HOM CHOUDHURY
IN/PA502
, Claims:We claim:
1. A dual-purpose polyamide microfiber-based reinforcement and three layered composite lining material (100-400) for handbags, comprising:
-a polyamide microfiber substrate (10) (Nylon) ranging from 40–55% by weight, wherein the repeating unit is –NH–(CH₂)₆–NH–CO–(CH₂)₄–CO–, characterized by long-chain polyamide through amide linkages (–CO–NH–) providing hydrogen-bonding sites that impart high tensile strength, flexibility, and dimensional stability;
-a thermoplastic adhesive layer (12) comprising an extruded EVA hot-melt film (EVA glue 210 D); and
-a polyurethane surface coating (14) in an amount ranging from 45–60% by weight
wherein the composite structure integrates reinforcement and lining into a single sheet and eliminates intermediate adhesive lamination wherein enables bonding activation at low temperature between 110–120 °C and pressure between 2–5 bar and ensures intimate contact and prevents delamination and formation of heat sensitive bonding zones by roll coating a microfiber substrate with EVA hot-melt adhesive film.

2. The composite as claimed in claimed 1 wherein the thickness between two layer varies from 0.4mm-1 mm wherein the thickness of Microfiber base (0.3–0.8 mm) thickness of EVA adhesive film (0.05–0.15 mm) and PU coating (0.05–0.1 mm)

3. The composite as claimed in claim 1 wherein tensile strength (length and width wise ) tongue tear(length and width wise) of composite material varies ≥ 280 standard softness 6 hardness(shore-D) 50 hardness(shore-C) 70 adhesive GSM 210 melting temperature(°c) 110-120.

4. The composite as claimed in claimed 1 wherein the nylon /polyester polymer structure undergoes melt spinning wherein Polymer chips are melted at ~250–280 °C and Filaments are drawn through micro-nozzles (much finer than human hair, ~0.1 denier) by extrusion and Spinnerets Filaments are stretched 3–4x under controlled tension to align molecules and enhance strength wherein Microfibers are bonded (via hydroentanglement or chemical binders) into a nonwoven microfiber fabric for softness, breathability, and dimensional stability.

5. A Process of Preparing Polyamide Microfiber-Based Reinforcement and Lining composite material characterized by

- Preparation of microfiber Substrate wherein Polyamide and polyethylene polymers are melt-spun into microfibers (0.1–0.3 denier) wherein fibers are bonded into a nonwoven microfiber sheet with thickness 0.3–0.8 mm
- Roll Coating of EVA Adhesive Film wherein an EVA (ethylene-vinyl acetate) thermoplastic hot-melt adhesive is extruded at 160–200 °C into a thin film (0.05–0.15 mm) and the film is directly applied to the microfiber sheet by roll coating
- Bonding (Heat & Pressure Lamination) wherein the microfiber substrate and EVA adhesive are laminated at 110–120 °C under 2–5 bar pressure and controlled dwell time range varies 10–30 seconds, to activate bonding without deforming the microfiber structure

wherein the process is characterized by pre-integration of reinforcement and lining functions into a single composite sheet and elimination of intermediate adhesive lamination steps, and activation of bonding at low temperature (110–120 °C) and pressure (2–5 bar), to enable faster assembly, reduced energy consumption, and minimized processing steps and produces a composite reinforcement material comprising of a microfiber substrate, an extruded EVA adhesive film, and a polyurethane surface coating and characterized anti-wrinkle pretreatment, Anti-delamination pretreatment Optional surface activation.

5. The Process as claimed in claim 4 wherein Anti-wrinkle based pretreatment before roll coating is done by silicone-based softeners or aqueous PU dispersions.

6. The process as claimed in claim 4 wherein anti-delamination pretreatment is done by of isocyanate crosslinkers or silane coupling agents that increase bonding between polyamide fibers and EVA film.
7. The process as claimed in claim 4 wherein the optional surface activation is done by Plasma or corona discharge treatment to improve adhesive wetting.
8. The process as claimed in claim 4 wherein Roll Coating Process employed to spread the EVA film uniformly by Knife-over-roll / gravure roll coating methods and EVA is extruded in molten state at 160–200 °C and pressed onto the microfiber sheet wherein cooling rolls solidify the adhesive layer, preventing wrinkles.
9. The process as claimed in claim 4 wherein in bonding formation process softens the EVA at 110–120 °C, flows into the pores of the microfiber, and recrystallizes upon cooling, forming a strong mechanical and thermoplastic bond .
10. The process as claimed in claim 4 wherein nylon / polyester polymers is preprocessed by melt Spinning wherein Polymer chips are melted at ~250–280 °C and then Extrusion through Spinnerets wherein Filaments are drawn through micro-nozzles (much finer than human hair, ~0.1 denier) and is processed for Drawing & Stretching wherein Filaments are stretched 3–4x under controlled tension to align molecules and enhance strength and then performed the Splitting wherein bicomponent fibers are split into ultra-fine strands using chemical or mechanical processes, Bonding: Microfibers are bonded (via hydroentanglement or chemical binders) into a nonwoven microfiber fabric for softness, breathability, and dimensional stability.

Signature :
Name :MAHUYA HOM CHOUDHURY
IN/PA502