PVC coated fabric structure

Abstract

The invention discloses a PVC (polyvinyl chloride) coated fabric structure, aiming at solving the problems of poor environmental protection property, insufficient mechanical property and weather resistance and single function of the existing PVC coated fabric. According to the structure, the prestress reinforced base cloth layer which is formed by blending basalt fibers and high-strength polyester and exerting prestress serves as a core framework; the two sides of the composite material are respectively in super-strong bonding with a functional bottom layer and a functional top layer which are made of non-phthalate environment-friendly plasticizers through high-bonding-force permeable layers containing organic coupling agents. The outer surface of the functional top layer is further coated with a super-weather-resistant self-cleaning surface treatment layer composed of a fluorine-containing polymer and nanometer titanium dioxide. The rare earth long afterglow material or the hollow glass beads are selectively compounded in the functional coating, so that the product is endowed with the characteristics of self-illumination at night, heat insulation, energy conservation and the like. The product is environment-friendly, non-toxic, high in mechanical strength, stable in size and long in weather-proof service life, and has the comprehensive advantages of self-cleaning, maintenance-free, firm interlayer bonding and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of polymer composite materials, and in particular to a PVC (polyvinyl chloride) coated cloth structure used in the fields of construction, transportation, advertising, protection, etc. Background Art

[0002] PVC-coated fabric, also known as tarpaulin, is widely used in truck tarpaulins, inflatable buildings, advertising inkjet printing substrates, tents, and other fields due to its reasonable cost, high strength, and excellent durability. Traditional PVC-coated fabric typically uses a polyester fiber base fabric coated on both sides with a PVC paste resin containing phthalate plasticizers, which is then plasticized by heating.

[0003] The existing technology mainly has the following defects: 1. Poor environmental protection: Commonly used phthalate plasticizers such as DOP and DBP have environmental hormone problems, are easy to migrate and precipitate, and pose a potential threat to human health and the ecological environment. Their use has been strictly restricted in the EU and other regions.

[0004] 2. Insufficient weather resistance: Ordinary PVC coatings are prone to yellowing, cracking, hardening and strength loss under long-term ultraviolet radiation and high and low temperature alternating environments, which limits their service life.

[0005] 3. Mechanical performance bottleneck: Although traditional polyester or nylon base fabrics have good strength, they are difficult to meet the stringent requirements of high-end applications (such as large-span tensile membrane structures) in terms of tear strength, dimensional stability and creep resistance.

[0006] 4. Single function: Existing products have relatively single functions, usually only having basic waterproofing and shielding functions, and lacking high value-added properties such as self-cleaning, flame retardancy, antistatic, and heat insulation.

[0007] Therefore, the development of a new PVC coated cloth structure with excellent environmental protection, ultra-high weather resistance, outstanding mechanical properties and composite functionality has important market value and practical significance. Summary of the Invention

[0008] The purpose of the present invention is to overcome the above-mentioned defects of the prior art and provide a high-performance, environmentally friendly and multifunctional PVC coated cloth structure, which has significant improvements in environmental safety, mechanical properties, weather resistance and composite functionality.

[0009] The above technical objectives of the present invention are achieved through the following technical solutions: A PVC coated cloth structure, comprising: The prestressed reinforced base fabric layer is woven from a blend of basalt fiber and high-strength synthetic fiber, and is prestressed in the warp and weft directions; The functional bottom layer and the functional top layer are respectively located on both sides of the prestressed reinforced base fabric layer, and both the functional bottom layer and the functional top layer are PVC coated with a non-phthalate environmentally friendly plasticizer; A high-adhesion permeation layer is provided between the prestressed reinforced base fabric layer and the functional bottom layer, and between the prestressed reinforced base fabric layer and the functional top layer, wherein the high-adhesion permeation layer is a modified PVC resin containing an organic coupling agent; The super weather-resistant self-cleaning surface treatment layer is coated on the outer surface of the functional top layer, and the super weather-resistant self-cleaning surface treatment layer comprises a fluorine-containing polymer and photocatalytic nanoparticles.

[0010] Furthermore, the high-strength synthetic fiber in the prestressed reinforced base fabric layer is high-strength polyester fiber.

[0011] Furthermore, the organic coupling agent in the high-adhesion permeation layer is a silane coupling agent or a titanate coupling agent.

[0012] Furthermore, nano silicon dioxide is added to the PVC coating of the functional bottom layer.

[0013] Furthermore, hollow glass microspheres are added to the PVC coating of the functional top layer.

[0014] Furthermore, rare earth long afterglow luminescent material is added to the PVC coating of the functional top layer.

[0015] Furthermore, the fluorine-containing polymer in the super-weather-resistant self-cleaning surface treatment layer is polyvinylidene fluoride or fluoroethylene-vinyl ether copolymer, and the photocatalytic nanoparticles are nano-titanium dioxide.

[0016] Furthermore, the non-phthalate environmentally friendly plasticizer is a bio-based plasticizer or a citrate plasticizer.

[0017] Furthermore, the prestress applied by the prestressed reinforced base fabric layer is achieved during a weaving process or a heat setting process.

[0018] Compared with the prior art, the present invention has the following beneficial effects: The core of this invention lies in its prestressed reinforced base fabric layer, which blends basalt fiber (with exceptionally high Young's modulus and stability) with high-strength synthetic fiber (with excellent flexibility) and incorporates bidirectional prestressing technology. Compared to existing technologies, this layer significantly improves tensile strength and tear resistance. More importantly, the application of prestress effectively suppresses creep and relaxation under long-term stress, imparting excellent dimensional stability to the final product. This makes it particularly suitable for applications with stringent material performance requirements, such as large-scale tensile membrane structures.

[0019] This invention explicitly requires the use of environmentally friendly, non-phthalate plasticizers in both the functional base and top layers. This feature eliminates the phthalate plasticizers (such as DOP and DBP) used in traditional PVC products, which pose a potential threat to human health and the ecological environment, resulting in a non-toxic and odorless product.

[0020] By applying a super-weather-resistant, self-cleaning surface treatment layer to the outermost layer, this invention achieves dual protection. First, the fluoropolymer (such as PVDF) inherently possesses excellent resistance to UV rays and chemical corrosion. Second, the compounded photocatalytic nanoparticles (such as nano-titanium dioxide) not only further shield against UV rays but also decompose attached organic contaminants under sunlight. This combination of properties ensures the product's long-term resistance to aging, yellowing, and cracking, extending its service life far beyond that of traditional products. Furthermore, its photocatalytic self-cleaning effect allows the surface to be restored to a clean state simply by washing with rainwater, achieving "maintenance-free" operation and significantly reducing long-term costs.

[0021] The high-adhesion permeable layer of this invention acts as a "molecular bridge." By adding an organic coupling agent, this layer chemically bonds with the inorganic basalt fiber surface at one end and physically entangles or reacts with the organic PVC coating at the other, firmly integrating the originally disparate base fabric and coating into a single entity. This results in interlayer peel strength far exceeding that of traditional bonding methods, ensuring that the product will not delaminate or peel even under the long-term effects of harsh environments such as wind, snow, and temperature fluctuations, thus maintaining the safety and integrity of the structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a detailed structural diagram of the present invention.

[0023] In the figure: 1. Functional bottom layer; 2. Prestressed reinforced base fabric layer; 3. High adhesion penetration layer; 4. Functional top layer; 5. Super weather-resistant self-cleaning surface treatment layer. DETAILED DESCRIPTION

[0024] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with the accompanying drawings and specific embodiments of the present invention. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0025] See also Figure 1The present invention discloses a PVC coated cloth structure, which comprises, from bottom to top, a functional bottom layer 1, a high-adhesion permeation layer 3, a prestressed reinforced base cloth layer 2, another high-adhesion permeation layer 3 and a functional top layer 4, and the outer surface of the functional top layer 4 is coated with a super weather-resistant self-cleaning surface treatment layer 5.

[0026] 1. Detailed description of the structure, principle and formula of each component The prestressed reinforced base fabric layer 2 is the core load-bearing framework of this invention. It is made from a blend of basalt fiber yarn and high-strength polyester (polyester) fiber yarn. Basalt fiber possesses an extremely high Young's modulus (approximately 80-90 GPa) and excellent chemical stability, providing the base fabric with exceptional dimensional stability and creep resistance, crucial for resisting long-term stress deformation. The high-strength polyester fiber, with its excellent flexibility, folding resistance, and high elongation at break, compensates for the brittleness of the basalt fiber, enhancing its overall tear resistance and durability. The combined strength and flexibility of these two materials contribute to the base fabric's unprecedented comprehensive mechanical properties.

[0027] Furthermore, to completely address the issues of "stress relaxation" and "creep elongation" experienced by coated fabrics under long-term tension, the present invention applies prestressing to the prestressed reinforced base fabric layer 2 in both the warp and weft directions. This technology applies precisely controlled tension during heat setting to preemptively eliminate internal stresses in the fibers and yarns generated during the weaving process, allowing the fiber chains to fully stretch and align under high tension. This effectively "pre-conditions" the material, achieving a highly stable internal structure and ensuring the final membrane's dimensional accuracy and stability over its decades-long design life.

[0028] The specific manufacturing parameters of the prestressed reinforced base fabric layer 2 in this embodiment are as follows: Yarn: 1800D basalt fiber yarn and 2000D high-strength polyester fiber filament are selected and twisted into blended yarn.

[0029] Weaving: Plain weave on a heavy duty prestressed loom with a warp and weft density of 9 x 9 threads / cm.

[0030] Prestress application: The woven base fabric is passed through a stenter setting machine and heat-set at a high temperature of 200°C, with a constant tension of 800N / m applied simultaneously in both the warp and weft directions for 3 minutes.

[0031] The high-adhesion permeable layer 3 is key to ensuring a secure bond between the inorganic basalt base fabric and the organic PVC coating, acting like a "molecular glue." Its core is a modified PVC resin with an organic coupling agent (in this case, a silane coupling agent). The silane coupling agent molecule possesses a unique amphiphilic structure: the hydrophilic group at one end (which forms -Si-OH upon hydrolysis) chemically bonds with the inorganic hydroxyl groups on the basalt fiber surface, forming a strong Si-O-Si bond. The organophilic group at the other end physically entangles or chemically reacts with the PVC macromolecule chain. This "molecular bridge" securely connects the base fabric and coating, originally distinct in nature, into a single, integrated whole.

[0032] The specific formula (in parts by weight) of the high-adhesion permeation layer 3 in this embodiment is as follows: PVC paste resin: 100 parts Environmentally friendly plasticizer (DOTP): 60 parts Calcium zinc composite heat stabilizer: 4 parts Silane coupling agent (KH-560): 3 parts Both the functional bottom layer 1 and the functional top layer 4 PVC coatings explicitly use non-phthalate environmentally friendly plasticizers (DOTP in this case), fundamentally eliminating the risk of traditional plasticizers (such as DOP) migrating and precipitating, which could harm human health and the ecological environment. This makes the product non-toxic, odorless, and compliant with international environmental regulations.

[0033] The formulas (in parts by weight) of the functional bottom layer 1 and the functional top layer 4 in this embodiment are as follows: Functional base layer 1 formula: PVC paste resin: 100 parts Environmentally friendly plasticizer (DOTP): 65 parts Calcium zinc composite heat stabilizer: 4 parts Nano silicon dioxide: 5 parts Nano-silica is added to the above formula, which utilizes its high hardness and nano effect to significantly improve the wear resistance and scratch resistance of the coating.

[0034] Functional Top 4 Formula: PVC paste resin: 100 parts Environmentally friendly plasticizer (DOTP): 65 parts Calcium zinc composite heat stabilizer: 4 parts Hollow glass microspheres: 15 parts Rare earth long afterglow luminescent material: 10 parts The above formula achieves dual functionality by adding hollow glass microspheres and rare earth long-lasting glow materials. The hollow microspheres utilize their internal vacuum layer to block heat conduction, providing insulation and energy conservation. The long-lasting glow material absorbs and stores light energy, slowly releasing it in darkness, achieving passive self-luminescence and enhancing safety.

[0035] The ultra-weather-resistant, self-cleaning surface treatment layer 5 is composed of a fluoropolymer (PVDF in this case) and photocatalytic nanoparticles (anatase-type nano-TiO2). The extremely high bond energy of the C-H bonds in the PVDF molecule imparts exceptional chemical stability, making it resistant to long-term erosion from ultraviolet rays, acid rain, and other factors, ensuring the product remains age-resistant, yellowing-resistant, and crack-free. Under UV light, the nano-TiO2 generates highly active free radicals that decompose attached organic contaminants into CO2 and H2O. Simultaneously, the surface becomes super-hydrophilic, allowing rainwater to easily wash away the decomposed contaminants and inorganic dust, achieving a maintenance-free, self-cleaning effect.

[0036] The specific process parameters of the super weather-resistant self-cleaning surface treatment layer 5 in this embodiment are as follows: The PVDF / TiO2 coating is applied by precision roller coating and rapidly cured at 220°C, eventually forming a dense protective film with a thickness of about 25 microns.

[0037] 2. Example of a complete manufacturing process S1. Fabric preparation and prestressing treatment First, prepare the prestressed reinforced base fabric as the core skeleton. 1800D basalt fiber yarn and 2000D high-strength polyester fiber filament are selected, and the two yarns are evenly blended into composite strands through a twisting and twisting process. Subsequently, plain weaving is carried out on a heavy loom, and the warp and weft density is set to 9×9 strands / cm to form a preliminary blended base fabric. In order to give the base fabric excellent dimensional stability, it is introduced into a large-scale stenter setting machine. Under a high temperature environment of 200°C, a constant tension of 800N / m is applied to the warp and weft directions of the base fabric at the same time, and heat setting treatment is carried out at a speed of 5 meters / minute. The whole process lasts about 3 minutes to complete the prestressing.

[0038] S2. Accurate preparation of PVC functional paste According to the functional requirements of different coatings, three types of PVC paste resins are precisely prepared in a high-speed mixer: 1. High adhesion penetration layer 3 paste: Mix the components evenly according to the following weight ratio: 100 parts of PVC paste resin, 60 parts of environmentally friendly dioctyl terephthalate (DOTP) plasticizer, 4 parts of calcium zinc composite heat stabilizer, and 3 parts of KH-560 silane coupling agent as a key adhesion enhancer.

[0039] 2. Functional bottom layer 1 paste: Mix the components evenly according to the following weight ratio: 100 parts of PVC paste resin, 65 parts of DOTP plasticizer, 4 parts of calcium zinc composite heat stabilizer, and 5 parts of nano-silicon dioxide for improving wear resistance.

[0040] 3. Functional top layer 4 paste: Mix the components evenly according to the following weight ratio: 100 parts of PVC paste resin, 65 parts of DOTP plasticizer, 4 parts of calcium-zinc composite thermal stabilizer, 15 parts of hollow glass microspheres for heat insulation, and 10 parts of rare earth long afterglow luminescent material for nighttime self-luminescence.

[0041] S3, double-sided simultaneous coating and plasticizing The double-sided synchronous scraper coating process is used. The prestressed base fabric is smoothly introduced into the coating production line. The coating heads on the production line operate in the following order: 1. First, apply the "high adhesion penetration layer 3 paste" thinly and evenly with a scraper and press it into both sides of the base fabric to ensure that it fully penetrates into the fiber gaps.

[0042] 2. Next, apply "functional bottom layer 1 paste" on one side of the base fabric (defined as the bottom layer side), and simultaneously apply "functional top layer 4 paste" on the other side (defined as the top layer side).

[0043] 3. The dry weight of the coating on both sides is precisely controlled by an online thickness gauge to ensure that the bottom layer reaches 300 g / m2 and the top layer reaches 350 g / m2.

[0044] After coating, the composite material is immediately transferred to a three-stage tunnel oven for heating and plasticization. The oven temperature is precisely set to 160°C in the first zone (preheating and solvent evaporation), 185°C in the second zone (main plasticization), and 200°C in the third zone (curing and stress relief). The total residence time in the oven is 2.5 minutes, ensuring that the PVC is fully plasticized into a uniform, dense elastomer.

[0045] S4, super weather-resistant self-cleaning surface treatment layer 5 construction The plasticized coil is introduced into the surface treatment section. First, polyvinylidene fluoride (PVDF) resin, an acrylate resin for adhesion, anatase nano-titanium dioxide, and related additives are mixed in a solvent to create a surface treatment coating with a 30% solids content. This coating is then evenly applied to the outer surface of the product's functional top layer (4) using precision roller coating. The coated cloth then rapidly passes through a curing oven at 220°C for 30 seconds to cure the coating, ultimately forming a dense, weather-resistant, and self-cleaning protective film approximately 25 microns thick on the product surface.

[0046] S5. Finished product arrangement and inspection Finally, the coated cloth that has completed all the processes will be cooled down by cooling rollers in turn, and then pass through the online defect detection system, automatic deviation correction and trimming machine and tension control winder to complete inspection, cutting and winding, and obtain the final high-performance, environmentally friendly and multifunctional PVC coated cloth product.

[0047] 3. Comparative Examples and Effect Verification To objectively and quantitatively demonstrate the superior performance of the present invention, comparative example 1 (a conventional polyester tarpaulin using a DOP plasticizer and without a special functional layer or surface treatment) was prepared and subjected to standard testing with the examples of the present invention. The results are as follows:

[0048]

[0049] The comparative experiments above demonstrate that the warp / weft tensile strength (5500 / 5300N / 5cm) and tear strength (750 / 700N) of the present invention's products are nearly twice that of conventional products. The interlayer peel strength (>150N / 5cm) of the present invention is significantly higher than the <80N / 5cm of conventional products. Furthermore, its creep rate (<0.3%) is at most one-fifth that of conventional products. After 2000 hours of accelerated aging testing, the present invention's samples exhibited minimal color difference and virtually no strength loss, whereas conventional products exhibited severe discoloration and a significant loss in strength. In self-cleaning tests, stains on the present invention's samples were easily rinsed clean with clean water. No harmful plasticizer migration was detected in the present invention's products, and their thermal conductivity was significantly lower than that of conventional products.

[0050] In summary, this embodiment, through detailed principle explanation, specific process parameters and quantitative performance comparison, comprehensively proves that the PVC coated cloth structure disclosed in the present invention is a new product that far exceeds the existing technology level in terms of mechanical properties, dimensional stability, interlayer bonding strength, weather resistance, environmental safety and multifunctionality.

[0051] This specific embodiment is merely an explanation of the present invention and is not intended to limit the present invention. After reading this specification, those skilled in the art may make non-creative modifications to this embodiment as needed. However, as long as such modifications are within the scope of the claims of the present invention, they are protected by patent law.

Claims

1. A PVC coated cloth structure, characterized in that: include: The prestressed reinforced base fabric layer (2) is woven from blended yarns of basalt fiber and high-strength synthetic fiber, and is prestressed in the warp and weft directions; The functional bottom layer (1) and the functional top layer (4) are respectively located on both sides of the prestressed reinforced base fabric layer (2), and both the functional bottom layer (1) and the functional top layer (4) are PVC coatings using non-phthalate environmentally friendly plasticizers; A high-adhesion permeation layer (3) is provided between the prestressed reinforced base fabric layer (2) and the functional bottom layer (1), and between the prestressed reinforced base fabric layer (2) and the functional top layer (4), wherein the high-adhesion permeation layer (3) is a modified PVC resin containing an organic coupling agent; A super-weather-resistant self-cleaning surface treatment layer (5) is coated on the outer surface of the functional top layer (4), and the super-weather-resistant self-cleaning surface treatment layer (5) contains a fluorine-containing polymer and photocatalytic nanoparticles.

2. The PVC coated cloth structure according to claim 1, characterized in that: The high-strength synthetic fibers in the prestressed reinforced base fabric layer (2) are high-strength polyester fibers.

3. The PVC coated cloth structure according to claim 1, characterized in that: The organic coupling agent in the high-adhesion permeation layer (3) is a silane coupling agent or a titanate coupling agent.

4. The PVC coated cloth structure according to claim 1, characterized in that: Nano-silicon dioxide is added to the PVC coating of the functional bottom layer (1).

5. The PVC coated cloth structure according to claim 1, characterized in that: Hollow glass microspheres are added to the PVC coating of the functional top layer (4).

6. A PVC coated cloth structure according to claim 1 or 5, characterized in that: Rare earth long afterglow luminescent material is also added to the PVC coating of the functional top layer (4).

7. The PVC coated cloth structure according to claim 1, characterized in that: The fluorine-containing polymer in the super-weather-resistant self-cleaning surface treatment layer (5) is polyvinylidene fluoride or fluoroethylene-vinyl ether copolymer, and the photocatalytic nanoparticles are nano-titanium dioxide.

8. The PVC coated cloth structure according to claim 1, characterized in that: The non-phthalate environmentally friendly plasticizer is a bio-based plasticizer or a citrate plasticizer.

9. The PVC coated cloth structure according to claim 1, characterized in that: The prestress applied by the prestressed reinforced base fabric layer (2) is achieved during a weaving process or a heat setting process.

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