Base fabric for coating

Abstract

The invention relates to a base fabric for coating applications used in the field of technical textiles for various purposes and in diverse areas of use. More particularly, the invention concerns a base fabric suitable for the production of coated fabrics comprising filament yarns in the warp direction.

Description

[0001] BASE FABRIC FOR COATING

[0002] Technical Field

[0003] The present invention relates to the field of technical textiles and, more particularly, to a base fabric for coating applications used for various purposes and in various applications such as mechanized curtains, truck tarpaulins, and placemats.

[0004] State of The Art

[0005] In the field of technical textiles, fabric coating is a frequently applied method used to impart functional properties to the fabric depending on its intended purpose. In coating methods used to create textile products with technical and functional features, the technical characteristics provided to the fabric by the method are prioritized over the appearance and aesthetic features. The performance and functional properties of coated fabrics vary depending on the coating material used, the coating technique applied, and the structure and properties of the textile surface. Coated fabrics are used in various fields such as agricultural and medical textiles, home textiles, and protective clothing.

[0006] The fabrics that can be used for coating can be woven or knitted fabrics, as well as nonwoven fabrics that are produced directly from fibers. Additionally, coating can be applied to yarns in yarn form, and then coated fabric can be obtained thereafter.

[0007] In coated fabrics, the base fabrics used typically provide properties such as tensile strength, tear resistance, and elongation in the final product; whereas the coating material provides impermeability, chemical and environmental protection, and in some cases, visual improvement.

[0008] In the field of textiles, base fabrics used for coating are generally made of fabrics in which both warp and weft yarns are 100% staple fiber. However, working with staple fiber is difficult. Staple fiber yarn causes a significant amount of lint during weaving and dyeing stages, which reduces production performance and increases the rate of defects.

[0009] It is difficult to ensure the uniformity of the yarn in fabrics made of staple fiber, and therefore it is also difficult to obtain a smooth fabric surface. As a result, fabrics formed with staple fiber structures have a rougher surface. However, in order to achieve a homogeneous coating, it is desired that the base fabric used has a surface that is as smooth as possible. A coating base fabric made of staple fiber can be formed by using single-ply staple fiber yarn in the warp. However, to form fabric from such yarn, it is necessary to apply sizing before weaving. This sizing process increases both the production process and, accordingly, the cost, and also causes defects arising from the sizing. Due to these defects, the rate of nonconformity in the fabric increases. In addition, for coating, it is necessary to remove the sizing from the base fabric, which requires an extra process. Excessive water consumption and wastewater load during size removal makes the process environmentally unfriendly. This is one of the most important disadvantages of producing coating base fabric from staple fiber.

[0010] Another method used to form coating base fabric is that the staple fiber warp yarn is used as doubleply. However, in such fabrics, the cost increases significantly due to the doubling process.

[0011] Coating base fabrics can be positioned directly in front of sunlight. In such fabrics, any surface irregularity becomes clearly visible as a defect due to the light coming from behind. This makes the surface uniformity a critical quality parameter for coating base fabrics.

[0012] This situation reveals the need for developing a solution for base fabrics to be used in coating applications.

[0013] Patent document No. CN101280522B relates to a high-strength fabric for suitcases and bags and a manufacturing method for it. This method describes a coated fabric woven using high-strength polyester filament yarn, which has a higher strength index. This invention relates to high-strength products. In other words, its intended use is completely different from our invention. Furthermore, the invention requires both the warp and weft to be filament yarns. In our invention, the warp's filament yarn is sufficient to create a coated ground fabric. Conventional polyester yarns can be used instead of high-strength yarns.

[0014] In the utility model document No. CN203344433U, a coated fabric for shading purposes is disclosed. The fabric coated for shading comprises an outer layer and a base fabric. The outer layer is made of a fluorocarbon resin material. The base fabric is formed by the interlacing of warp and weft yarns. The warp yarns consist of two types of yarns: polyester filaments and nylon filaments. The warp yarns are arranged in a repeating sequence consisting of three polyester filament yarns and two nylon filament yarns. As the weft yarn, polytetrafluoroethylene fibers are used. In our invention, on the other hand, homogeneity of the warp is important for surface smoothness. Therefore, it is composed of a single type of polymer. In the patent document No. JP2000110072A, a coated fabric made from bicomponent yarn having a polyester core and a nylon outer surface is described. Due to the yarn used in this fabric, the entire fabric surface consists of nylon. In our invention, such a bicomponent yarn is not used, and the fabric obtained through our invention is entirely different from the fabric disclosed in that document.

[0015] As a result, a need has arisen for a solution to be developed for base fabrics that can be used for coating applications.

[0016] Objectives and Brief Description of the Invention

[0017] The purpose of the invention is to increase production performance in coating base fabrics, reduce the defect rate in the resulting coated fabric, and obtain a more homogeneous surface.

[0018] Another purpose of the invention is to form fabric by reducing linting during the weaving and dyeing stages in the production of coating base fabrics.

[0019] To achieve the above purposes, the invention is a coating base fabric comprising polyester filament yarn. The number of filaments in the mentioned polyester filament yarn is between 24-1126. The density of the mentioned polyester filament yarn is between 5-60 yarns / cm. The coating base fabric generally has a plain weave, basket weave, or satin weave structure, but it can also be produced in different armure or jacquard weaves.

[0020] Detailed Description of the Invention

[0021] The present invention relates to a base fabric for coating applications, consisting of polyester filament yarn in the warp direction, having a filament density of 5-60 yarns / cm and a filament count between 24-1126.

[0022] In coated fabrics, the surface of the base fabric is smoothed by applying a coating material. This causes the final coated fabric to have a stiffer handle and a loss in drapability. Coated fabrics created in this way can be used on smoother surfaces. Coated fabrics are used in mechanical blinds, such as roller blinds. However, they are also used in areas such as truck tarpaulins and placemats.

[0023] The base fabrics used for coating purposes are generally made of 100% staple fiber yarns in both warp and weft directions. Working with staple fiber yarn has several disadvantages. These yarns generate a significant amount of lint during weaving and dyeing processes, which leads to reduced production performance and an increased rate of defects in the fabric. When creating a base fabric with staple fiber yarns, it is possible to use single-ply staple fiber yarns in the warp. However, weaving such staple fiber yarns requires sizing beforehand. This increases both the process cost and the risk of defects caused by the sizing, thereby increasing the fabric’s defect rate. Additionally, it becomes necessary to remove the sizing from the fabric after coating. Removing the sizing requires an extra process, excessive water consumption, and causes a significant wastewater load, making the process environmentally unfriendly. In the present invention, the use of filament yarns instead of staple fiber yarns in the warp allows achieving the desired properties for base fabrics for coating applications without the need for sizing. In this way, the invention is both environmentally friendly and reduces costs due to the elimination of additional processing. It also causes less lint during weaving and dyeing stages.

[0024] In the known art, the use of double-ply staple fiber yarns in the warp of coated fabrics is also common. However, this practice also increases the fabric cost. In constructions made from staple fiber yarns, the surface of the fabric tends to be rougher. Since surface smoothness is a desired property in base fabrics for coating, this roughness makes it difficult to achieve both a homogeneous coating and a smooth final surface.

[0025] In the present invention, the use of filament yarns instead of staple fiber yarns in the warp improves the fabric performance and quality of the base fabrics for coating applications. All other synthetic fibers can be used as alternatives to filament yarns. The fabric made from filament yarns in the invention has a smoother surface compared to fabrics made from staple fibers. Therefore, the base fabric formed in the present invention can be produced at lower costs, with smoother surfaces, and in higher quality. Additionally, thanks to the TiO2content in the filament yarns used, the matte surface reflects sunlight more effectively, preventing excessive heating of indoor spaces.

[0026] The polyester filament yarns used in the invention are flat and non-bulky after yarn extrusion. Therefore, in the texturing process, the filaments are made crimped, i.e. , bulky, by the effect of heat and tension. Although filament yarns can be textured with any kind of texturing process, air texturing is preferably used in the invention. With this texturing process, the filaments gain high bulk and intertwine with each other, which reduces the risk of yarn breakage during weaving. Moreover, due to the texturing process, there is no need to support the filament yarns with chemicals such as sizing. In the invention, by giving bulk to the filament yarns with special texturing processes, fabrics having similar bulk, drape, and handle to those made from staple fiber yarns can be obtained. This texturing process allows the yarn to be woven and a smoother fabric surface to be obtained, enabling better coating of the fabric. The filament warp yarns used are first placed on the creel and then transferred to the warp beam. In the case of staple fiber yarns, the yarns in the beam are passed through a sizing bath to coat them with sizing material and then dried before being transferred to the weaving beam. When filament yarns are used as warp yarns, as in the present invention, there is no need for sizing during weaving because the yarns do not require the strength provided by sizing and are not prone to defects caused by hairiness. Moreover, in fabrics formed with staple fiber yarns, the sizing material must be washed off the fabric after weaving. This leads to the formation of wastewater contaminated with sizing and increases the process cost due to additional washing. In the present invention, since filament yarns are used in the warp, there is no need for sizing and thus no need to remove sizing afterward. In the invention, filament yarns are used as warp yarns. The linear density of these warp yarns is between 50 denier and 1000 denier, preferably 450 denier. The weft yarns range from Ne 80 / 1 to Ne 4 / 1 , preferably Ne 30 / 1. The yarn density is between 5 and 60 yarns / cm, preferably 15 yarns / cm. The base fabric of the invention can be woven using basic weave structures such as plain weave, basket weave, satin weave, or alternative dobby structures such as leno weave, and even jacquard patterns depending on the intended use.

Claims

CLAIMS1. A base fabric for coating applications, characterized in that it comprises polyester filament yarn.

2. The base fabric for coating applications according to claim 1, characterized in that the linear density of the polyester filament yarn is between 50 denier and 1000 denier.

3. The base fabric for coating applications according to claim 1 , characterized in that the number of filaments in the polyester filament yarn is between 24 - 1126.

4. The base fabric for coating applications according to claim 1 or 2, characterized in that the polyester filament yarn has a density between 5 - 60 yarns / cm.

5. The base fabric for coating applications according to any of the preceding claims, characterized in that it has a plain weave, basket weave, satin weave, dobby weave or jacquard weave structure.