Binder-Treated Fabric Laminates for Adhesion and Flexibility
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Solution Overview
Problem
The production of coated fabrics using impregnation methods with polyvinyl chloride, rubbers, and polyurethanes results in increased weight and cost, reduced flexibility, and altered polymer properties, necessitating a method to enhance material properties while maintaining mechanical integrity.
Innovation Solution
A method involving the preparation of binder-treated fabric materials by applying a binder dispersion, removing the solvent, and curing the binder, followed by laminating polymer films to improve adhesion and tensile strength, utilizing low modulus binders compatible with polymer films to enhance fiber penetration and material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If full impregnation of fabric with polymer materials is performed, then adhesion strength and tensile strength are improved, but weight increases and flexibility decreases
Solution Approach 1:
The patent applies partial impregnation instead of full impregnation, using only enough binder to achieve the necessary adhesion strength between fabric and polymer film. This partial action approach achieves the required bonding strength without over-impregnating the fabric, thereby avoiding unnecessary weight increase and flexibility loss.
Solution Approach 2:
The binder is applied locally at the interface between the fabric and polymer film where adhesion is needed, rather than uniformly impregnating the entire fabric. This localized application ensures strong bonding at the critical interface while minimizing binder content throughout the fabric structure, thus reducing weight while maintaining adhesion strength.
2Strength
If full impregnation of fabric with polymer materials is performed, then adhesion strength and tensile strength are improved, but flexibility decreases
Solution Approach 1:
The patent uses partial impregnation with minimal binder content (e.g., 0.5-5% by weight) sufficient to achieve the required tensile strength and adhesion. This partial action avoids excessive binder that would restrict fabric movement, thereby maintaining flexibility while achieving the necessary strength improvement.
Solution Approach 2:
The binder is concentrated at the fabric-polymer film interface where it provides the necessary bonding and tensile strength enhancement. This localized placement ensures strength improvement without distributing binder throughout the fabric in a way that would compromise flexibility.
3Ease of operation
If additives are added to impregnating material to increase flexibility, then flexibility of coated fabric is improved, but strength of polymer coating is reduced
Solution Approach 1:
The patent uses a specifically formulated binder as an intermediary substance that provides both flexibility and strength simultaneously. This binder acts as a mediator between the fabric and polymer film, containing plasticizers and other additives that enhance flexibility while maintaining coating strength, rather than adding such additives directly to the polymer coating material.
Solution Approach 2:
The patent modifies the chemical composition parameters of the binder to achieve the desired balance between flexibility and strength. By adjusting binder formulation parameters (such as plasticizer content, molecular weight, and crosslinking density), the system achieves both flexibility enhancement and strength maintenance in the final composite structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method significantly increases tensile strength by over 100% and adhesion strength by about 400% compared to untreated fabrics, while maintaining flexibility similar to untreated materials, through improved binding between the fabric and polymer films.
Implementation Method 1
The binder dispersion is applied to the fabric material and penetrates through the fabric, with the binder saturating the fabric structure
Implementation Method 2
removing the solvent from the binder dispersion-treated fabric material
Implementation Method 3
curing the binder in the binder dispersion-treated fabric material to provide a binder-treated fabric material
Implementation Method 4
laminating a polymer film to at least one surface of the binder-treated fabric material
Implementation Method 5
laminating a polymer film on at least one fabric surface of the binder-treated fabric material to provide a laminated fabric material
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Provided are methods for preparing fabric laminated with polymer film(s) and the laminated fabric prepared according to the methods disclosed herein. The laminated fabric has flexibility similar to fabric not laminated with polymer films and improved adhesion and tensile strength.