Backside Coated Fabric With Spacer Layer for Water Barrier and Natural Hand
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Solution Overview
Problem
Existing coated fabrics lack improved water barrier properties while maintaining a natural hand and aesthetic qualities, as they are not adequately resistant to stains and microbial growth, and their manufacturing methods are not economical or durable.
Innovation Solution
A coated fabric design featuring a fabric substrate with a water permeable spacer layer having collapsed pores with an aspect ratio less than 0.5 and a water impermeable barrier layer, where the spacer layer allows water penetration at hydrostatic pressures up to a first pressure and the barrier layer prevents penetration at higher pressures, with the spacer layer having a mass density less than 80% of the barrier layer, resulting in a water-repellent, stain-resistant, and durable fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a water impermeable barrier layer is applied to provide water barrier properties, then water repellency is improved, but the fabric loses its natural hand and aesthetic qualities
Solution Approach 1:
The coating is divided into two distinct layers: a water permeable spacer layer (first layer) and a water impermeable barrier layer (second layer). The spacer layer provides breathability and maintains natural hand feel, while the barrier layer provides water repellency. This segmentation allows each layer to perform its specific function without compromising the overall fabric performance.
Solution Approach 2:
Different regions of the coating have different properties: the spacer layer is water permeable to maintain breathability and natural hand, while the barrier layer is water impermeable to provide protection. This local differentiation of properties allows the fabric to simultaneously achieve water barrier properties and natural hand feel.
2Reliability
If a thick water impermeable barrier layer is used to enhance water repellency, then water barrier properties are improved, but the fabric becomes stiffer and less comfortable
Solution Approach 1:
The coating system is segmented into two layers with the thinner barrier layer providing water repellency without excessive stiffness, while the spacer layer maintains flexibility and comfort. This segmentation allows optimization of each layer's thickness for its specific function.
Solution Approach 2:
The fabric uses a composite structure combining a water permeable spacer layer and a water impermeable barrier layer. This composite material approach allows the fabric to achieve both water barrier properties and maintained flexibility through the combination of different material properties.
3Reliability
If conventional coating methods are used to provide water barrier properties, then water repellency is improved, but manufacturing cost increases and durability decreases
Solution Approach 1:
The water permeable spacer layer is applied first as a preliminary layer before applying the water impermeable barrier layer. This preliminary action creates an optimized substrate for the barrier layer, improving adhesion and reducing the amount of barrier material needed, which lowers manufacturing costs while maintaining durability.
Solution Approach 2:
The dual-layer composite coating structure provides improved durability through better adhesion and stress distribution, while the optimized layer configuration reduces material usage and manufacturing complexity, making the process more economical.
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 fabric achieves enhanced water repellency and stain resistance with a natural hand, is easy to handle, and is economical to produce, while maintaining durability and improved water barrier properties.
Implementation Method 1
The water permeable spacer layer allows penetration of water therethrough at hydrostatic pressures applied to the front face of the fabric substrate greater than or equal to a first hydrostatic pressure
Implementation Method 2
The water impermeable barrier layer does not allow penetration of water through the article at hydrostatic pressures applied to the front face of the fabric substrate up to a second hydrostatic pressure
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
A backside coated fabric includes a fabric substrate having a front side (face) and a back side. A water permeable spacer layer is applied to the back side of the fabric substrate. The water permeable spacer layer allows penetration of water into its matrix when hydrostatic water pressure is applied to the face of the fabric substrate. The water permeable spacer layer provides a smooth coating surface onto which subsequent water impermeable barrier layers can be applied creating a physical separating layer between the fabric substrate and the water impermeable barrier layer. A water impermeable barrier layer is disposed over the water permeable spacer layer to provide an impermeable water barrier layer that does not allow penetration of water through the coated fabric when hydrostatic water pressure is applied to the face of the fabric construction.