Composite Fabric Barrier via Adhesive Layer Segmentation
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Solution Overview
Problem
Existing methods for producing flexible composite fabrics with high barrier properties, such as those used in sewer pipe rehabilitation, face challenges in achieving sufficient leakproofness and flexibility for applications under high pressure, particularly when using a two-coating-station transfer coating line, which limits barrier layer thickness and consistency.
Innovation Solution
A composite fabric is created with a fabric backing, an adhesive layer, and a midlayer barrier bonded to the fabric, followed by an external barrier, allowing for variable composition and thickness of the barrier layers, achieving hydrostatic pressure resistance of at least 100 psi and sufficient flexibility for tubular formation and use in CIPP repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-coating-station transfer coating line is used to produce barrier fabric, then the process remains economical and relatively simple, but the barrier layer thickness and leakproofness are severely limited
Solution Approach 1:
The barrier fabric construction is segmented into multiple functional layers: a barrier layer applied at the first coating station, an adhesive layer applied at the second coating station, and a separate scrim layer. This segmentation allows each layer to perform its specific function optimally while maintaining process simplicity.
Solution Approach 2:
The invention transitions from a single-layer barrier approach to a multi-layer three-dimensional structure. By stacking the barrier layer, adhesive layer, and scrim layer, the system achieves enhanced leakproofness and mechanical properties without complicating the two-coating-station process.
2Reliability
If the barrier layer thickness is increased to achieve leakproofness, then barrier properties improve, but the fabric loses flexibility and ability to stretch
Solution Approach 1:
Different layers are assigned different functional qualities: the barrier layer provides leakproofness with appropriate thickness, while the scrim layer provides flexibility and stretch. This local quality assignment allows the composite fabric to exhibit both barrier properties and flexibility simultaneously.
Solution Approach 2:
The invention creates a composite fabric by combining materials with complementary properties: a polymer-based barrier layer for leakproofness and a scrim (mesh-like structure) for flexibility and dimensional stability. The composite structure achieves properties that neither material could provide alone.
3Ease of manufacture
If a single barrier layer is applied to achieve leakproofness, then the process is simple, but it is nearly impossible to guarantee substantially leakproof quality
Solution Approach 1:
The barrier layer is applied and dried at the first coating station as a preliminary step, establishing a consistent base barrier. Subsequent layers are then applied in a controlled sequence, ensuring each layer contributes to the overall leakproofness without compromising process simplicity.
4Adaptability or versatility
If variable composition and thickness of barrier layers are implemented to meet different pipe rehabilitation situations, then adaptability improves, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is made dynamic by allowing independent variation of barrier layer and adhesive layer compositions and thicknesses. This enables the system to adapt to different pipe rehabilitation requirements (gravity-driven vs. pressure pipes) without requiring a completely different manufacturing setup.
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 solution enables the production of substantially leakproof composite fabrics with enhanced barrier properties, flexibility, and durability, suitable for both gravity-driven and pressure-pipe applications, including those transporting potable water, while maintaining economic efficiency and process simplicity.
Implementation Method 1
an adhesive layer; a midlayer barrier bonded to the fabric backing by the adhesive layer
Implementation Method 2
the composite fabric has a hydrostatic pressure resistance of at least 100 psi
Data Source
AI summary
A composite fabric includes: a fabric backing; an adhesive layer; a midlayer barrier bonded to the fabric backing by the adhesive layer; and an external barrier bonded to the midlayer barrier, wherein the composite fabric has a hydrostatic pressure resistance of at least 100 psi and is sufficiently flexible such that it can be formed into a tube and everted. A process and an apparatus for producing the composite fabric are also disclosed. The composite fabric is particularly suitable for use as a liner in a cured-in-place pipe repair method.