Composite Textile Thermal Bonding Solvent-Free Strength
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Solution Overview
Problem
Conventional textile surface processing methods using polymer coatings or adhesive films with organic solvents fail to enhance textile strength and are harmful to health and the environment, with issues of solvent residue and adhesion degradation over time.
Innovation Solution
A composite textile is created by combining a fabric layer made of thermoplastic elastomer or a combination of thermoplastic elastomer and polymer with a membrane layer, where the membrane layer's lower melting point allows it to penetrate into the fabric's pores, enhancing binding and strength without using organic solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polymer coating solution is applied on textile surface, then water-proofing function is enhanced, but textile strength cannot be enhanced and organic solvent residue remains harmful
Solution Approach 1:
The patent merges the fabric layer and membrane layer into a single composite textile structure where the membrane layer is bonded to the fabric layer, achieving both water-proofing and strength enhancement simultaneously. The membrane layer provides water-proofing while the fabric layer maintains structural strength, and their integration creates a unified strong structure.
Solution Approach 2:
The patent uses composite materials by combining fabric (textile fibers) and membrane (polymer material) into a composite textile structure. This composite structure leverages the strengths of both materials: the fabric provides tensile strength and breathability, while the membrane provides water-proofing, achieving both functions without harmful solvent residues.
2Ease of manufacture
If organic solvent is used in polymer coating, then coating process is achieved, but processing time extends due to evaporation and maturation requirements
Solution Approach 1:
The patent extracts and eliminates the organic solvent component from the coating process. Instead of using polymer coating solution requiring evaporation, the invention directly bonds the membrane layer to the fabric layer through heat and pressure, removing the time-consuming evaporation and maturation steps while maintaining the water-proofing function.
3Ease of manufacture
If adhesive film is applied on textile, then combination is achieved, but adhesion degrades over time causing detachment
Solution Approach 1:
The patent replaces the chemical adhesion mechanism (adhesive bonding) with a physical/thermal bonding mechanism. The membrane layer is bonded to the fabric layer through heat and pressure, creating a more stable and durable connection that does not degrade over time like adhesive bonds. This thermal bonding method provides long-term reliability.
4Ease of manufacture
If organic solvent is used in thermosol solution, then film sticking is achieved, but health and environmental harm occurs due to solvent residue
Solution Approach 1:
The patent extracts and eliminates the organic solvent from the thermosol solution. Instead of using solvent-based adhesive, the invention uses direct thermal bonding between the membrane layer and fabric layer, achieving the same film sticking effect without generating harmful solvent residues that affect health and environment.
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 composite textile achieves improved strength and water resistance with enhanced tearing strength and pressure tolerance, eliminating the need for organic solvents and ensuring a safer, more sustainable processing method.
Implementation Method 1
the melting point of the first membrane layer is lower than the melting point of the first fabric layer
Implementation Method 2
parts of the fourth surface of the first membrane layer permeate into the multiple pores of the first fabric layer
Implementation Method 3
applying heat and pressure to the stacked structure
Implementation Method 4
applying heat and pressure to the stacked structure
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Provided is a composite textile (10) includes a first fabric layer (11A, 13) which is formed by weaving, wherein the first fabric layer (11A, 13) comprises a first surface (111A, 131), a second surface (112A, 132) and multiple pores (113A, 133); and a first membrane layer (14), wherein the melting point of the first fabric layer (13) is higher than the melting point of the first membrane layer (14); wherein the first membrane layer (14) comprises a third surface (141) and a fourth surface (142), and the fourth surface (142) of the first membrane layer (14) is attached to the first surface (131) of the first fabric layer (13), and parts of the fourth surface (142) of the first membrane layer (14) permeate into the multiple pores (133) of the first fabric layer (13).