Dry Sliding Layer Production on Textile Backing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing a sliding layer on a flexible backing, such as a textile, involve wet-bonding processes that are time-consuming and require complex equipment, leading to issues like shrinkage, porosity, and reduced service life.
Innovation Solution
A dry production method involving the application of a hot-applied adhesive binder and a lubricant like graphite or PTFE to a flexible backing, where the binder is applied in a dry form and joined with heat, eliminating the need for water or steam and allowing for a denser, more durable sliding layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wet-bonding process is used to apply lubricant to the backing, then the lubricant can be fastened to the cloth, but the production time increases and complex equipment is required
Solution Approach 1:
The patent extracts and eliminates the water component from the traditional wet-bonding process. Instead of using a water-based dispersion to apply and bond the lubricant, the invention uses a dry bonding process where the binder is applied in dry form and activated by heat exposure, completely removing the drying step and associated equipment requirements
Solution Approach 2:
The patent changes the physical state parameter of the binder from liquid (in wet-bonding) to dry/powder form. This parameter change allows the binder to be applied as a dry substance that is then activated by thermal energy, fundamentally altering the bonding mechanism from chemical dissolution in water to thermal activation and elimination of water
2Ease of manufacture
If a wet-bonding process with water or steam is used, then the binder can be applied, but shrinkage or contraction of the sliding layer or backing occurs
Solution Approach 1:
The patent extracts and removes water and steam from the manufacturing process entirely. By using a dry binder application method followed by heat exposure, the process eliminates the source of moisture that causes shrinkage and contraction, thereby maintaining dimensional stability of both the backing and sliding layer
Solution Approach 2:
The patent creates an inert environment by eliminating moisture from the bonding process. The dry bonding process operates in a moisture-free environment, preventing water-induced shrinkage and contraction that would otherwise occur during wet-bonding and subsequent drying
3Ease of manufacture
If a wet-bonding process is used, then the lubricant can be applied, but the porosity of the sliding layer increases
Solution Approach 1:
The patent extracts water from the bonding process, allowing the lubricant to be applied in a dry state. This eliminates the formation of pores and voids that would otherwise be created by water evaporation, resulting in a denser sliding layer with improved lubricant distribution
Solution Approach 2:
The patent changes the application state of the lubricant from liquid suspension (in wet-bonding) to dry powder form. This parameter change allows for more uniform distribution and eliminates the porosity that results from water evaporation, creating a denser, more compact sliding layer
4Ease of manufacture
If a wet-bonding process is used, then the lubricant can be fastened to the backing, but the service life of the sliding layer is reduced
Solution Approach 1:
The patent extracts water from the bonding process, eliminating the porosity and voids that would otherwise be present in the sliding layer. This results in a denser, more durable structure with improved lubricant retention and distribution, directly extending service life by up to 50%
Solution Approach 2:
The patent creates a composite structure where the dry binder and lubricant particles are intimately mixed and bonded together through heat exposure. This composite formation ensures uniform lubricant distribution within the binder matrix, improving wear resistance and extending the service life of the sliding layer
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
This method significantly reduces production time, improves quality by preventing shrinkage, and extends the service life of the sliding layer by up to 50% while allowing for thicker layers and better lubricant dispersion, resulting in reduced wear and enhanced operational efficiency.
Implementation Method 1
applying a binder, more particularly an adhesive, preferably a hot-applied adhesive, more preferably a hotmelt, to the backing
Implementation Method 2
is joined to the backing with exposure to heat
Implementation Method 3
the lubricant is better able to disperse itself between the binder, producing a denser sliding layer
Implementation Method 4
a binder which is present in the dry state, as a particle between two lubricant particles, is able to melt on exposure to heat in order to be able to hold the lubricant particles more effectively
Data Source
AI summary
A method for dry production of a sliding layer on a flexible backing, in particular a backing that includes a textile or an abrasive backing, includes at least the following. A binder, or more particularly an adhesive such as a hot-applied adhesive or a hotmelt, is applied to a flexible backing. The binder is applied in dry form, such as via scattering, and is joined to the backing via exposure to heat to form a sliding layer on the backing and to hold the sliding layer at least one of on and in the backing. A lubricant, or more particularly a lubricant that includes graphite or PTFE, is applied to at least one of the backing and the binder.