Dual-Sided Embossed Thermoplastic Textile for Cloth-Like Performance
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Solution Overview
Problem
Existing synthetic fabrics that mimic natural cloth-like characteristics lack adequate flame resistance, water proofness, and other desirable properties while failing to replicate the natural appearance and feel, and vice versa, resulting in products with un-natural appearance or inadequate performance.
Innovation Solution
A flexible thermoplastic composite with a textured exterior and interior, featuring a multi-phase adhesive system and a core reinforcing layer, embossed and texturized using a unique system of rolls to create a natural cloth-like surface on both sides, combining the aesthetic and performance benefits of natural fabrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If dyed acrylic fabric is used to imitate natural cloth-like characteristics, then aesthetic appearance is improved, but flame resistance and water proofness deteriorate
Solution Approach 1:
The patent applies composite materials by combining thermoplastic polymer layers with fabric reinforcement layers to create a multi-layer composite structure. This composite approach allows the material to simultaneously achieve the aesthetic appearance of dyed acrylic fabric while incorporating the flame resistance and water proofness of thermoplastic polymers, resolving the contradiction between appearance and performance
2Reliability
If thermoplastic polymers are used to provide flame resistance and water proofness, then performance characteristics are improved, but aesthetic look and feel deteriorate
Solution Approach 1:
The patent uses composite materials with multiple layers where thermoplastic polymer layers provide flame resistance and water proofness, while fabric reinforcement layers and embossed surfaces provide the aesthetic look and feel of natural cloth. This composite structure resolves the contradiction by allowing each layer to contribute its superior properties
3Productivity
If metal embossing cylinder is used to texturize surface on one side, then production efficiency is improved, but natural cloth-like appearance on both sides deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the embossing process into separate operations for each side of the composite material. The first embossing operation texturizes the initial surface, then after lamination, a second embossing operation texturizes the opposite surface. This segmented approach maintains production efficiency while achieving natural cloth-like appearance on both sides
4Device complexity
If print pattern is used to imitate embossing, then manufacturing complexity is reduced, but natural appearance deteriorates
Solution Approach 1:
The patent applies the copying principle by using embossing rollers that physically replicate the surface texture of natural cloth fabrics. Instead of merely printing a pattern, the embossing process creates actual three-dimensional surface relief that copies the tactile and visual characteristics of natural cloth, achieving authentic appearance without excessive manufacturing complexity
5Ease of manufacture
If one-sided embossing is used to create cloth-like appearance, then production cost is reduced, but utility and application versatility deteriorate
Solution Approach 1:
The patent applies segmentation by implementing separate embossing operations for each side of the composite material. The first embossing creates cloth-like appearance on the initial surface, and the second embossing after lamination creates matching appearance on the opposite surface. This segmented approach increases production cost slightly but dramatically improves utility and versatility by making the material suitable for applications requiring aesthetic appearance from both sides
Data Source
AI summary
An embossing and texturizing system capable of imparting a natural cloth-like surface to a flexible thermoplastic material or film simultaneously to either or both of its two exterior surfaces, through the use of a unique device and technique combining metal rolls, metal and rubber rolls, and embossing and texturizing fabric rolls into an embossing system creating the desired visual and tactile feel of natural fabrics as well as additional performance characteristics. The embossing and texturizing system embosses and texturizes the exterior surface of the flexible thermoplastic material or film by selectively altering the exterior surface, and therefore, the film can be embossed simultaneously on either or both of its two exterior surfaces (face and reverse) without necessitating major interruption or adjustment of the system. The use of the embossing and texturizing mechanism and its alignment to the core and stabilizing reinforcing substrate enables the exterior texturized surface and the bottom side exterior texturized surface to be identical in all manner.