3D Fabric Coating via Gas Pressure Differential
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing articles with fabric coatings face challenges such as poor bonding between the coating and fabric, incorrect placement of the coating, and instability in three-dimensional shapes due to restoring forces from the coating, leading to issues like buckling and creases.
Innovation Solution
A method involving a support structure with a raised or embossed surface that allows gas circulation, where the fabric is placed over the embossed portion and a coating is applied with a gas pressure differential to ensure strong bonding and conform to the fabric's three-dimensional shape, using a draping membrane for additional pressure and heat for improved adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coating is applied to the fabric while the fabric is in a two-dimensional flat shape, then the coating application process is simple, but the coating does not fit the three-dimensional shape of the article and causes buckling and cracks
Solution Approach 1:
The fabric is pre-formed into its three-dimensional shape on a last before the coating is applied. This preliminary shaping ensures that when the coating is subsequently applied, it conforms to the final article shape, eliminating buckling and cracking issues that occur when coating flat fabric that is later shaped.
2Manufacturing precision
If the coating is applied to the three-dimensional shaped fabric, then the coating fits the article shape, but the coating creates restoring forces that try to return the fabric to two-dimensional shape
Solution Approach 1:
The coating is applied while the fabric is in its three-dimensional shape, merging the coating application process with the shaped state of the fabric. This ensures the coating conforms to the final shape and the fabric maintains its three-dimensional form without restoring forces, as the coating is applied to and with the fabric already in its final configuration.
3Ease of manufacture
If conventional coating methods are used, then the coating can be applied to the fabric, but the bonding between the coating and fabric is poor
Solution Approach 1:
A vacuum system is used to press the coating against the fabric surface, creating strong bonding through suction. The vacuum applicator component draws the coating material onto the fabric, ensuring intimate contact and strong adhesion between the coating and fabric layers.
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 achieves excellent bonding between the coating and fabric, maintains the fabric's three-dimensional shape, and ensures precise placement, enhancing properties like water repellency and abrasion resistance while maintaining the fabric's breathability and texturing.
Implementation Method 1
applying a gas pressure differential between the second surface of the coating and the first surface of the fabric
Implementation Method 2
a vacuum source connected to the support structure for applying a gas pressure differential
Implementation Method 3
using a draping membrane for additional pressure and heat for improved adhesion
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E
AI summary
The present invention relates to a method of manufacturing an article comprising a fabric (10), wherein the method comprises at least the steps of: (a.) providing a fabric (10) comprising a first surface and a second surface opposite the first surface; (b.) placing the fabric (10) on a surface of a support structure (11), wherein the support structure (11) is adapted to permit gas circulation through at least a portion of its surface (12) and comprises at least a raised or embossed portion (13) on its surface (12), and wherein the fabric (10) is placed such that the first surface of the fabric (10) faces the surface (12) of the support structure (11) and such that the fabric (10) is arranged at least in part over the raised or embossed portion (13) of the support structure (11); (c.) providing at least one coating (14) comprising a first surface and a second surface opposite the first surface; (d.) placing the coating (14) at least partially on the second surface of the fabric (10), such that the first surface of the coating (13) faces the fabric (10); and (e.) applying a gas pressure differential between the second surface of the coating (14) and the first surface of the fabric (10).