Methods of coating fiber containing materials and coated fiber containing materials
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Solution Overview
Problem
Fiber containing materials, such as woven materials made from carbon fibers, often dislodge or deform during coating processes, and lose flexibility, necessitating a coating process that addresses these drawbacks.
Innovation Solution
A method involving applying a liquid solution with dispersed polymers containing urethane and/or urea linkages, forming a network of discontinuous dried polymeric particles, followed by a film-forming resin coating to enhance adhesion, using a film-forming resin that interacts with the dried polymeric material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating processes are applied to fiber containing materials, then coating can be achieved, but fibers dislodge or deform and flexibility is lost
Solution Approach 1:
A liquid solution containing dispersed polymer particles is applied to the fiber-containing material before the actual coating process. This preliminary treatment creates a prepared surface that enables subsequent coating while protecting fiber integrity and maintaining flexibility.
Solution Approach 2:
The dispersed polymer particles in the liquid solution act as an intermediary layer between the fiber-containing material and the final coating. This intermediate polymeric material facilitates coating adhesion while preserving fiber stability and flexibility during the manufacturing process.
2Reliability
If coating is applied to provide protective layer and color, then desired properties are achieved, but fibers lose flexibility
Solution Approach 1:
The liquid solution contains dispersed polymer particles that locally treat the fiber surface without forming a continuous rigid layer. This localized treatment provides protective properties while maintaining fiber flexibility through the discontinuous distribution of polymeric material.
Solution Approach 2:
The coating system uses a flexible polymeric material formed from dispersed polymer particles that creates a thin, flexible film on the fiber surface. This flexible coating provides protection and color while preserving the underlying fiber flexibility rather than creating a rigid shell.
3Strength
If continuous polymeric coating is applied, then adhesion is improved, but fiber flexibility and processing capability are reduced
Solution Approach 1:
The polymeric coating is applied as dispersed particles rather than a continuous film. This segmentation of the coating into discrete particles provides adequate adhesion through particle-to-fiber contact while leaving gaps that preserve fiber flexibility and processing capability.
Solution Approach 2:
The coating structure formed from dispersed polymer particles creates a porous or discontinuous layer on the fiber surface. This porous structure provides sufficient adhesion for the coating while maintaining fiber flexibility and allowing further processing operations that would be restricted by a solid continuous coating.
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 method provides improved adhesion and maintains flexibility of fibers, preventing dislodging and deformation during coating, enabling effective further processing.
Implementation Method 1
drying at least a portion of the liquid solution applied over the fibers of the material to obtain a dried polymeric material that forms a network of discontinuous dried polymeric particles over the fibers
Implementation Method 2
a first coating composition comprising a film-forming resin that interacts with the dried polymeric material to improve at least adhesion of the first coating layer over the plurality of fibers
Data Source
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AI summary
A method for coating a material having a plurality of fibers includes treating at least a portion of the fibers by applying a liquid solution over at least a portion of the fibers of the material in which the liquid solution includes a polymer dispersed in a liquid medium, drying at least a portion of the liquid solution applied over the fibers of the material to obtain a dried polymeric material that forms a network of discontinuous dried polymeric particles over the fibers, applying to at least a portion of the fibers a first coating composition comprising a film-forming resin that interacts with the dried polymeric material, and drying the first coating composition to form a first coating layer over at least a portion of the fibers. A coated material is also included.