Multilayer Fiber Web Coating for Incompatible Polymers
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Solution Overview
Problem
Conventional methods for applying multiple polymeric coatings onto fibrous substrates face challenges due to chemical or physical incompatibilities between materials, limiting the ability to combine beneficial properties in a single fabric structure, and require multiple steps that can lead to inconsistent bonding and processing issues.
Innovation Solution
A hybrid coating technique combining pan-fed reverse roll coating and dip and squeeze coating methods, allowing for the application of different polymeric materials onto a fibrous substrate without regard to incompatibilities, where a first polymeric material is applied directly to the fibers and a second material is transferred from a support, enabling the creation of a multilayer coating with improved adhesion and consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple polymeric coatings are applied using conventional sequential methods, then different polymeric materials can be combined, but chemical or physical incompatibilities between materials limit the ability to combine beneficial properties
Solution Approach 1:
The coating process is segmented into two independent stages: first applying a polymeric coating to the fibrous substrate, then applying a second polymeric coating to a support surface and transferring it to the first coating. This segmentation allows incompatible materials to be applied without direct interaction during the application process, resolving the compatibility issue while maintaining the ability to combine different polymeric properties.
Solution Approach 2:
A support surface acts as an intermediary medium in the second coating application. The second polymeric material is applied to the support and then transferred to the fibrous substrate, preventing direct contact between incompatible polymeric materials during application while still achieving the desired multilayer structure with combined properties.
2Adaptability or versatility
If multiple coating steps are used to apply different polymeric materials, then material properties can be combined, but the number of processing steps increases leading to inconsistent bonding and processing issues
Solution Approach 1:
The method merges the application of two polymeric coatings into a coordinated process where the second coating is applied to a support and then transferred to the fibrous substrate in immediate succession. This merging reduces the number of independent processing steps compared to conventional sequential coating methods, improving consistency while maintaining the ability to combine different polymeric properties.
Solution Approach 2:
The second polymeric material is applied to a support surface in advance before being transferred to the fibrous substrate. This preliminary action allows for better control of the coating application and reduces processing complexity by separating the application and transfer steps, ensuring more consistent bonding.
3Ease of manufacture
If a single polymeric binder material is used to coat fibers, then processing is simplified, but the composite cannot achieve both superior ballistic properties and high rigidity simultaneously
Solution Approach 1:
The invention uses a composite structure with two different polymeric materials applied in sequence. The first polymeric coating provides ballistic resistance properties, while the second polymeric coating provides rigidity. This composite approach allows the fibrous substrate to achieve both superior ballistic properties and high rigidity simultaneously, overcoming the limitations of using a single polymeric binder material.
Data Source
Figure 1
AI summary
A method for applying multiple polymeric coatings onto a fibrous substrate. More particularly, a method for applying multiple polymeric coatings onto fibrous substrates without regard to chemical or physical incompatibilities of the polymeric coating materials. A first polymeric material is applied onto at least one fibrous substrate, and a second polymeric material is applied onto a support. The fibrous substrate and support are joined, contacting the first polymeric material with the second polymeric material, followed by separating the support from the fibrous substrate, such that at least a portion of the second polymeric material remains on the first polymeric material on the fibrous substrate.