Coated polyester fabric

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Solution Overview

Problem

Conventional methods for improving adhesion and printability of polyolefin and polyester fabrics are hindered by the low surface energy and polarity of polyolefins, which limit their applications, and require high load fillers that complicate adhesion and degrade flexibility and flame retardancy, while existing coatings often rely on halogenated compounds.

Innovation Solution

A halogen-free coating system comprising an ethylene/vinyl acetate/maleic anhydride terpolymer or an ethylene/methyl acrylate/glycidyl methacrylate terpolymer crosslinked with a polyisocyanate, applied to a polyester fabric, along with an outer layer of ethylene/α-olefin multi-block copolymer and filler, providing strong adhesion without degrading flexibility or flame retardancy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If polyolefin is used as an alternative to PVC, then halogen-free and cost-effectiveness are improved, but adhesion to polyester fabric and flexibility are degraded due to low surface energy and polarity

Engineering Contradiction:

Improvehalogen contentVSAvoidadhesion strength

Core Design Contradiction:

Object-generated harmful factorsVSStrength

Solution Approach 1:

A primer layer comprising a polyolefin resin with grafted polar groups (such as carboxyl, hydroxyl, or amine groups) is applied between the polyester fabric and the filled polyolefin outer layer. This primer acts as an intermediary that provides both adhesion to the polyester fabric through its polar groups and compatibility with the non-polar filled polyolefin outer layer, thereby resolving the adhesion problem while maintaining the halogen-free advantage

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The coating system uses a composite structure with a polyolefin resin base modified by grafting polar functional groups. This creates a material that combines the desirable properties of polyolefin (halogen-free, cost-effective) with improved adhesion characteristics through the incorporated polar groups, enabling strong bonding to polyester fabric without sacrificing flexibility

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If high load filler is added to polyolefin to provide flame retardant properties, then flame retardancy is improved, but adhesion to polyester fabric and flexibility are degraded

Engineering Contradiction:

Improveflame retardancyVSAvoidadhesion strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The coating system is segmented into two distinct layers: a primer layer that provides adhesion to the polyester fabric, and an outer layer containing the filled polyolefin that provides flame retardancy. This segmentation allows each layer to be optimized for its specific function without compromising the other, resolving the contradiction between flame retardancy and adhesion

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The primer layer serves as an intermediary between the polyester fabric and the high filler-load outer layer. It provides the adhesion function that would be compromised by high filler content, while allowing the outer layer to achieve optimal flame retardancy through high filler loading without directly contacting the fabric

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If conventional surface modification treatments are applied to improve adhesion and printability, then adhesion and printability are improved, but processing time and complexity are increased

Engineering Contradiction:

Improveadhesion strengthVSAvoidprocessing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The polyolefin resin is pre-modified during manufacturing by grafting polar functional groups onto the polyolefin chains. This preliminary action incorporates the adhesion-enhancing functionality directly into the material itself, eliminating the need for subsequent surface modification treatments and thereby reducing processing time and complexity while maintaining strong adhesion

Inventive Principle:

Principle #10Preliminary action

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 solution achieves strong adhesion between the polyester fabric and the filled polyolefin layer, maintaining flexibility and flame retardancy, and supports printing and painting applications with a halogen-free, cost-effective coating system.

Implementation Method 1

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

ethylene/methyl acrylate/glycidyl methacrylate terpolymer crosslinked with a polyisocyanate

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Implementation Method 3

maintaining flexibility and flame retardancy

Methodology Applied

Scientific EffectFlame retardancy:

Data Source

PatentEP3519622B1Coated polyester fabric

Publication Date: 2020.11.25 DOW GLOBAL TECHNOLOGIES LLC

AI summary

The present disclosure provides and article. The article includes: (A) a polyester fabric; (B) a coating on a surface of the polyester fa brie, the coating comprising at least one of (i) an ethylene/vinyl acetate/maleic anhydride terpolymer and (ii) an ethylene/methyl acrylate/glycidyl methacrylate terpolymer.