High-Strength Hydroentangled Scrim Sheet for Low-Stretch Abrasive Backings
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Solution Overview
Problem
Existing abrasive backings face challenges in achieving high tensile strength while maintaining low stretch properties, particularly when using polyester or glass fiber scrims, which are prone to failure under rapid folding and require flexibility in applications with sharp angles.
Innovation Solution
A method involving hydroentangling a scrim sheet with staple fibers from both sides, followed by calendaring, impregnation with a saturant composition, drying, application of a bond coat, and a top coat, to create a high-strength, low-stretch abrasive backing suitable for applications requiring flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fiber scrims are used to achieve high tensile strength and low stretch properties, then tensile strength is improved, but rapid folding causes glass fibers to break resulting in backing failure
Solution Approach 1:
The invention uses a composite structure combining a scrim layer (for strength) with an abrasive backing layer (for flexibility and durability). This composite approach allows the final product to achieve both high tensile strength and resistance to folding failure, as the abrasive backing protects the glass fibers from breakage during rapid folding while the scrim provides the necessary tensile strength.
2Adaptability or versatility
If polyester fibers are used to provide flexibility and high strength properties, then flexibility is improved, but stretch characteristics increase causing slippage
Solution Approach 1:
The invention applies different properties to different layers: the scrim layer provides high strength and low stretch properties to prevent slippage, while the abrasive backing layer provides flexibility for applications with sharp angles. This local differentiation of material properties allows the overall structure to achieve both low stretch and high flexibility without the trade-off present in single-material solutions.
3Adaptability or versatility
If cellulose based substrates are used to provide flexibility, then adaptability is improved, but tensile strength properties are insufficient
Solution Approach 1:
The invention combines a scrim layer (made of glass or polyester fibers providing high tensile strength) with an abrasive backing layer (made of cellulose-based or other flexible materials providing adaptability). This composite structure allows the final product to achieve both high tensile strength from the scrim and flexibility/adaptability from the abrasive backing, overcoming the limitation of cellulose-based substrates alone.
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 process results in a high-tensile and tear-resistant scrim sheet with a smooth surface for subsequent coatings, suitable for abrasive backings, providing improved strength and flexibility without excessive stretch, suitable for applications with sharp angles.
Implementation Method 1
hydroentangling a scrim sheet having a first layer of staple fibers on a first side of the scrim sheet and a second layer of staple fibers on a second side of the scrim sheet
Implementation Method 2
calendaring the hydroentangled scrim sheet to form a calendared hydroentangled scrim sheet
Implementation Method 3
impregnating the hydroentangled scrim sheet with a saturant composition
Implementation Method 4
drying the saturant composition impregnated into the calendared hydroentangled scrim sheet
Data Source
Figure 1~2
AI summary
Methods for forming a hydroentangled scrim sheet are provided. The method can include hydroentangling a scrim sheet having a first layer of staple fibers on a first side of the scrim sheet and a second layer of staple fibers on a second side of the scrim sheet to form a hydroentangled scrim sheet; calendaring the hydroentangled scrim sheet to form a calendared hydroentangled scrim sheet; impregnating the hydroentangled scrim sheet with a saturant composition; drying the saturant composition impregnated into the calendared hydroentangled scrim sheet; applying a bond coat onto a surface of the calendared hydroentangled scrim sheet; and applying a top coat onto the bond coat. The top coat is, in one embodiment, configured to provide a surface for further coatings thereon.