High strength hydroentangled scrim sheet and methods of producing the same
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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 flexible substrates for applications with sharp angles.
Innovation Solution
A method involving hydroentangling a scrim sheet with staple fibers from both sides, calendaring, impregnating with a saturant composition, drying, applying 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 fiber breakage and backing failure
Solution Approach 1:
The patent 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 from the scrim and resistance to folding-induced failure from the flexible backing layer, resolving the contradiction between strength and reliability under rapid folding.
2Strength
If polyester fiber scrims are used to achieve high strength properties, then strength is improved, but stretch characteristics increase causing slippage
Solution Approach 1:
The patent combines polyester scrim (providing strength) with glass fiber components or treatment (providing low stretch properties). The composite structure allows the polyester to contribute strength while the glass fiber or treatment reduces stretch characteristics, preventing slippage while maintaining high strength properties.
3Adaptability or versatility
If cellulose based substrates are used to achieve flexibility, then flexibility is improved, but tensile strength properties are insufficient
Solution Approach 1:
The patent creates a composite structure where the cellulose-based substrate provides flexibility and adaptability, while the integrated scrim layer (made of polyester and/or glass fiber) provides the necessary tensile strength. This composite approach allows the final abrasive backing to simultaneously achieve high flexibility for sharp angle applications and high tensile strength to prevent failure.
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 results in a high-tensile and tear-strength scrim sheet with a smooth surface for subsequent coatings, suitable for abrasive backings, providing improved durability and flexibility without slippage.
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
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.