Knitted Fabric Adhesive Tape with Transverse Weft Threads
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Solution Overview
Problem
Existing hand-tearable textile adhesive tapes face challenges such as high manufacturing costs, limited tearability, and dimensional instability due to the use of strong and expensive substrates like polyester and rayon fabrics, which also result in poor noise dampening and abrasion resistance.
Innovation Solution
A self-windable adhesive tape with a knitted fabric substrate that incorporates transverse weft threads within its stitches, allowing for direct adhesive coating without a primer and enhancing tearability, stability, and performance characteristics like noise dampening and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If polyester or rayon fabric substrates are used to achieve hand-tearability, then tearability is improved, but manufacturing costs increase and tensile strength decreases
Solution Approach 1:
The substrate is segmented into two functional layers: a knit fabric base structure providing dimensional stability and a separate loop pile surface layer providing hand-tearability. This segmentation allows each layer to optimize its specific function without compromising the other, achieving tearability through the loop pile structure rather than relying on expensive rayon fabrics.
Solution Approach 2:
The invention uses a composite substrate combining knit fabric with an attached loop pile surface layer. This composite structure integrates the dimensional stability of the knit base with the tearable characteristics of the loop pile, creating a material that achieves hand-tearability without the high costs associated with rayon or acrylate-coated rayon fabrics.
2Strength
If dense knit fabric structure is used to improve tensile strength, then strength is improved, but tearability deteriorates
Solution Approach 1:
The substrate is segmented into two functional layers: a knit fabric base structure providing dimensional stability and a separate loop pile surface layer providing hand-tearability. This segmentation allows each layer to optimize its specific function without compromising the other, achieving tearability through the loop pile structure rather than relying on expensive rayon fabrics.
Solution Approach 2:
Different regions of the substrate have different properties: the knit fabric base provides high tensile strength and dimensional stability, while the loop pile surface layer provides ease of tearing. This local differentiation of material properties allows the substrate to simultaneously achieve both strength and tearability in different directions and layers.
3Reliability
If primer coating is applied before adhesive coating, then adhesive bonding is improved, but manufacturing complexity increases
Solution Approach 1:
The invention extracts and eliminates the primer coating step from the traditional two-step coating process. By selecting a pressure-sensitive adhesive specifically formulated to bond directly to the loop pile substrate without requiring a primer, the process is simplified to a single direct adhesive coating step, reducing manufacturing complexity while maintaining reliable bonding.
Solution Approach 2:
The loop pile substrate structure itself provides the necessary surface characteristics for adhesive bonding without requiring additional primer treatment. The substrate is self-sufficient for direct adhesive application, eliminating the need for the separate primer coating step and simplifying the overall manufacturing process.
4Quantity of substance
If UV-crosslinkable acrylate adhesive is applied to open structure fabric, then adhesive coverage is improved, but adhesive control deteriorates due to high fluidity
Solution Approach 1:
The invention changes the physical parameters of the adhesive application process by using a rotary screen printing method that controls adhesive deposition through screen mesh size and rotation speed. This allows precise control of adhesive quantity and distribution, preventing excessive fluidity from causing runneling while ensuring complete coverage of the loop pile substrate with UV-crosslinkable acrylate adhesive.
Data Source
AI summary
A self-windable, transversely tearable textile industrial adhesive tape (1) having a tape-shaped substrate (2) which has a thickness (D2) in the range of 0.05 mm to 1.8 mm, consisting of a knitted fabric (3) having stitches (5) made of yarn (4), and which is provided on one side with a pressure-sensitive adhesive coating (6) which is applied directly to the substrate (2) with a specific weight per unit area in the range of 20 g/m2 to 300 g/m2. In order to obtain improved manufacturability as well as improved functional characteristics, in particular an improved dimensional stability during the process, while preserving the advantages of using a substrate (2), it is proposed that the substrate (2) includes weft threads (7) running mutually parallel in the transverse direction, which weft threads (7) are held in the stitches (5) of the knitted fabric (3).