Laser-Cut Polyurethane Laminated Fabric with In-Process Edge Coating
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Solution Overview
Problem
Polyurethane laminated fabrics present a challenge when cut, as the cut woven fibers or threads often protrude from the edges, resulting in a ragged and cosmetically unappealing appearance, especially when they are a different color than the polyurethane layer.
Innovation Solution
The use of laser cutting techniques that direct a laser beam to melt a portion of the polymer layer, creating a pool of melted polymer material that coats the fibers along the edge, preventing their exposure and creating a clean, cosmetically appealing cut edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cutting methods are used on polyurethane laminated fabric, then cutting speed and productivity are improved, but the cut edges become ragged and cosmetically unappealing due to exposed fibers
Solution Approach 1:
The patent changes the physical state of the polymer layer from solid to liquid through controlled heating, allowing it to flow and coat the fabric edges. This parameter change (temperature control) enables the polymer to seal exposed fibers while maintaining efficient cutting speeds, thus resolving the contradiction between productivity and edge quality.
Solution Approach 2:
The invention utilizes the phase transition of the polymer layer from solid to liquid state during cutting. The polymer melts and flows to coat the fabric edges, preventing fiber exposure. This phase transition mechanism allows simultaneous achievement of high cutting speed and clean edge appearance, resolving the technical contradiction.
2Manufacturing precision
If laser cutting is used to improve edge quality by melting polymer, then cosmetic appearance is improved, but energy consumption and process time increase
Solution Approach 1:
The patent employs the polymer layer itself as the coating material that seals the edges. The polymer melts and flows under laser heat to coat the fabric edges, using its own material properties to solve the edge quality problem. This self-service approach eliminates the need for separate coating materials or complex multi-step processes, reducing overall energy consumption while maintaining high edge quality.
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
This method efficiently produces clean and cosmetically appealing edges on laminated fabrics by using a laser to melt and coat the polymer layer during the cutting process, ensuring the fibers are fully covered and the edges appear consistent and aesthetically pleasing.
Implementation Method 1
The laser beam locally heats the polymer layer forming a pool of melted material
Implementation Method 2
the laser beam melts a portion of the polymer layer forming a pool of melted polymer material
Data Source
AI summary
Processes for forming cosmetically appealing edges on laminated fabric structures are described. The methods involve a laser cutting process that includes in-process melting of polymer material within the laminated fabric so as to coat fibers of the laminated fabric. The resultant cut laminated fabric has a cosmetic edge that has no exposed fibers. The laser cutting and melting can be performed in a single laser cutting operation, making it well suited for integration into manufacturing product lines.