Process for the manufacture of a membrane adapted for coupling to a fabric, and product so obtained
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for replicating marble's aesthetic and tactile effects on textiles are limited by the rigidity, heaviness, and inflexibility of marble, as well as issues with granulometry in marble powder coatings, leading to defects and inadequate thickness in membrane production.
Innovation Solution
A process involving a single or multiple layers of marble powder blended with polyurethane, with specific granulometry (1-100 μm) to create a membrane that enhances abrasion resistance and flame retardancy, allowing for flexible and aesthetic applications in various fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If marble powder with granulometry not higher than 150 microns is used, then the membrane can be produced with multiple layers, but the membrane thickness becomes inadequate and the calcium carbonate can compromise and pierce the thin microfilm
Solution Approach 1:
The patent changes the granulometry parameter of marble powder from the conventional ≤150 microns to a finer range of 0-50 microns. This parameter change allows the membrane to be produced with adequate thickness while preventing the calcium carbonate particles from piercing the microfilm, thus resolving the contradiction between membrane thickness control and membrane integrity
Solution Approach 2:
The patent applies local quality by using marble powder with non-uniform but controlled granulometry (0-50 microns) rather than a single size. This distribution of particle sizes allows smaller particles to fill gaps and larger particles to provide structure, achieving both adequate thickness and integrity without piercing
2Length of stationary object
If several coating layers of marble powder are made on polyurethane base, then the membrane can achieve adequate thickness, but the manufacturing process becomes difficult to implement
Solution Approach 1:
The patent segments the marble powder granulometry into a controlled distribution (0-50 microns) rather than using a single coarse size. This segmentation allows adequate thickness to be achieved in a single or reduced number of coating layers, simplifying the manufacturing process while maintaining membrane integrity
Solution Approach 2:
By changing the granulometry parameter to 0-50 microns, the patent enables adequate membrane thickness to be achieved with fewer coating layers, directly reducing manufacturing complexity while maintaining the required thickness
3Productivity
If marble powder with larger granulometry is used, then the membrane can be produced faster, but the presence of calcium carbonate compromises and pierces the thin microfilm
Solution Approach 1:
The patent optimizes the granulometry parameter to 0-50 microns, which is fine enough to prevent piercing the microfilm but not so fine as to require excessive numbers of layers. This optimized parameter range maintains membrane integrity while enabling efficient production without the need for multiple thick layers
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 membrane achieves improved abrasion resistance, flame retardancy, and aesthetic appeal, with the ability to be used in clothing, furnishing, and other applications without the limitations of traditional marble use, while utilizing marble powder from waste materials.
Implementation Method 1
a membrane which comprises rock powder dispersed in a polymer or a polymer mixture
Data Source
AI summary
Object of the present invention is a process for manufacturing a membrane adapted for coupling to a fabric or other supports that can be used in the field of the clothing or furnishing, and so-obtained product.