Microporous Coated Fabric Using a Non-Stretchable Substrate Web
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for applying a waterproof and breathable coating to knitted fabrics face issues with uneven coating layers due to the fabric's stretchability and the use of releasing papers with low structural strength, which can deform and break under tension, affecting the functional integrity of the coating.
Innovation Solution
A method involving a non-stretchable and releasable substrate web is used, where a coating solution is applied and then laminated with a base fabric, followed by immersion in water for solidification and drying to create a uniform coating layer, avoiding the limitations of traditional methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a coating material is applied to a knitted fabric using a roller coating machine, then the coating process can be automated and continuous, but the coating layer becomes uneven in thickness due to fabric stretchability
Solution Approach 1:
The knitted fabric is first stretched to a predetermined tension state before the coating material is applied. This preliminary stretching action ensures that the fabric maintains a stable, uniform state during coating application, preventing deformation and ensuring even coating thickness while allowing continuous processing
2Manufacturing precision
If a releasing paper is used to apply coating material evenly, then the coating layer can be uniform, but the releasing paper breaks under high tension during conveyance
Solution Approach 1:
The invention uses a disposable stretching substrate that is designed to be used once and then discarded. This substrate provides the necessary tensile strength to prevent breaking during conveyance under high tension, while also ensuring uniform coating application. The substrate is replaced after each use, eliminating the need to reuse weakened material
3Stability of the object's composition
If the knitted fabric is conveyed under high tension to maintain stability, then the coating application becomes easier, but the releasing paper structure is damaged
Solution Approach 1:
The stretching substrate is designed as a disposable component that can withstand high tension forces during the coating process. After serving its purpose of maintaining fabric stability and enabling uniform coating application, the substrate is discarded rather than reused, avoiding the problem of structural degradation from repeated high-tension conveyance
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 approach ensures a uniform and functional coating layer with improved tensile strength and water permeability, preventing deformation and enhancing the waterproof and breathable properties of the coated fabric.
Implementation Method 1
applying a coating solution of a resin in an organic solvent on a roller-conveyed non-stretchable and releasable substrate web at a coating station to form a coating layer
Implementation Method 2
guiding the laminate along the running route to pass through at least one tank containing water at an immersing station to immerse the laminate in water such that the coating layer is solidified and the organic solvent contained in the coating layer is replaced by water
Implementation Method 3
guiding the laminate coming out of the tank to a drying station to remove water from the coating layer by drying so as to leave micropores in the coating layer
Data Source
AI summary
A method for making a coated fabric includes the steps of: applying a coating solution of a resin in an organic solvent to a roller-conveyed non-stretchable and releasable substrate web to form a coating layer; laminating a roller-conveyed base fabric to the coating layer to form a laminate; guiding the laminate to pass through at least one tank containing water to immerse the laminate in water such that the coating layer is solidified and the organic solvent contained in the coating layer is replaced by water; and removing water from the coating layer by drying to leave micropores in the coating layer.