Multilayer fabric materials for roofing applications
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Solution Overview
Problem
The manufacturing process of multilayer fabric mats is complex and expensive, particularly due to the need for additional needling steps to bind layers together, which increases costs and complexity.
Innovation Solution
A method using B-stage binders to laminate polymer nonwoven layers with non-polymer fiber layers without an additional needling step, where the B-stage binder cures and glues the layers together during a single process step, simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional needling steps are used to bind layers together, then the mechanical strength and dimensional stability are improved, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent replaces the mechanical needling process with a chemical bonding mechanism using B-stage binders. The binder layers chemically bond the nonwoven and fabric layers together during heating and pressing, eliminating the need for mechanical needling equipment and steps while achieving equivalent or superior layer bonding and mechanical strength
Solution Approach 2:
The patent utilizes the B-stage condition of the binder, which is a partially cured state that allows the binder to be applied and positioned before final curing. By controlling the curing parameters (temperature, pressure, time) during the heating and pressing step, the binder transitions from a flexible B-stage state to a fully cured bonded state, achieving strong layer adhesion without mechanical needling
2Stability of the object's composition
If additional needling steps are used to bind layers together, then the dimensional stability is improved, but the production costs increase
Solution Approach 1:
The patent replaces expensive mechanical needling equipment and processes with a chemical bonding system using B-stage binders. The heating and pressing equipment required for binder curing is standard industrial equipment, significantly reducing capital investment and operational costs while achieving the same dimensional stability through chemical adhesion rather than mechanical interlocking
3Device complexity
If B-stage binder is used to laminate layers in a single process step, then the manufacturing complexity is reduced, but the binding strength may be compromised
Solution Approach 1:
The patent applies the B-stage binder to the layers in advance, allowing the binder to be positioned and distributed uniformly before the final curing step. This preliminary application ensures proper bonding geometry and contact between layers, and the subsequent heating and pressing completes the curing process to achieve full binding strength without requiring additional mechanical reinforcement steps
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 results in cost-effective, simplified production of multilayer fabric mats with enhanced mechanical strength, dimensional stability, and improved flame retardation properties, suitable for use as bituminous roofing felts, while eliminating the need for additional binders and needling, thus reducing production complexity and costs.
Implementation Method 1
the B-stage binder being present in at least one of the two or more different layers and being in the B-stage finally cures and glues the layers together
Implementation Method 2
By heating up the laminate and pressing the two or more different layers together (e.g. via a press roll or similar means) the B-stage binder being present in at least one of the two or more different layers and being in the B-stage finally cures and glues the layers together
Data Source
AI summary
The invention relates to two- or multilayer fabric laminate comprising (i) at least one polymer nonwoven layer and (ii) at least one fabric layer of non-polymer fibers, characterized in that the at least two different layers (i) and (ii) have been laminated using at least one B-stage binder, a method for their production and their use. The laminates according to the instant invention are suitable as carrier for roofing felts, for bituminous roofing felts, sealing membranes or PVC floor coverings, in particular as bitumious roofing felts. The invention further relates to the method of manufacture these new multilayer laminates and the use thereof.