Base Nonwoven Fabric Dimensional Stability Coating
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Solution Overview
Problem
Existing methods for producing base nonwoven fabrics as coating carriers face challenges in achieving sufficient dimensional stability and a smooth structure to withstand coatings without fiber protrusion, while meeting requirements for diffusion-open, waterproof, and mechanically resilient properties.
Innovation Solution
A method involving cross-laying and lengthwise laying of a polyester fiber mixture with a 5:3 fiber draw-in ratio, followed by consolidation using high-pressure water jets and application of a binder above the crosslinking temperature to create a gradient structure and smooth surface, ensuring dimensional stability and ease of coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a base nonwoven fabric is produced by laying fiber web crosswise and lengthwise with conventional fiber draw-in ratios, then the fabric structure is formed, but the dimensional stability in the longitudinal direction is insufficient to withstand subsequent coating processes without damage
Solution Approach 1:
The invention changes the fiber draw-in ratio parameter from conventional values to a specific range of 2.5:1.5 to 6:4 (crosswise:lengthwise). This parameter modification optimizes the fiber distribution and orientation in the nonwoven fabric, providing sufficient dimensional stability in the longitudinal direction to withstand coating processes without fabric damage while maintaining manufacturing precision.
2Ease of manufacture
If the base nonwoven fabric has a conventional fiber arrangement, then the fabric is formed, but fibers protrude from the surface in a disruptive manner during subsequent coating steps
Solution Approach 1:
The invention modifies the fiber draw-in ratio parameter to create an optimized fiber arrangement where crosswise and lengthwise fibers are distributed in specific proportions. This results in a smooth surface structure that prevents fiber protrusion during coating operations, simultaneously improving ease of coating and maintaining high surface smoothness quality.
3Stability of the object's composition
If the fiber draw-in ratio is adjusted to improve dimensional stability, then the fabric structure becomes more stable, but the complexity of the laying process increases
Solution Approach 1:
The invention implements dimensional stability improvement through a straightforward parameter adjustment of the fiber draw-in ratio rather than through complex mechanical or process modifications. The ratio range of 2.5:1.5 to 6:4 can be easily controlled in conventional laying processes, achieving enhanced stability without significantly increasing device or process complexity.
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 method produces a base nonwoven fabric with enhanced dimensional stability and a smooth structure, allowing for successful coating without fiber protrusion, while maintaining mechanical resilience and ease of installation, meeting stringent standards for roofing membranes.
Implementation Method 1
application of a binder above the crosslinking temperature to create a gradient structure and smooth surface
Data Source
AI summary
The invention relates to a method for producing a base non-woven fibre as support for a coating, made from a polyester fibre (PES) mixture by cross and lengthwise laying of the fibre web. According to the invention, the ratio of the fibre core between the cross and lengthwise fibres is essentially 5:3, wherein a first base non-woven fibre layer is made up of cross-laid fibre web and a second base non-woven fibre layer is made up of lengthwise laid fibre web and the fibre web layers have a surface area density of ca. 70 - 300 g/m?. The provision of the first and second base non-woven fibre layer with a binder occurs in one working step. A treatment above the cross-linking temperature of the binder or binder system is then carried out to give a desired smoothing, sealing and/or reinforcing of the base fibre web material.