Polymer-Dot Fabric Coating for Abrasion Resistance and Lightweightness
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Solution Overview
Problem
Existing textile fabrics face challenges in achieving improved abrasion resistance without compromising appearance, lightweightness, and water repellency durability, as conventional methods often impair these qualities due to excessive coating or texture changes.
Innovation Solution
A fabric coated with polymer dots of average maximum diameter 0.5 mm or less, applied uniformly to convexities on the fabric surface, providing enhanced abrasion resistance while maintaining a smooth appearance and lightweightness, and incorporating a flexible film for improved water repellency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hot-melt resin is arranged as an abrasion-resistant polymer on a fabric surface by melt spray method with weight per unit area of 5g/m2 to 40 g/m2, then abrasion resistance is improved, but appearance, texture, and lightweightness are significantly impaired
Solution Approach 1:
The continuous polymer layer is segmented into discrete polymer dots with average maximum diameter of 0.5 mm or less. This segmentation allows the polymer to provide abrasion resistance at specific high-wear points (convexities) without forming a continuous thick layer that would impair appearance and texture.
Solution Approach 2:
The polymer dots are selectively arranged to cover convexities on the fabric surface where abrasion resistance is most needed, while leaving concavities uncovered. This local application provides targeted protection without uniformly coating the entire fabric surface, preserving overall appearance and texture.
2Reliability
If a hot-melt resin is arranged as an abrasion-resistant polymer on a fabric surface with weight per unit area of 5g/m2 to 40 g/m2, then abrasion resistance is improved, but the fabric becomes heavier
Solution Approach 1:
The polymer is divided into discrete dots rather than forming a continuous layer, significantly reducing the total polymer quantity required. The segmentation allows concentrated polymer placement at critical wear points, minimizing overall fabric weight while maintaining abrasion resistance.
Solution Approach 2:
Instead of coating the entire fabric surface uniformly, the polymer dots are applied partially only to convexities that require abrasion resistance. This partial action reduces polymer consumption and fabric weight while providing sufficient protection at high-wear areas.
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 solution effectively enhances abrasion resistance and water repellency durability while preserving the fabric's appearance and lightweightness, ensuring the fabric remains aesthetically pleasing and functional.
Implementation Method 1
treated with heat to fuse the abrasion-resistance polymer with each other and with the fabric
Implementation Method 2
transferring the polymer composition on the gravure pattern roll onto a surface of a fabric to coat the surface of the fabric with polymer dots
Data Source
AI summary
A first objective of the present invention is to provide a technology for improving the abrasion resistance of a fabric or a composite fabric for use in textile products such as clothing products and the like without impairing the appearance thereof, and further, a second objective of the present invention is to provide a technology for achieving both the abrasion resistance and the lightweightness of a fabric or a composite fabric without impairing the appearance and the texture thereof. By coating a surface of a fabric with polymer dots as an abrasion-resistant resin and causing the average maximum diameter of the polymer dots to be equal to or less than 0.5 mm, the abrasion resistance of the fabric can be improved without impairing the appearance of the fabric. Further, by causing the surface-coating amount of the polymer dots to range from 0.2 g/m2 to 3.0 g/m2, both the abrasion resistance and the lightweightness can be achieved.