Thermofusible sheet material
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Solution Overview
Problem
Conventional aqueous paste systems used in coating thin, transparent, flexible cover materials in the clothing industry lead to contamination of production plants, inhomogeneous glue dots, and reduced composite quality due to penetration and smearing issues, making it difficult to achieve lightweight and open-structured interlinings.
Innovation Solution
A thermally fusible fabric with a polyurethane foam coating applied to a textile substrate, featuring a pore structure where over 50% of pores have diameters between 5 to 30 μm, providing a homogeneous and stable coating that minimizes penetration and maintains air permeability, allowing for effective bonding and improved wear comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If aqueous paste systems are used for coating thin, transparent, flexible cover materials, then the coating process can be performed with conventional materials, but contamination of production plants occurs, inhomogeneous glue dots are formed, and penetration and smearing issues arise
Solution Approach 1:
The invention changes the physical state of the coating material from liquid aqueous paste to foam form. This parameter change allows the coating to be applied homogeneously without penetration or smearing issues, while maintaining ease of manufacture with conventional coating equipment.
Solution Approach 2:
The invention uses foam as the coating material, which has a porous structure. This porous foam coating prevents penetration into the substrate while allowing homogeneous distribution, eliminating the smearing and inhomogeneity problems associated with liquid paste systems.
2Productivity
If conventional coating methods are used, then production can proceed with standard materials, but penetration and smearing issues reduce composite quality
Solution Approach 1:
By changing the coating material from liquid paste to foam, the invention maintains production continuity while significantly improving composite quality. The foam structure prevents penetration and smearing, ensuring reliable bonding without compromising productivity.
3Weight of moving object
If lightweight, open-structured interlinings are used, then wear comfort is improved, but coating stability and homogeneity become difficult to achieve
Solution Approach 1:
The foam coating material has a porous structure that matches well with lightweight, open-structured interlinings. This allows the coating to conform to the substrate structure, achieving homogeneous coverage on lightweight materials without penetration or smearing issues.
Solution Approach 2:
By using foam instead of liquid paste, the invention enables stable and homogeneous coating on lightweight interlinings. The foam's gas-filled structure reduces weight while maintaining coating stability and homogeneity on delicate substrates.
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 polyurethane foam coating ensures a stable, breathable, and resilient interlining with enhanced wash resistance and air permeability, maintaining quality and process efficiency while preventing contamination and inhomogeneous dot formation, thus supporting the use of lightweight, open-structured cover materials.
Implementation Method 1
the polyurethane foam has a pore structure in which more than 50% of the pores have a diameter, measured according to DIN ASTM E 1294, which is in a range of from 5 to 30 μm
Data Source
AI summary
A thermofusible sheet material which can be used as a fusible interlining in the textile industry, has a carrier layer made from a textile material to which a polyurethane foam coating is applied. The polyurethane foam has a pore structure in which more than 50% of the pores have a diameter, measured according to DIN ASTM E 1294, which is in the range of 5 to 30 μm.