Textile fabric-elastomer composite
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Solution Overview
Problem
Current methods for enhancing the elastic modulus of textiles result in bulkiness, reduced breathability, and discomfort due to the creation of non-continuous air-impermeable layers or require sophisticated machinery, compromising both aesthetic and comfort properties.
Innovation Solution
A composite material comprising a textile substrate with a cured elastomeric material layer that penetrates into the peripheral region of yarns but not the core, maintaining breathability and flexibility, and is formed from a blend of elastomers with specific viscosity and hardness properties to enhance elastic modulus without affecting drapability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If elastomeric coatings are applied to fabric to increase elastic modulus, then the elastic modulus is improved, but the fabric becomes non-breathable and bulky
Solution Approach 1:
The elastomeric coating is segmented into discrete droplets or islands distributed across the fabric surface, rather than forming a continuous layer. This segmentation allows air to pass through the gaps between coating droplets, maintaining breathability while still providing elastic modulus enhancement where the coating is present.
Solution Approach 2:
The elastomeric coating is applied locally to specific areas or zones of the fabric where increased elastic modulus is desired, rather than uniformly across the entire fabric. This localized application maintains breathability in uncoated areas and reduces overall bulkiness while achieving the desired mechanical properties in target regions.
2Strength
If elastomeric coatings are applied to fabric to increase elastic modulus, then the elastic modulus is improved, but the fabric becomes bulky
Solution Approach 1:
The coating is divided into discrete droplets or islands rather than a continuous layer, significantly reducing the overall volume of elastomeric material applied to the fabric while maintaining elastic modulus enhancement at the droplet locations.
Solution Approach 2:
Instead of applying a continuous coating that would provide complete coverage and maximum bulk, the invention applies partial coverage with discrete elastomeric droplets or islands, achieving sufficient elastic modulus enhancement without the excessive bulkiness of full coverage.
3Strength
If fabrics with different elastic modulus properties are joined by stitching or gluing, then the elastic modulus is improved in specific areas, but the joints are visually and physically prominent causing discomfort
Solution Approach 1:
The invention merges the fabric and elastomeric coating into a single integrated composite structure, eliminating the need for separate stitching or gluing operations to join different fabric pieces. The elastomeric droplets are embedded within or on the fabric surface, creating a unified structure without visible or physical joints.
4Strength
If thermoplastic yarn is used in knitting to increase elastic modulus, then the elastic modulus is improved, but the garment becomes heavier and thicker
Solution Approach 1:
The invention uses a composite structure combining textile fabric with discrete elastomeric droplets or islands. This composite approach provides elastic modulus enhancement through the elastomeric phase while maintaining the lightweight and thin characteristics of the original fabric, avoiding the weight and thickness increase associated with thermoplastic yarn incorporation.
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 provides a wash-durable, soft, and breathable textile with enhanced elastic modulus, maintaining continuity of comfort and aesthetic properties while allowing for increased power retention after multiple wash cycles, without the bulkiness and stiffness issues of previous methods.
Implementation Method 1
The cured elastomeric material penetrates into the yarn and is attached to the fibres or filaments in the peripheral region of the yarn
Data Source
AI summary
Disclosed herein is a composite material that is formed from a textile substrate having a surface, the textile substrate formed from a yarn, where the yarn is formed from a plurality of fibres or filaments, such that the yarn has a core region of fibres or filaments surrounded by a peripheral region of fibres or filaments; and a cured elastomeric material layer laid over the whole or part of the textile substrate surface, where the cured elastomeric material penetrates into the yarn and is attached to the fibres or filaments in the peripheral region of the yarn.