Coated, Laminated and Bonded Fabrics
Multi-Component Fabric
Coted Fabric:
Coated fabrics are engineered composite materials, produced by a combination
of a textile fabric and a polymer coating applied to the fabric surface. The polymer
coating confers new properties on the fabric, such as impermeabilty to dust
particles, liquids and gases, and it can also improve existing physical properties,
such as fabric abrasion. The fabric component generally determines the tear and
tensile strength, elongation and dimensional stability, while the polymer mainly
controls the chemical properties, abrasion resistance and resistance to penetration
by liquids and gases. Many properties, however, are determined by a combination
of both these components, and both base-fabric and polymer must be carefully
selected by a thorough consideration of the properties required in the finished
article.
Coatings used in the production of technical textiles are largely limited to those
products that can be produced in the form of a viscous liquid, which can be spread
on the surface of a substrate. This process is followed by a drying or curing
process, which hardens the coating so that a non-blocking product is produced.
Thus the coatings for these products are limited to linear polymers, which can be
coated as a polymer melt or solution and on cooling form a solid film or form a
solid film by evaporation of the solvent. There are some types of coatings that
can be applied in the liquid form and then chemically crosslinked to form a solid
film. The coatings used in technical textiles are all thermoplastic polymers, which
are long chain linear molecules, some of which have the ability to crosslink. The
properties of these polymeric materials directly influence the durability and
performance of the end product.
The most familiar coated fabric is probably the waterproof jacket worn for
protection from the rain. Protective clothing for the police, firemen, postmen and
the services also made from coated fabric. Examples of domestic articles made
from coated fabrics include shower curtains, mattress tickings, flame retardant
(FR) upholstery, wipe-clean table cloths and curtain linings. Aesthetic effects and
easy clean features can also be achieved by fabric and polymer combinations, and
man-made leathers used for seat covers and apparel are essentially coated fabrics.
Coated fabrics in the industrial area include materials for tarpaulins, life jackets,
life rafts, aircraft safety chutes, hovercraft skirts, protective coverings, awnings,
aircraft fuel tanks and flexible containers. Seat upholstery for automobiles,
coaches and trains is likely to be coated to improve abrasion resistance, improve
FR properties and reduce dust particle penetration. The product enjoying the
largest growth at the time of writing is the airbag, which is coated mainly in order
to control porosity, although coating also reduces edge fraying and makes panel
cutting and certain other processes easier to carry out.
Some examples of coating chemicals: Polyvinyl chloride (PVC), Polyvinylidene
chloride (PVDC), Polytetrafluoroethylene (PTFE), Rubber, etc.
Polymer materials, which may not be easily formulated into a resin or
a paste for coating, can be combined with a fabric by first preparing a
film of the polymer, and then laminating it to the fabric in a separate
process. There are various techniques and several different types of
adhesives and machinery used in the lamination process. Producing an
adhesive bond, which will ensure no delamination or failure in use,
requires lamination skills and knowledge of which adhesive to use. It
is generally relatively simple to produce a strong enough bond, the
challenge is to preserve the original properties of the fabric and to
produce a flexible laminate with the required appearance, handle and
durability.
Adhesives are available as water-based or solvent-based fluids or as a
‘hot melt’ material, i.e. a material which is either a solid or a jelly and
which melts on the application of heat. Hot melt adhesives are produced
in the form of films, webs (rather like a net curtain), granules, powders
or as jellies. They can be of several different chemical types, such as
polyolefin, polyurethane, polyester, polyamide, or alloys, or blends of
different polymers or copolymers. Of course, different machinery is
required to apply the different forms of adhesive and this must be done
under controlled production conditions to produce an acceptable bond
without stiffening the fabric or any other undesirable effects.
Which lamination process and which machinery to use are also
determined by the physical properties of the fabric being processed and
by the performance requirements, such as bond strength and durability
of the laminate being produced. The fabric may be a flat woven, which
is dimensionally stable and which can be tensioned to produce a flat
uniform surface for the lamination process to take place without any
difficulty, or it may be a stretchy knit material or a fabric with a pile or
raised surface, which is easily distorted or crushed. Machines and
methods of lamination are available to process each of these fabrics
without altering the physical properties or appearance. The machinery
selected should also produce the required performance specifications at
a commercial production rate and cost.
As has been mentioned, lamination techniques have been used in the
garment industry for collars, waistbands and hems, generally replacing
or supplementing sewing. The lamination process shortened production
times, reduced costs and allowed more consistent quality. Lamination
techniques are also used to replace sewing in other areas, such as the
automotive and even sail making industries. Laminated fabrics are used
in waterproof and breathable protective clothing, car seat upholstery,
footwear, and in numerous other applications. According to the Textile
Institute’s definition, car headliners, parcel trays and door casings are
also laminated fabrics – they are certainly covered by a laminated
fabric. As will be seen, environmental considerations also play a
significant part in process selection, and they are likely to become more
important in the future.
Properties that can be obtained by fabric resin coating or by film
lamination:
Properties that can be developed by fabric resin coating or by film
lamination:
Properties of fibres commonly used in coating and laminating:
Fiber Performance in Coating and Lamination:
Performance of Common Coating Materials:
Materials for lamination:
Films:
Polyurethane foam:
Polyolefin foam:
Summary of adhesive types:
Different Lamination Process of fabric for apparel:
In the apparel industry, handle, flexibility and drape are of major
importance, but durability to flexing and to washing are also important.
The problem arises, therefore, of finding the best method and adhesive
materials for a durable bond and applying them in a controlled manner
to maintain the fabric flexibility and aesthetics during the lamination
process. For a bond of high strength, it is generally necessary for the
adhesive to penetrate the material and to cover the widest possible
surface area. The challenge is to select the best adhesive and application
process which has the least effect on the substrate aesthetics. Ideally,
the least amount of a highly effective adhesive should be applied. Too
much adhesive is a waste of resources and likely to lead to fabric
stiffening and it could also result in thermal discomfort in the garment,
because the adhesive itself could form an impermeable barrier to
perspiration.
