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Bonded, Laminated & Bonded fabric (1).pptx

  1. LAMINATE, BONDED AND COATED FABRICS Laminated fabric: A material composed of two or more layers at least one of which is textile fabric, bonded closely together by the adhesive properties of one or more of the component layers. Laminating: A pre-made or extruded film layer is bonded onto the substrate, generally with thermal or adhesive bonding. Curing is generally not required.
  2. ¢ A laminated or more specifically foam laminated usually consists of three layers adhered together; a face fabric, a middle foam layer (usually polyurethane foam), and a backing fabric (usually acetate or nylon tricot). ¢ Laminated fabrics are sometimes produced without any backing, these fabrics are called unbacked or foam backed laminated fabric. The foam laminates can be produced up to ½ inch thickness of foam layers however, in most cases they are produced in the range of 1/8 to 3/16 inch. ¢ Foam laminated fabrics are mainly produced for clothing insulation, interlining. Sometimes the outer fabric is directly laminated, which is economical because it eliminated sewing of the fabric and interlining, however the fabrics becomes stiffer and the garment retains all of its drapability. ¢ This is why this type of lamination is used in case coat which does not take any unsightly appearance.
  3. ¢ Abonded material is used to joined two layer of fabrics that have been adhered together. The backing fabric is usually acetate or nylon tricot, and the face fabric may be almost any conceivable type of cloth. ¢ Both of the face and backing fabrics are individually unsuitable for apparel for their lightweight and cost (when weight is increased). After bonding two fabrics, much better fabric having all the good properties including substantial gain weight can be produced this can be used for specific purposes. ¢ Thus bonded fabrics are very important in textile and apparel market as they provide better appearance, surface, touch stability and durability at much lower cost than identical single fabric.
  4. DIFFERENCE BETWEEN BONDED AND LAMINATED FABRIC Laminated Bonded fabric 1. Fabric is attached with a continuous sheet 1. Two fabrics are joined together by adhesive 2. Good wrinkle resistance 2. Poor wrinkle resistance 3. Tailoring property not so good 3. Good tailoring property 4. Good insulation property with light weight 4. Insulation property is not so good 5. Stability is less than bonded fabric 5. Good stability 6. Not so hygienic for wearing 6. Hygienic & good for wearing 7. Comparatively heavier than bonded fabrics 7. Relatively light weight.
  5. TECHNIQUES OF LAMINATION i. Roller (heated) ii. Spray iii. Film iv. Flame v. Hot pressing vi. Curing of the adhesive ¢ Different types of bonding agent iii. i. Liquid bonding agent ii. Powdered ( may be thermoplastic e.g PVC, PVA, PE or it can be melted by infra red radiation then calendaring) Cold setting of water based rubber iv. High temperature resin
  6. ADVANTAGES OF POLYURETHANE SHEET OVER POLYETHER & POLYESTER iii. vii. viii. xii. xiii. xiv. i. Weak solubility in conventional organic solvent. ii. Resistance to elevated temp. Good thermal insulation. iv. High adhesiveness to practically all materials. v. High degree of elasticity. vi. Lightness. Resistance to creasing. They may be given any degree of elasticity. ix. Higher dimensional stability. x. Excellent sound proofing quality. xi. Does not support growth of bacteria. Odorless or non-odor retaining. Does not bunch, melt, shrink or stretched. It is perspiration proof, non toxic and non allergic.
  7. THE REASONS FOR GOOD THERMAL INSULATION PROPERTY OF LAMINATE iii. i. No. of trapped air in laminated fabric is more. So, laminated fabric has good thermal property. ii. The product is as like as woolen type, as a result the fabric is warmth in nature. Due to adhesive materials layer used in laminated fabric, the resulting thickness of laminated fabric will increased, this will increase the thermal insulation property. iv. Thermal insulation of fabric will increase due to the uses of polyurethane foam. Because there is air pocket in the foam which will obstact the transfer of heat. v. Due to the polymer the fabric has good thermal insulation property.
  10. COATING ¢ Coating: Polymer or elastomer, usually in viscous form, is applied directly onto the fabric and cured. A variety of techniques are used. A bond-coat (adhesive) may or may not be used. ¢ COATING is a layer of polymeric material on a textile which imparts new characteristics to the base fabric. The resultant coated fabric may have functional properties, such as resistance to soiling, penetration of fluids, etc., or have an entirely different aesthetic appeal, such as finished leather. ¢ Awide range of textile materials is used as substrates for coated fabrics. These may be woven, knitted, or nonwoven materials. ¢ The types of fiber commonly used in coating are cotton, rayon, nylon, polyester, and blends of polyester with cotton or rayon, depending on the end use requirements. Polyester is the most popular in staple form for nonwoven material and in spun form for woven material. High performance fibers like Kevlar®, Nomex®, PBI, etc., are used in specialized applications.
  12. THE CHOICE OF FABRIC FOR COATING ¢ The following aspects need to be considered: i. Fiber type and form such as staple, filament, etc. ii. Yarn type and construction iii. Fabric form, i.e., woven, nonwoven, and knitted and their construction iv. Strength and modulus v. Creep behavior vi. Resistance to acids and chemicals vii. Adhesion requirement viii. Resistance to microbiological attack ix. Environmental acceptability x. Durability xi. Dimensional stability xii. Cost
  13. COATING METHODS ¢ Fluid coating: the coating material is in the form of paste, solution, or latices. i. Knife coaters, wire wound bars, round bars, etc.: these are post-metering devices. ii. Roll coaters, reverse roll coaters, gravure coaters, dip coaters, etc.: these are pre-metered application systems. iii. Impregnators: material to be coated is dipped in the fluid, and the excess is removed by squeeze roll or doctor blades. iv. Spray coaters: the material is sprayed directly on the web or onto a roll for transfer.
  14. COATING METHODS Reverse Roll Coating Slot Die Coating Immersion Coating
  15. COATING METHODS Knife Over Roll Coating Air Knife Coating Metering Rod Coating Gravure Coating
  16. COATING METHODS ¢ Coating with dry compound (solid powder or film): i. Melt coating: extrusion coating, powder coating, etc. ii. Calendaring: for thermoplastic polymers and rubber compounds. iii. Lamination
  19. FACTORS FOR COATING METHOD SELECTION ¢ The choice of a coating method depends on several factors. They are as follows: i. Nature of the substrate ii. Form of the resin and viscosity of the coating fluid iii. End product and accuracy of coating desired iv. Economics of the process
  20. NECESSARY EQUIPMENT FOR COATING Preparation Foam mixer Electric stirrer Coating head Coating Drying Dryer Stenter Treatment Crush roller Calander
  21. COMMON FEATURES OF FLUID COATING UNITS Figure : Layout of direct coating line: (1) Fabric let-off arrangement, (2) Coating head, (3) Drying oven, and (4) Fabric take-up section.
  22. ARRANGEMENTS OF KNIFE COATING Figure : Different types of knife coating: (1) support table, (2) rubber blanket, (3) rubber or steel roll, (4) knife, (5) fabric, and (6) coating material. Air Knife
  23. COATING KNIVES Figure : Profiles of knives: (a) knife type, (b) V type, (c) bull nose, and (d) shoe.
  24. SOME APPLICATIONS OF COATED TEXTILES Truck Tarpaulins Bio gas-bag multi-utility vehicles Static Covering
  25. Machinery Covers Pond Liners Container Covers Architecture and Building Covers Leisure Tents Leisure Tents Collapsible Bags Awnings
  26. Cricket Pitch cover Ducting Sports wear Automotives interiors Inflatable's Bus seat cover Liquid storage tank Aqua Barrier