WO2003087452A1 - A water-resistant sheet material - Google Patents
A water-resistant sheet material Download PDFInfo
- Publication number
- WO2003087452A1 WO2003087452A1 PCT/IB2003/001316 IB0301316W WO03087452A1 WO 2003087452 A1 WO2003087452 A1 WO 2003087452A1 IB 0301316 W IB0301316 W IB 0301316W WO 03087452 A1 WO03087452 A1 WO 03087452A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- sheet material
- base layer
- threads
- fabric base
- water
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Ceased
Links
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
- D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2403/00—Details of fabric structure established in the fabric forming process
- D10B2403/01—Surface features
- D10B2403/011—Dissimilar front and back faces
- D10B2403/0112—One smooth surface, e.g. laminated or coated
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2403/00—Details of fabric structure established in the fabric forming process
- D10B2403/01—Surface features
- D10B2403/012—Alike front and back faces
- D10B2403/0122—Smooth surfaces, e.g. laminated or coated
Definitions
- THIS INVENTION relates to a water-resistant sheet material. It relates also to a method of manufacturing the sheet material.
- a water-resistant sheet material including: a fabric base layer which is made of knitted extruded polymer threads comprising
- each monofilament thread is formed into pillar stitches extending in a warp direction
- a coating layer in the form of a water-resistant polymer sheet element which is bonded to a side of the fabric base layer thereby providing the sheet material with water-resistant properties.
- the monofilament threads may have 111 pillar stitches per inch of fabric.
- the monofilament threads may be approximately 400 Denier.
- the fabric base layer may be produced on a warp knitting machine having at least three guide bars, with the second series of monotape threads extending across the equivalent of four needle gaps in a weft direction.
- the monotape threads may be approximately 350 Denier.
- the monotape threads may have a width of approximately 1.8mm and a thickness of approximately 0.035mm.
- the third series of monotape threads may be added to the monofilament threads and the second series of monotape threads to traverse the equivalent of one needle gap in a weft direction to provide a filler.
- the needle gaps may be 1/8 of an inch.
- the threads of the fabric base layer may be of high-density polyethylene.
- the coating layer may be in the form of an extruded low-density polyethylene film.
- the coating layer may be approximately 1 micron thick.
- the sheet material may comprise a coating layer bonded to each of two sides of the fabric base layer.
- a method of manufacturing a water-resistant sheet material including: providing a fabric base layer which is made of knitted threads of an extruded polymer compound;
- the method may include pre-heating the polymer coating compound to approximately 250°C.
- the method may include extruding the polymer coating compound in the form of a film having a thickness of approximately 1 micron, onto the fabric base layer.
- a predetermined preheated amount of said polymer coating compound may be extruded onto the other side of the fabric base layer in the form of a film to form a water-resistant coating layer on said other side of the fabric base layer.
- the method may include pre-heating the fabric base layer to approximately 30°C prior to extruding the coating layer onto the base layer.
- the fabric base layer may be equivalent to the fabric base layer which forms part of the sheet material as defined hereinabove in accordance with the first aspect of the invention.
- the coating layer may be equivalent to the coating layer forming part of the sheet material as defined hereinabove in accordance with the first aspect of the invention.
- Figure 1 shows a vertical section of a warp knitting machine of the type used to make the fabric base layer of the water-resistant sheet material in accordance with the invention
- Figure 2 is a pattern diagram illustrating the configuration of the different stitches of the threads forming the fabric base layer
- Figure 3 is a pattern diagram which illustrates the knit configuration of the base layer.
- Figure 4 is a schematic block diagram illustrating a method of manufacturing the water-resistant sheet material in accordance with the invention.
- the sheet material in accordance with the first aspect of the invention comprises a fabric base layer which is made of knitted threads of high-density polyethylene (abbreviated "HDPE”) and which is coated on both sides thereof with a polymer coating compound of low-density polyethylene (abbreviated "LDPE”) which provides the sheet material with water-resistant properties.
- HDPE high-density polyethylene
- LDPE low-density polyethylene
- the fabric base layer is produced on a 16-gauge Raschel-type warp knitting machine.
- a 16-gauge Raschel-type warp knitting machine comprises a series of latch needles 10, a trick plate 12 and three guide bars, the first guide bar carrying a series of guide needles 14.1, the second guide bar carrying a series of guide needles 14.2, and the third guide bar carrying a series of needles 14.3.
- the latch needles of the knitting machine are spaced 1/8 of an inch apart. Hence, the needle gaps are 1/8 of an inch.
- a knitting fabric 16 made on the knitting machine comprises a single series of monofilament threads M each of which passes through the eye of a corresponding one of the guide needles 14.1 , a second series of threads in the form of monotapes T1 each of which passes through the eye of a corresponding one of the guide needles 14.2, and a third series of threads in the form of monotapes T2 each of which passes through the eye of a corresponding one of the guide needles 14.3.
- the monofilament threads M are 400 Denier monofilament threads.
- the tapes T1 and T2 are each in the form of 350 Denier tape having a width of 1.8mm and a thickness of 0.035mm.
- each of the monofilament threads M are knitted to form a pillar stitch which gives the fabric strength in the longitudinal or warp direction.
- the monofilament threads are knitted with 11 4 pillar stitches per inch of fabric.
- the tapes T1 are knitted in a zig-zag fashion to form a binding between adjacent pillar stitches.
- the tapes T1 are knitted in a closed "Sammt" stitch and traverse the equivalent of four needle gaps in a weft direction per machine cycle.
- the monotapes T2 are added to the monofilament threads and the monotapes T1 and traverse the equivalent of one needle gap in a weft direction.
- the configuration of the monotapes T1 and T2 in particular, provide the knitted fabric with its "coverage" properties for shade protection.
- the fabric base layer Due to the knit configuration of the fabric base layer, the fabric base layer exhibits equal elongation and tensile strength properties in both warp and weft directions.
- the knit configuration thus provides a knitted fabric having uniform properties in both warp and weft directions. Due to the material properties and stitches used for the monotapes of the second and third series, the monotapes exhibit sufficient tensile strength in the weft direction, thereby obviating the need for monofilament threads in the weft direction.
- the "throw" of the monotapes T1 in the knit fabric are relatively long thereby providing a more stable knit fabric.
- the monofilament threads and the monotapes do not slide over one another.
- the Sammt construction to anchor the weft monotapes T1 with the pillar stitches of the monofilament threads, the fabric is provided with stability in both weft and warp directions.
- the relatively tight knit configuration of the fabric provides the fabric with a smoother surface texture which allows for coating of the fabric with more precision thereby providing the fabric with enhanced aesthetic appeal.
- the following pattern chain is used to set up the knitting machine and defines the knit configuration.
- the fabric base layer 20 is fed in the direction shown by arrow "A" at a feed rate of approximately 25m/min along feed rollers 22 to a position below an extruder 24 which extrudes pre-heated LDPE film 26 having a thickness of 1 micron, onto the surface of an upper side of the fabric base layer.
- the coating compound is pre-heated to approximately 250°C.
- the fabric base layer Prior to being coated with the LDPE film, the fabric base layer undergoes corona treatment and is preheated.
- a corona treatment unit 28 provides a corona discharge which etches the upper surface of the fabric base layer thereby to provide a chemically active surface which enhances bonding of the extruded LDPE film with the fabric base layer.
- An oil heated roller 30 heated to approximately 90°C, is provided for preheating the fabric base layer to a temperature of approximately 30°C, through contact with roller 30.
- a water-chilled roller 32 is provided downstream of the extruder for cooling the coating layer and the fabric base layer.
- the fabric base layer coated on one side thereof with the LDPE coating layer is turned over and the other side thereof is similarly coated with a further LDPE coating layer thereby to coat both sides of the fabric base layer with 1 micron thick LDPE coating layers.
- the process described above is repeated by extruding the second coating layer in the form of a sheet element onto the uncoated side of the fabric base layer which now faces upwardly, thereby to coat it with the coating layer.
- the sheet material can be used as a shade cloth having good water-resistant properties.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Knitting Of Fabric (AREA)
Abstract
Description
Claims
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2003226576A AU2003226576A1 (en) | 2002-04-12 | 2003-04-10 | A water-resistant sheet material |
| EP03746382A EP1495173A1 (en) | 2002-04-12 | 2003-04-10 | A water-resistant sheet material |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| ZA200202899 | 2002-04-12 | ||
| ZA2002/2899 | 2002-04-12 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2003087452A1 true WO2003087452A1 (en) | 2003-10-23 |
Family
ID=29251513
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/IB2003/001316 Ceased WO2003087452A1 (en) | 2002-04-12 | 2003-04-10 | A water-resistant sheet material |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP1495173A1 (en) |
| AU (1) | AU2003226576A1 (en) |
| WO (1) | WO2003087452A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20080188152A1 (en) * | 2007-02-02 | 2008-08-07 | Chiu-Shiung Tsai | Moisture-vapor- permeable and water-resistant fiber |
| US20120238166A1 (en) * | 2011-03-18 | 2012-09-20 | Gale Pacific Usa, Inc. | Coated waterproof fabric |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2143612A2 (en) * | 1967-07-12 | 1973-02-09 | Chomarat & Cie | Coated textile fabric - comprising knitted base web of synthetic filaments coated with plastic film |
| GB2043126A (en) * | 1978-12-15 | 1980-10-01 | Becker Wilhelm Ab | Coated cloth |
| WO1996010107A1 (en) * | 1994-09-26 | 1996-04-04 | Polysack Plastic Industries Nir Itzhak-Sufa | Light reflecting screen |
| US6159877A (en) * | 1993-01-25 | 2000-12-12 | 3M Innovative Properties Company | Fabric backing for orthopedic support materials |
| WO2002044452A2 (en) * | 2000-11-30 | 2002-06-06 | Alnet (Proprietary) Limited | A knitted fabric |
-
2003
- 2003-04-10 EP EP03746382A patent/EP1495173A1/en not_active Withdrawn
- 2003-04-10 WO PCT/IB2003/001316 patent/WO2003087452A1/en not_active Ceased
- 2003-04-10 AU AU2003226576A patent/AU2003226576A1/en not_active Abandoned
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2143612A2 (en) * | 1967-07-12 | 1973-02-09 | Chomarat & Cie | Coated textile fabric - comprising knitted base web of synthetic filaments coated with plastic film |
| GB2043126A (en) * | 1978-12-15 | 1980-10-01 | Becker Wilhelm Ab | Coated cloth |
| US6159877A (en) * | 1993-01-25 | 2000-12-12 | 3M Innovative Properties Company | Fabric backing for orthopedic support materials |
| WO1996010107A1 (en) * | 1994-09-26 | 1996-04-04 | Polysack Plastic Industries Nir Itzhak-Sufa | Light reflecting screen |
| WO2002044452A2 (en) * | 2000-11-30 | 2002-06-06 | Alnet (Proprietary) Limited | A knitted fabric |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20080188152A1 (en) * | 2007-02-02 | 2008-08-07 | Chiu-Shiung Tsai | Moisture-vapor- permeable and water-resistant fiber |
| US8247334B2 (en) * | 2007-02-02 | 2012-08-21 | G-Fun Industrial Corporation | Moisture-vapor-permeable and water-resistant fiber |
| US20120238166A1 (en) * | 2011-03-18 | 2012-09-20 | Gale Pacific Usa, Inc. | Coated waterproof fabric |
Also Published As
| Publication number | Publication date |
|---|---|
| AU2003226576A1 (en) | 2003-10-27 |
| EP1495173A1 (en) | 2005-01-12 |
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