METHOD AND DEVICE FOR MANUFACTURING A COATED FABRIC OR A COATED KNIT FABRIC

Abstract

Methods and systems for producing a coated fabric or knit fabric. A coating material is applied to a first carrier material such that the first carrier material is at least partially coated with the coating material. The fabric or knit fabric and the first carrier material that is at least partially coated with the coating material are brought together. The coating material is at least partially transferred from the first carrier material to the fabric or knit fabric.

Claims

1. A method of manufacturing a coated fabric comprising: providing a fabric; providing a first carrier material; providing a coating material; applying the coating material to the first carrier material such that the first carrier material is at least partially coated with the coating material 10; bringing together the fabric and the first carrier material, that is at least partially coated with the coating material; establishing contact between the fabric and the coating material; at least partially transferring the coating material from the first carrier material to the fabric by adjusting at least one of a predetermined pressure and a predetermined temperature to thereby provide a fabric coated with the coating material

2. The method of claim 1, further comprising: removing the first carrier material from the coated fabric.

3. The method of claim 2, wherein the first carrier material is removed from the coated fabric by applying a separation force, wherein the separation force has a value range of 6N/4 m to 600 N/4 m, preferably a value range of 50 N/4 m to 500 N/4 m, or more preferably a value range of 100 N/4 m to 450 N/4 m.

4. The method of claim 1, wherein the first carrier material (18) comprises a siliconized web material or a silicone paper.

5. The method of claim 4, wherein the at least partial transfer of the coating material from the first carrier material to the fabric has an application weight of 5 g/m.sup.2 to 150 g/m.sup.2, preferably a value range of 10 g/m.sup.2 to 100 g/m.sup.2, or more preferably a value range of 15 g/m.sup.2 to 70 g/m.sup.2.

6. The method of claim 5, wherein, upon establishing contact between the fabric and the coating material the coating material is in a liquid state.

7. The method of claim 6, further comprising: preventing a phase transition of the coating material into the gaseous state during the at least partial transfer of the coating material from the first carrier material to the fabric.

8. The method of claim 7, further comprising: drying or solidifying the liquid coating material temporally after manufacturing the coated fabric.

9. The method of claim 8, further comprising: allowing post-crosslinking of the coating material temporally after providing the coated fabric and temporally before removing the first carrier material from the coated fabric

10. The method of claim 9, further comprising: intermediate-storing the coated fabric temporally after providing the coated fabric and temporally before removing the first carrier material from the coated fabric.

11. The method of claim 10, wherein the intermediate-storing of the coated fabric is performed over a period of at least 72 hours, preferably over a period of at least 120 hours, more preferably over a period of at least 168 hours.

12. The method of claim 11, wherein the at least partially transferring the coating material from the first carrier material to the fabric comprises at least partially transferring the coating material to a first fabric side of the fabric to thereby provide a fabric coated on one side with the coating material

13. The method of claim 12, further comprising: providing a second carrier material; applying the coating material to the second carrier material such that the second carrier material is at least partially coated with the coating material; bringing together the fabric and the second carrier material that is at least partially coated with the coating material; establishing contact between a second fabric side of the fabric and the coating material that coats the second carrier material; at least partially transferring the coating material from the second carrier material to the second fabric side of the fabric by adjusting at least one of a predetermined pressure and a predetermined temperature to thereby provide a fabric coated on two sides with the coating material removing the second carrier material from the fabric coated on two sides.

14. The method of claim 13, wherein the at least partially transferring the coating material from the first carrier material to the first fabric side of the fabric occurs simultaneously with the at least partially transferring the coating material from the second carrier material to the second fabric side of the fabric.

15. The method of claim 12, further comprising: directly applying the coating material to a second fabric side of the fabric by establishing contact between the second fabric side of the fabric and the coating material; at least partially transferring the coating material to the second fabric side of the fabric by adjusting at least one of a predetermined pressure and a predetermined temperature to thereby provide a fabric coated on two sides with the coating material.

16. The method of claim 15, further comprising: drying the coating material temporally after applying the coating material to the first carrier material and temporally before establishing contact between the fabric and the coating material.

17. An apparatus for manufacturing a coated fabric, comprising: a fabric supply unit for providing a fabric; a carrier material supply unit for providing a first carrier material; a roller for providing a coating material; a coating unit; wherein the carrier material supply unit is adapted to guide the first carrier material over the roller to thereby at least partially coat the first carrier material with the coating material; wherein the fabric supply unit is adapted to guide the fabric to the first carrier material that is at least partially coated with the coating material; wherein the coating unit is adapted to establish contact between the fabric and the coating material; wherein the coating unit is adapted to at least partially transfer the coating material from the first carrier material to the fabric by adjusting at least one of a predetermined pressure and a predetermined temperature to thereby provide a coated fabric.

18. A method of manufacturing a coated knit fabric (10), comprising: providing a knit fabric; providing a first carrier material; providing a coating material; applying the coating material to the first carrier material such that the first carrier material is at least partially coated with the coating material; bringing together the knit fabric and the first carrier material, that is at least partially coated with the coating material; establishing contact between the knit fabric and the coating material; at least partially transferring the coating material from the first carrier material to the knit fabric by adjusting at least one of a predetermined pressure and a predetermined temperature to thereby provide a knit fabric coated with the coating material.

19. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0056] FIG. 1 depicts a device for manufacturing a coated fabric.

[0057] FIG. 2A depicts a perspective view of a coating unit when manufacturing a fabric coated on one side.

[0058] FIG. 2B depicts a side view of a coating unit when manufacturing a fabric coated on one side.

[0059] FIG. 3A depicts a perspective view of a coating unit when manufacturing a fabric coated on two sides.

[0060] FIG. 3B depicts a side view of a coating unit when manufacturing a fabric coated on two sides.

[0061] FIG. 4 depicts a cross-sectional view of components of a process for manufacturing a fabric foil-coated on one side.

[0062] FIG. 5A depicts a flow diagram for a method of manufacturing a coated fabric.

[0063] FIG. 5B depicts a flow diagram for a method of manufacturing a fabric coated on two sides.

DETAILED DESCRIPTION

[0064] The illustrations in the figures are schematic and not to scale. If the same reference numerals are used for different figures in the following description of the figures, these denote the same or similar elements. However, the same or similar elements may also be denoted by different reference numerals.

[0065] FIG. 1 shows an apparatus 1 for manufacturing a coated fabric 10. The apparatus comprises a fabric supply unit 12 for providing a fabric 14. For example, the fabric 14 may be provided in the form of a flexible fabric sheet or a flexible fabric layer. The apparatus 1 further comprises a carrier material supply unit 16 for providing a first carrier material 18. The first carrier material 18 may also be provided in the form of a flexible carrier material sheet or a flexible carrier material layer, wherein the first carrier material may be a siliconized web material, in particular a silicone paper. In the example shown, the carrier material supply unit 16 comprises a first roller 16a or deflection roller 16a and a second roller 16b, via which the first carrier material 18 is conveyed into the region of a third roller 20.

[0066] The third roller 20 is adapted to provide a coating material 22. In particular, the third roller 20 is adapted to convey the coating material 22 onto the first carrier material 18. In the example shown in FIG. 1, the third roller 20 conveys the coating material 22 from a container 21. In doing so, the third roller 20 at least partially dips into the liquid coating material 22, wherein, as a result of the rotating movement of the third roller 20, the surface or lateral surface of the third roller 20 is wetted with coating material 22 from the container 21. Likewise, the first carrier material 18 is guided over the third roller 20 such that, as a result of the rotation of the third roller 20, the coating material 22 located on the roller surface comes into contact with the first carrier material 18. In doing so, the first carrier material 18 is at least partially coated with the coating material 22. The first carrier material 18 coated with coating material 22 may subsequently be guided around a fourth roller 23 before it is then conveyed into a coating unit 24.

[0067] The second roller 16b and the fourth roller 23 are arranged opposite the third roller 20 such that the first carrier material 18 is pressed down onto the third roller 20 by means of the second roller 16b and the fourth roller 23, as shown in FIG. 1, such that an areal contact between the first carrier material 18 and the third roller 20 is ensured. The respective directions of rotation of the second, third and fourth rollers 16b, 20, 23 are indicated by arrows in FIG. 1. After the first carrier material 18 is stripped off from the third roller 20, it is finally at least partially or even completely coated, i.e. wetted, with the coating material 22. In one example, the carrier material layer of the carrier material 18 is provided on one side with coating material 22.

[0068] The first carrier material 18 coated with coating material 22 is then conveyed into the coating unit 24, where it is brought together with the fabric 14. The coating unit 24 may be adapted to establish contact between a first fabric side 14a of the fabric 14 and the first carrier material 18 coated with coating material 22, in particular to establish contact between the first fabric side 14a of the fabric 14 and the coating material 22 itself. In this case, the coating material 22 is arranged between the first carrier material 18 and the fabric 14. Transfer of the coating material 22 to the fabric 14 is made possible here. The coating unit 24 may in particular be adapted to at least partially transfer the coating material 22 from the first carrier material 18 to the fabric 14 by adjusting at least one of a predetermined pressure and a predetermined temperature to thereby provide a coated fabric 10.

[0069] After outputting the coated fabric 10 from the coating unit 24, as can be seen in FIG. 1, the coated fabric 10 is still provided or glued with the first carrier material 18. Since the first carrier material 18 is not intended to remain on the fabric 10 coated with coating material 22, a detachment unit, not shown in FIG. 1, may be provided, by means of which the first carrier material 18 may be separated from the coated fabric 10, i.e. detached or pulled off. In one example, the separation force for separating the first carrier material 18 from the coated fabric 10 is adjusted such that the coated fabric 10 is not destroyed by parts of the coating material 22 being detached from the fabric 14 again, but only the first carrier material 18 is detached from the coated fabric 10.

[0070] In the example shown, only the first fabric side 14a was coated with the coating material 22. In a further example, however, it may be provided that the second fabric side 14b of the fabric 14 is also coated with coating material 22. Here, the coating of the second fabric side 14b may be carried out in the same way as the coating of the first fabric side 14a. The apparatus 1 may accordingly be supplemented analogously to the above description for the supply of a second carrier material coated with coating material 22, wherein, for example, mirroring of the apparatus 1 shown in FIG. 1 is possible in order to enable the two-sided coating.

[0071] FIG. 2A shows a perspective view of a coating unit 24 when manufacturing a fabric 10 coated on one side. In doing so, a carrier material layer of a first carrier material 18 may be at least partially coated with a coating material 22 or wetted by the same. The coating material 22 may in this case be a web material made of plastic. This wetting process is not shown in FIG. 2A. The first carrier material 18 coated with the coating material 22 or the carrier material layer is introduced into the coating unit 24, which in the example shown in FIG. 2A is formed by two opposing rollers 25, 26. Likewise, a fabric layer of the fabric 14 is introduced simultaneously into the coating unit 24. In doing so, the carrier material layer of the first carrier material 18 coated with the coating material 22 and the fabric layer of the fabric 14 are guided together through a gap formed between the two rollers 25, 26.

[0072] FIG. 2B shows a side view of the coating unit 24, wherein the gap lying between the two rollers 25, 26 can be seen. By means of the two rollers 25, 26, a compressive force is exerted on the carrier material layer coated with coating material 22 and the fabric layer, by means of which both material layers are pressed together. This enables an at least partial transfer of the coating material 22 from the carrier material layer to the fabric layer of the fabric 14, for example by adjusting a predetermined roller pressure and optionally additionally by applying a predetermined temperature. By means of the transfer of the coating material 22 to the fabric layer, an adhesive connection between the coating material 22 and the fabric is established, whereby a fabric 10 coated with the coating material 22 is generated as a result. It may again be provided that the first carrier material 18 is removed from the coated fabric 10 after the coating, as described with respect to FIG. 1.

[0073] It can further be seen in FIG. 2A that only a part of the fabric 14 or the fabric layer is provided with the coating material 22 such that an uncoated fabric region 11a and a coated fabric region 11b are produced.

[0074] FIG. 3A shows a perspective view of a coating unit 24 when manufacturing a fabric 10 coated on two sides. In doing so, a carrier material layer of a first carrier material 18a may be at least partially coated with coating material 22 or wetted by the same. Further, a carrier material layer of a second carrier material 18b may be at least partially coated with coating material 22 or wetted by the same. This wetting process is not shown in FIG. 3A. The first carrier material 18a coated with the coating material 22 and the second carrier material 18b coated with the coating material 22 are introduced into the coating unit 24, which in the example shown in FIG. 3A is again formed by two opposing rollers 25, 26. Likewise, a fabric layer of the fabric 14 is introduced simultaneously into the coating unit 24. In doing so, the two carrier material layers of the first carrier material 18a or the second carrier material 18b coated with the coating material 22 and the fabric layer of the fabric 14 are guided together through a gap formed between the two rollers 25, 26. The coating material 22 is provided between the carrier material layer of the first carrier material 18a and the fabric layer of the fabric 14. Likewise, the coating material 22 is provided between the carrier material layer of the second carrier material 18b and the fabric layer of the fabric 14.

[0075] FIG. 3B shows a side view of the coating unit 24, wherein the gap lying between the two rollers 25, 26 can be seen. By means of the two rollers 25, 26, a compressive force is exerted on the two carrier material layers coated with coating material 22 and the fabric layer, by means of which all material layers are pressed together. This enables an at least partial transfer of the coating material 22 from the carrier material layers to both sides of the fabric 14, for example by adjusting a predetermined roller pressure and optionally additionally by applying a predetermined temperature. Thus, the first side 14a of the fabric 14 and the second side 14b of the fabric 14 (cf. FIG. 1) can be provided with the coating material 22. By means of the two-sided transfer of coating material 22 to the fabric layer, an adhesive connection between the coating material 22 and the fabric 14 is established, whereby a fabric 10 coated with the coating material 22 on both sides is generated as a result. It may again be provided that the first carrier material 18a and/or the second carrier material 18b is removed from the coated fabric 10 after the coating, as described with respect to FIG. 1.

[0076] It can further be seen in FIG. 3A that only a part of the fabric 14 or the fabric layer is provided with the coating material 22 such that an uncoated fabric region 11a and a coated fabric region 11b are produced. This may apply to both sides of the coated fabric 10, wherein this can be seen in FIG. 3A only for one side of the coated fabric 10.

[0077] FIG. 4 shows a cross-sectional view of components of a process for manufacturing a fabric 10 foil-coated on one side. The apparatus 1 described with respect to FIG. 1 and/or the method described below with respect to FIGS. 5A and 5B may also be used, for example, for a foil coating of the fabric 14. The coating material 22 described herein may be formed by a web material such as, for example, a plastic foil. Such a foil coating may be effected in particular by means of a web material 22 which is applied by means of wet coating to the first carrier material 18, for example silicone paper, and is subsequently dried. The coating material 22 is first applied in the form of liquid plastic, which later forms the coating, to the first carrier material 18 or the silicone paper. Subsequently, drying of the plastic on the first carrier material 18 is effected before the first carrier material 18 together with the dried plastic layer is introduced into the coating unit formed by the rollers 25, 26 (see arrows 30 in FIG. 4). Only when the first carrier material 18 together with the dried plastic layer is introduced between the rollers 25, 26, a pressure and/or a temperature is applied, whereby the fabric 14 simultaneously guided between the rollers 25, 26 is brought into contact with the dried plastic layer. During this contact, the coating of the fabric 14 with the plastic layer or the plastic foil is again effected. As a result, a fabric 10 coated with the plastic sheet, i.e. the coating material 22, is produced. The first carrier material 18 may subsequently be removed from the coated fabric 10, as already explained.

[0078] FIG. 5A shows a flow diagram for a method of manufacturing a coated fabric. The method is, for example, a method which may be carried out with the apparatus 1 of FIG. 1 in order to manufacture the coated fabric 10. In one step S1, the method comprises providing a fabric 14. A further step S2 comprises providing a first carrier material 18. A further step S3 comprises providing a coating material 22. A further step S4 comprises applying the coating material 22 to the first carrier material 18 such that the first carrier material 18 is at least partially coated with the coating material 22. A further step S5 comprises bringing together the fabric 14 and the first carrier material 18 that is at least partially coated with the coating material 22. A further step S6 comprises establishing contact between the fabric 14 and the coating material 22. A further step S7 comprises at least partially transferring the coating material 22 from the first carrier material 18 to the fabric 14 by adjusting at least one of a predetermined pressure and a predetermined temperature to thereby provide a fabric 10 coated with the coating material 22.

[0079] In a further optional step S8, the first carrier material 18 may be removed from the coated fabric 14 after the at least partial transfer of the coating material 22 to the fabric 14 is completed.

[0080] In a further optional step S4a, the coating material 22 may be dried temporally after applying the coating material 22 to the first carrier material 18 and temporally before establishing contact between the fabric 14 and the coating material 22.

[0081] In a further optional step S7a, a phase transition of the coating material 22 into the gaseous state may be prevented during the at least partial transfer of the coating material 22 from the first carrier material 18 to the fabric 14.

[0082] In a further optional step S7b, the coating material 22 may be dried temporally after manufacturing the coated fabric 14.

[0083] In a further optional step S7c, post-crosslinking of the coating material 22 may be allowed temporally after providing the coated fabric 14 and temporally before removing the first carrier material 18 from the coated fabric 10.

[0084] In a further optional step S7d, the coated fabric 14 may be intermediate-stored temporally after providing the coated fabric 14 and temporally before removing the first carrier material 18 from the coated fabric 10.

[0085] Steps S7b, S7c and S7d may thus temporally follow step S7.

[0086] FIG. 5B shows a flow diagram for a method of manufacturing a fabric coated on two sides. This method may be provided in the form of parallel steps or in the form of additional steps to the method steps described in FIG. 5A. In one step S20, the method comprises providing a second carrier material. A further step S40 comprises applying the coating material 22 to the second carrier material such that the second carrier material is at least partially coated with the coating material 22. A further step S50 comprises bringing together the fabric 14 and the second carrier material that is at least partially coated with the coating material 22. A further step S60 comprises establishing contact between a second fabric side 14b of the fabric 14 (cf. FIG. 1) and the coating material 22. A further step S70 comprises at least partially transferring the coating material 22 from the second carrier material to the second fabric side 14b of the fabric 14 by adjusting at least one of a predetermined pressure and a predetermined temperature to thereby provide a fabric 10 coated on two sides with the coating material 22.

[0087] In a further optional step S80, the second carrier material may again be removed from the fabric 10 coated on two sides.

[0088] In a further optional step S70a, a phase transition of the coating material 22 into the gaseous state may be prevented during the at least partial transfer of the coating material 22 from the second carrier material to the second fabric side 14b of the fabric 14.

[0089] In a further optional step S70b, the coating material 22 may be dried temporally after manufacturing the fabric 10 coated on two sides.

[0090] In a further optional step S70c, post-crosslinking of the coating material 22 may be allowed temporally after providing the fabric 10 coated on two sides and temporally before removing the first carrier material 18 from the fabric 10 coated on two sides.

[0091] In a further optional step S70d, the fabric 10 coated on two sides may be intermediate-stored temporally after providing the fabric 10 coated on two sides and temporally before removing the first carrier material 18 from the fabric 10 coated on two sides.

[0092] Steps S70b, S70c and S70d may thus temporally follow step S7 or S70.

[0093] The foregoing description is merely illustrative in nature and is not intended to limit the embodiments of the subject matter or the application and uses of such embodiments.

[0094] Furthermore, there is no intention to be bound by any expressed or implied theory presented in the technical field, background, or the detailed description. As used herein, the word exemplary means serving as an example, instance, or illustration. Details of the exemplary embodiments or other limitations described above should not be read into the claims absent a clear intention to the contrary. Any implementation described herein as exemplary is not necessarily to be construed as preferred or advantageous over other implementations, and the exemplary embodiments described herein are not intended to limit the scope or applicability of the subject matter in any way. Accordingly, it should be appreciated that the exemplary embodiment or embodiments described herein are not intended to limit the scope, applicability, or configuration of the claimed subject matter in any way. Rather, the foregoing detailed description will provide those with ordinary skill in the art with a convenient road map for implementing the described embodiment or embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope defined by the claims, which includes known equivalents and foreseeable equivalents at the time of filing this patent application.