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The
Presentation
On
“TEXTILE COATING”
UNDER THE GUIDANCE OF
Prof. (Dr.) M.D.TELI
BY
Omkar S. Parmaj
Research scholar in
In...
INTRODUCTION
 Coating has now become a very important technique for adding value to
textiles.
 Coating enhances and exte...
DEFINITION
 Coating is an application of an appropriate chemical system to
form a layer of a coating compound on the subs...
COATING FORMULATIONS
 Formulation contain a wide range of chemicals
depending upon :
 Nature of polymer
 Necessary addi...
POLYMER USED FOR
COATING
 Polyvinyl chloride (PVC)
 Polyvynilidene chloride
(PVDC)
 Polyurethane (PU)
 Acrylic
 Ethyl...
PHYSICAL FORMS OF
COATING COMPOUNDS
 Solvent based systems
 Waterbased systems-dispersions and emulsions.
 100% solids ...
COATING PROCESS
Process flow diagram of coating
SUBSTRATE
 A wide range of textile materials is used as substrates for coated fabrics.
 Woven
 Knitted
 Nonwoven mater...
SELECTION OF FABRIC
The following aspects need to be considered:
 Strength and modulus
 Creep behaviour
 Resistance to ...
PARAMETERS for uniform
COATING
• The parameters necessary for uniformity in coating add-on are as
follows:
 Substrate ten...
METHODS OF APPLICATIONS
The technique that is selected for any given product will be
dependent upon a number of factors su...
COATING METHODS
 Direct Coating
 Foamed And Crushed Foam
Coating
 Transfer Coating
 Hot Melt Extrusion Coating
 Calen...
DIRECT COATING
 Direct application of coating fluid is done on to the textile fabric by
uniform spreading of coating by t...
KNIFE ON
AIR
 This type of knife coating is a blade over air, or floating knife
process.
 The knife is fixed above the s...
KNIFE ON ROLLER
 In this process knife blade is suspended above a roller.
 The roller can be steel or rubber coated.
 T...
FOAMED AND CRUSHED FOAM COATING
 The method can apply polymer to Woven fabrics, Knitted
fabrics, fabric produced from spu...
FOAMED AND CRUSHED FOAM
COATING
TRANSFER COATING
The principle of transfer coating is first to spread the polymer on to
release paper to form a film and t...
TRANSFER COATING
HOT MELT
EXTRUSION
COATING
 This method is used for thermoplastic polymers such as
polyurethane, Polyolefins and PVC.
 T...
CALENDER COATING
 Calenders are primarily used to produce unsupported films of PVC and
rubbers from compounded polymer ‘d...
ROTARY SCREEN COATING
 The rotary screen technique applies to a fabric by forcing
it through a cylindrical screen, it is ...
SPRAY COATING
 A coating material can be sprayed directly onto the
substrate surface.
 Spray coating methods are:
 Pres...
DRY POWDER COATING
 There are two processes in this category,
1. scatter coating and, 2. dot coating.
 These processes a...
CURTAIN COATING
 In curtain coating the coating fluid forms a freely falling liquid
sheet and is deposited onto a moving ...
SLOT DIE OR EXTRUSION COATING
 In this method plasticized coating compound is pressed
through a sheeting die and transfer...
MAYER ROD COATING
 In this method, compound is applied
on the web by a single-roll
applicator.
 The coating is post-mete...
KISS ROLL COATING
 The coating is applied on the web as it touches
the nip-to-nip of the applicator roll.
 The pickup ro...
GRAVURE ROLL COATING
 Engraved dots or lines of the
engraved roller fill with the
coating material.
 The excess coating ...
REVERSE ROLL COATERS
 The coating material is measured onto the applicator
roller by precision setting of the gap between...
REVERSE ROLL COATERS
APPLICATIONS
 Agriculture
 Construction
 Clothing
 Geotextiles
 Home Furnishings
 Industrial
 Medical
 Transportat...
APPLICATIONS FOR COATED
FABRICS
 Agriculture - Bulk containers, Fencing,
Seed/crop covers, Bags, Irrigation systems, Pond...
 Geotextiles - Settling pond
liners, Irrigation liners,
Landfill liners & covers,
Soil stabilizers, Erosion
barriers.
 H...
 Medical – Implants, plaster, Gloves,
Upholstery.
 Transportation - Seating/Trim for,
automotive, trucks, aircraft, buse...
 Protective – Gloves, Aprons, Chemical
Suits, Footwear Space Suits, Ballistic
Protection.
 Packaging - Bulk containers,G...
ADVANCED COATING POLYMER
 In today’s era the requirements of human beings has been
totally changed , so research is going...
ADVANCED COATING TECHNIQUES
 Atmospheric Plasma Coating
 Phase Change Material Coating
ATMOSPHERIC PRESSURE PLASMA COATING
 Water-repellent and self-cleaning coatings can be produced with
the aid of atmospher...
PHASE CHANGE MATERIALS
 Phase change materials (PCM) take advantage of latent heat that
can be stored or released from a ...
Phase change material
SMART TEXTILES
Smart Textiles
Passsive
Ex.Conductive fabric
Active
Ex .PCM , SMM
Ultra
Ex.-Musical Jackets
SMART TEXTILES: Conductive Coating
 Polypropylene (PP) and viscose (VS) were modified by the insitu synthesis of a
conduc...
Flame Retardancy
• Two types of Di-ammonium hydrogen phosphate (DAHP)
microcapsules based flame retardent with respectivel...
Antibacterial Coating
• A novel antibacterial coating for cotton fabrics has been developed
using core-shell particles tha...
ULTRA-EVER DRY COATING
• Ultra-Ever Dry is a superhydrophobic (water) and
oleophobic (hydrocarbons) coating that will repe...
Ultra-Ever Dry Features
• Anti-Wetting-
– The superhydrophobic coating keeps objects dry. Water
and many other liquids are...
APPLICATIONS OF ADVANCE COATED TEXTILES
 Comfort wear
 Heat protection
 Medical applications
 Military applications
 ...
CONCLUSION
 The coating and lamination gives a powerful tool for the
advancement of textile technology.
 It provides the...
Textile coating
Textile coating
Textile coating
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Textile coating

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The presentation is about textile coating there are all types of coating is included and there applications in various fields.

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Textile coating

  1. 1. The Presentation On “TEXTILE COATING” UNDER THE GUIDANCE OF Prof. (Dr.) M.D.TELI BY Omkar S. Parmaj Research scholar in Institute of chemical technology Mumbai
  2. 2. INTRODUCTION  Coating has now become a very important technique for adding value to textiles.  Coating enhances and extends the range of functional performance properties of textiles.  The use of these techniques is growing rapidly as the applications for technical textile material has become more diverse.  The key to success in textile coating and lamination depends upon the application of appropriate technology using advanced machinery.
  3. 3. DEFINITION  Coating is an application of an appropriate chemical system to form a layer of a coating compound on the substrate.  Coating is a process in which a polymeric layer is applied directly on one or both the surfaces of the fabric.  Depending upon the end-use, heavy-duty technical textile coatings may be applied.  Unlike woven textile materials now coating is being done on other textile substrates also such as warp-knitted, weft-knitted and nonwovens.
  4. 4. COATING FORMULATIONS  Formulation contain a wide range of chemicals depending upon :  Nature of polymer  Necessary additives for the specific end-use.  Whether coating has to be foamed prior to application.  Type of coating machinery to be used.
  5. 5. POLYMER USED FOR COATING  Polyvinyl chloride (PVC)  Polyvynilidene chloride (PVDC)  Polyurethane (PU)  Acrylic  Ethylene vinyl acetate (EVA)  Poly tetra fluoro ethylene (PTFE)  Styrene butadine rubber(SBR)  Natural rubber (NR)  Silicone  Polyolefins , LDPE, HDPE, Polypropylene
  6. 6. PHYSICAL FORMS OF COATING COMPOUNDS  Solvent based systems  Waterbased systems-dispersions and emulsions.  100% solids materials -Film, Powder, Hot Melt.
  7. 7. COATING PROCESS Process flow diagram of coating
  8. 8. SUBSTRATE  A wide range of textile materials is used as substrates for coated fabrics.  Woven  Knitted  Nonwoven materials Cotton, Rayon, Nylon, Polyester and blends such as of polyester with cotton or rayon are used as substrate. Polyester is the most popular in staple form for nonwoven material and also in spun form for woven material. Polypropylene is emerging as the fibre of choice because of its low specific gravity, strength properties, chemically inert nature and low cost.
  9. 9. SELECTION OF FABRIC The following aspects need to be considered:  Strength and modulus  Creep behaviour  Resistance to acids and chemicals  Adhesion requirement  Resistance to microbiological attack  Environment of use  Durability  Dimensional stability  Cost
  10. 10. PARAMETERS for uniform COATING • The parameters necessary for uniformity in coating add-on are as follows:  Substrate tension  Viscosity of the coating material  Substrate uniformity and porosity  Any variation in these parameters may lead to a non uniform coating.  The coating range is limited to about 0.02 to 0.5 mm thickness.
  11. 11. METHODS OF APPLICATIONS The technique that is selected for any given product will be dependent upon a number of factors such as:  Required coat-weight.  The nature of the compound to be applied in terms of its viscosity and other physical characteristics.  The degree of penetration required into the substrate.  Cost that can be accepted in the end-product.
  12. 12. COATING METHODS  Direct Coating  Foamed And Crushed Foam Coating  Transfer Coating  Hot Melt Extrusion Coating  Calender Coating  Rotary Screen Coating  Spray Coating  Dry Powder Coating  Curtain Coating  Slot Die Or Extrusion Coating  Mayer Rod Coating  Kiss Roll Coating  Gravure Roll Coating  Reverse Roll Coaters
  13. 13. DIRECT COATING  Direct application of coating fluid is done on to the textile fabric by uniform spreading of coating by the means of a fixed knife.  The gap between the bottom of the knife and the top of the fabric controls the thickness of the coating.  The main techniques used are as follows:  Knife on air  Knife over roller  Direct coating uniformity depend upon:  Shape of knife  Angle of knife to fabric  Position of knife
  14. 14. KNIFE ON AIR  This type of knife coating is a blade over air, or floating knife process.  The knife is fixed above the substrate.  The doctor blade presses the upper surface of the substrate and forces the coating layer to penetrate into the substrate.  The amount of coating applied is controlled by fabric tension and depression of the knife .  The sharpness of the blade, alignment angle and degree of depression into the substrate influence the amount of coating applied.
  15. 15. KNIFE ON ROLLER  In this process knife blade is suspended above a roller.  The roller can be steel or rubber coated.  The knife does not touch the substrate directly and there is a gap between substrate and knife which controls the thickness of the coating.
  16. 16. FOAMED AND CRUSHED FOAM COATING  The method can apply polymer to Woven fabrics, Knitted fabrics, fabric produced from spun yarns or fabrics of an open construction which cannot generally be direct coated.  Fabrics of a general open construction which cannot generally be directly coated.  Foam, which is rather like shaving cream, sits on the top of fabric and Crushed by roller and coat the fabric.  Fabric become much softer handles and better drape than can generally produced by direct coating.  Application: Apparel goods, floor coverings, wall coverings ,black-out curtains and curtain linings .
  17. 17. FOAMED AND CRUSHED FOAM COATING
  18. 18. TRANSFER COATING The principle of transfer coating is first to spread the polymer on to release paper to form a film and then to laminate this film to the fabric. The process is divided in few steps such as:  Coat the resin (which will become the top layer) on to the transfer paper and evaporate off the solvent.  Coat on the second layer, which will become the base layer (and is actually the adhesive which joins the top layer to the fabric).  Lay the fabric on top of the coating, nip together, evaporate the solvent and crosslink the two layers together.  Peel the coated fabric off the release paper.  Application: footwear, gloves and waterproof mattress covers. Woven velvet automotive seat fabric,
  19. 19. TRANSFER COATING
  20. 20. HOT MELT EXTRUSION COATING  This method is used for thermoplastic polymers such as polyurethane, Polyolefins and PVC.  These are applied by feeding granules of the material into the nip between moving heated rollers.  This method can apply resin (in the form of films) to fabric at a faster rate than that can be achieved by transfer coating or direct coating.  This process is used to produce light weight coverings or tarpaulins.
  21. 21. CALENDER COATING  Calenders are primarily used to produce unsupported films of PVC and rubbers from compounded polymer ‘dough’.  This process can also be adapted to apply freshly produced film to fabric.  Calenders consist of a number of massive rollers.  Rollers rotate to crush the ‘dough’ and smooth it into films of uniform thickness.  The thickness of the film is determined by the gap separation of the rollers.  The more rollers, film produced is more accurate.
  22. 22. ROTARY SCREEN COATING  The rotary screen technique applies to a fabric by forcing it through a cylindrical screen, it is used mainly for textile printing.  The technique can also be used for coating polymer onto fabric with add-ons in between 5 and 500 g/m2.  The add-on is controlled by :  Resin viscosity,  Mesh of the cylindrical screen,  Speed ,and  Pressure of the squeegee bar inside Screen .
  23. 23. SPRAY COATING  A coating material can be sprayed directly onto the substrate surface.  Spray coating methods are:  Pressed air vaporization,  Airless pressure spray,  Hot vapour impelled spray ,  Electrostatic spray and  Dry powder resin spray.  The most common method is compressed air vaporization, where air and coating materials are pressed out through a nozzle.  Limitations  Lack of uniformity and precision of application  Occasional blocking of spray nozzle Fig: Spray coating machine
  24. 24. DRY POWDER COATING  There are two processes in this category, 1. scatter coating and, 2. dot coating.  These processes are used for coating fusible polymer powder i.e , polyethylene, polyamide, polyester, and Ethylene-vinyl acetate (EVA).  The products are used for fusible interlinings, carpet backcoating, especially in the automotive industry for contoured car carpets, and for lamination.  Scatter coating process, polymer powder of 20–200 µm size is spread uniformly onto a moving textile substrate. The web is then passed through a fusion oven and calendered. The coating weight is dependent on feed rate and web speed.  Powder dot coating process, a heated web having a surface temperature slightly less than the melting point of the polymer is brought in contact with an engraved roller embedded with dry powder. The web is thus coated with a tacky polymer powder in a pattern dependent on the engraving. The engraved roller is kept cool to prevent the polymer from sticking to the roll.
  25. 25. CURTAIN COATING  In curtain coating the coating fluid forms a freely falling liquid sheet and is deposited onto a moving substrate as shown in figure.  No friction is involved so the coating fluid is not forced to penetrate the substrate structure but follows its surface to form a film.  This method is capable of producing a thin film with a range of few microns and the film thickness is not affected by substrate roughness.  Preventing air entrapment and establishing stable fluid curtains are the keys to achieving quality curtain coating.
  26. 26. SLOT DIE OR EXTRUSION COATING  In this method plasticized coating compound is pressed through a sheeting die and transferred directly onto the substrate to be coated.  In the traditional slot die coating system the die lip is in contact with the substrate and backed by the roller which imparts pressure on the substrate.  This is called a closed system, where there is no contact between the coating materials and the air.
  27. 27. MAYER ROD COATING  In this method, compound is applied on the web by a single-roll applicator.  The coating is post-metered by a wire wound rod, known as the Mayer rod that removes excess coating.  An excess of the coating is deposited onto the substrate as it passes over the bath roller.  The wire-wound metering rod, sometimes known as a Meyer Rod, allows the desired quantity of the coating to remain on the substrate.  The quantity is determined by the diameter of the wire used on the rod.
  28. 28. KISS ROLL COATING  The coating is applied on the web as it touches the nip-to-nip of the applicator roll.  The pickup roll may be rubber covered, and the applicator roll made of steel.  The metering is done by nip pressure, and consequently, the amount of material coated on the web is dependent on nip pressure, speed of the operation, roll hardness, and its finish.
  29. 29. GRAVURE ROLL COATING  Engraved dots or lines of the engraved roller fill with the coating material.  The excess coating wiped off by the Doctor Blade.  The coating deposited onto the substrate as it passes between the Engraved roller and a Pressure Roller.
  30. 30. REVERSE ROLL COATERS  The coating material is measured onto the applicator roller by precision setting of the gap between the upper metering roller and the application roller below it.  The coating is 'wiped' off the application roller by the substrate as it passes around the support roller at the bottom.  4-roll versions are more common than 3 roll versions.
  31. 31. REVERSE ROLL COATERS
  32. 32. APPLICATIONS  Agriculture  Construction  Clothing  Geotextiles  Home Furnishings  Industrial  Medical  Transportation  Sport/Leisure  Packaging  Protective
  33. 33. APPLICATIONS FOR COATED FABRICS  Agriculture - Bulk containers, Fencing, Seed/crop covers, Bags, Irrigation systems, Pond liners.  Construction - Safety fencing, wind cover, Safety vests, Hose, Conveyer Belting, Drainage ditches, Architectural Structures.  Clothing - Shoe uppers and linings, Artificial leather, Rainwear ,Garment linings, Water/stain, repellants, Gloves, Hats.
  34. 34.  Geotextiles - Settling pond liners, Irrigation liners, Landfill liners & covers, Soil stabilizers, Erosion barriers.  Home Furnishings – Upholstery, Trim, Carpet backing, Drapery backing, Bedding, Artificial leather.  Industrial - Conveyor belts, Filtration, Barrier materials, Field covers.
  35. 35.  Medical – Implants, plaster, Gloves, Upholstery.  Transportation - Seating/Trim for, automotive, trucks, aircraft, buses, Belts,Tires, carpet, airbag.  Sport/Leisure - Athletic shoes, Artificial leather/bags/belts, Rainwear, football.
  36. 36.  Protective – Gloves, Aprons, Chemical Suits, Footwear Space Suits, Ballistic Protection.  Packaging - Bulk containers,Gas holding, Barrier packaging, Liquid bulk storage/hauling, Waterproof materials
  37. 37. ADVANCED COATING POLYMER  In today’s era the requirements of human beings has been totally changed , so research is going on to achieve human needs .  Some of such achievements are phase change coatings, conductive coating, anti- bacterial coating etc.  After all introduction of nanotechnology has changed the thinking. Some of those are discussed below.
  38. 38. ADVANCED COATING TECHNIQUES  Atmospheric Plasma Coating  Phase Change Material Coating
  39. 39. ATMOSPHERIC PRESSURE PLASMA COATING  Water-repellent and self-cleaning coatings can be produced with the aid of atmospheric-pressure plasma processes.  The basis of these coatings is aA microstructured surface which has been provided with a hydrophobic top layer.
  40. 40. PHASE CHANGE MATERIALS  Phase change materials (PCM) take advantage of latent heat that can be stored or released from a material over a narrow temperature range. Working principle of PCM : Figure . Change in phase change material with the change in temperature.  This interesting property of PCMs would be useful for making protective textiles in all-season. fibre, fabric and foam with PCMs could store the heat body creates then release it back to body, as it needs.  Coating, lamination, finishing, melt spinning, bi-component synthetic fibre extrusion, molding, foam techniques are some of the convenient processes for PCMs’ incorporation into the textile matrix.
  41. 41. Phase change material
  42. 42. SMART TEXTILES Smart Textiles Passsive Ex.Conductive fabric Active Ex .PCM , SMM Ultra Ex.-Musical Jackets
  43. 43. SMART TEXTILES: Conductive Coating  Polypropylene (PP) and viscose (VS) were modified by the insitu synthesis of a conducting Polypyrrole (PPy) overlayer.  To improve adhesion of the conducting layer to the textile surface a Pyrrole- functionalized silane (SP) was synthesized and bonded onto the surface before Polypyrrole formation.  To introduce hydroxyl groups into the surface PP was pretreated by grafting vinyltrimethoxysilane by means of a radiofrequency plasma discharge.  In the case of Polypropylene the effect of pretreatment with SP is much better than for viscose.  Higher concentration of SP leads to improved fastness of the conductive layer which indicates that the coating promoted by means of SP is more favoured than for viscose.
  44. 44. Flame Retardancy • Two types of Di-ammonium hydrogen phosphate (DAHP) microcapsules based flame retardent with respectively: 1. Polyether- polyurethane shell, and 2. Polyester-polyurethane shell, were evaluated as intumescent flame retardant (FR) in a commercial poly-urea coating for textiles The advantages of this new concept of encapsulated FR agent are to be compatible with a polymeric matrix in order to give a permanent FR effect and to be itself an efficient FR intumescent formulation for many materials.
  45. 45. Antibacterial Coating • A novel antibacterial coating for cotton fabrics has been developed using core-shell particles that consist of poly (n-butyl acrylate) (PBA) cores and chitosan shells. Spherical particles are prepared via a surfactant-free emulsion copolymerization. The PBA-chitosan core-shell particles have a narrow particle size distribution with average particle diameter of approximately 300 nm, and display highly positive surface charges. The cotton fabric is coated with PBA-chitosan particles by using a conventional pad-dry-cure method. PBA-chitosan particles demonstrates an excellent antibacterial activity with bacterial reductions more than 99%.
  46. 46. ULTRA-EVER DRY COATING • Ultra-Ever Dry is a superhydrophobic (water) and oleophobic (hydrocarbons) coating that will repel most water-based and some oil-based liquids. • Ultra-Ever Dry uses proprietary omniphobic technology to coat an object and create a surface chemistry and texture with patterns of geometric shapes that have “peaks” or “high points”. These high points repel water, some oils, wet concrete, and other liquids unlike any other coating. • High adhesion and abrasion resistance. • Translucent White colour coating by xylene(top)and acetone(bottom) or nano composite polystyrene, Zinc oxide polystyrene (ZnO/PS) nano-composite.
  47. 47. Ultra-Ever Dry Features • Anti-Wetting- – The superhydrophobic coating keeps objects dry. Water and many other liquids are easily repelled. • Self-Cleaning - – Repels dirty water and some oils, and remains clean and virtually bacteria-free. – Dust, dirt or other molecules accumulate on superhydrophobic coated surface, a light spray of water or a blast of air grabs the dust and removes it. • Applications:- • Ultra-Ever Dry can be used : Fabric Protect from acids/bases, Fabrics used in Boats & marinas, Water /oil proofing fabrics etc.
  48. 48. APPLICATIONS OF ADVANCE COATED TEXTILES  Comfort wear  Heat protection  Medical applications  Military applications  Computing textiles  Fashion  Space research
  49. 49. CONCLUSION  The coating and lamination gives a powerful tool for the advancement of textile technology.  It provides the opportunities to produce the special fabrics like water-proof resistant tarpaulins, coverings, large tents and architectural uses, backcoating for upholstery including autoseats, Food packaging, Medical applications, parachutes, Woven curtains for heat- sensitive fabrics, automotive fabrics, disposable hospital apparel etc.  The recent developments also enhanced the lamination and coating technique into state-of-art process of the future in textile field.

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