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.

¢ 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.

¢ 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.

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.

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

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.

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.

VIDEO OF LAMINATION

FABRIC-TO-FOAM -TO-FABRIC LAMINATION PROCESS

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.

VIDEO OF COATING

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

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.

COATING METHODS
Reverse Roll Coating Slot Die Coating
Immersion Coating

COATING METHODS
Knife Over Roll Coating Air Knife Coating
Metering Rod Coating Gravure Coating

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

POWDER COATING

POWDER COATING PROCESS

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

NECESSARY EQUIPMENT FOR COATING
Preparation
Foam mixer
Electric stirrer
Coating head
Coating Drying
Dryer
Stenter
Treatment
Crush roller
Calander

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.

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

COATING KNIVES
Figure : Profiles of knives: (a) knife type, (b) V type, (c) bull nose, and (d) shoe.

SOME APPLICATIONS OF COATED TEXTILES
Truck Tarpaulins
Bio gas-bag
multi-utility vehicles
Static Covering

Machinery Covers Pond Liners
Container Covers
Architecture and Building Covers Leisure Tents
Leisure Tents Collapsible Bags
Awnings

Cricket Pitch cover Ducting
Sports wear
Automotives interiors
Inflatable's Bus seat cover
Liquid storage tank Aqua Barrier