US20160097155A1

US20160097155A1 - Strength retention fabric

Info

Publication number: US20160097155A1
Application number: US14/877,636
Authority: US
Inventors: Hua Fan; Michael J. Lussier; Michael P. Cushman; Gerard T. Buss; Marie J. Demers
Original assignee: Saint Gobain Performance Plastics Corp
Current assignee: Saint Gobain Performance Plastics Corp
Priority date: 2014-10-07
Filing date: 2015-10-07
Publication date: 2016-04-07
Also published as: JP6620157B2; TWI631259B; TW201614122A; WO2016057689A1; EP3204569A1; CN107109782A; EP3204569A4; JP2017537824A; CN107109782B

Abstract

A fabric includes a reinforcement material and a layer disposed adjacent to the reinforcement material including a fluoropolymer and an elastomer. The fabric can be an architectural fabric included in an architectural assembly.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 62/060,732 entitled “STRENGTH RETENTION FABRIC,” by Hua Fan et al., filed Oct. 7, 2014. Each Patent application cited herein is hereby incorporated by references in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a fabric, and more particularly to a fluoropolymer-containing fabric having improved strength retention.

RELATED ART

Fabrics, such as architectural fabrics, can be subjected to high tension and repeated flexing. For example, an architectural fabric can be used in a building structure or as part of a building structure to provide protection from environmental elements such as wind, sun, and rain. Such fabrics have long been used in tents, where ropes and poles provide tension to allow the fabric to withstand loads. This form of construction, generally referred to as a tension structure, has recently become more rigorously analyzed and widespread in larger structures as the strength of architectural fabrics has improved. A tension structure can be permanent or temporary, as well as retractable or removable, for example by folding, rolling, or otherwise storing. Thus, a need exists for a fabric capable of meeting requirements such as one or more of long-term structural integrity, long-term aesthetic appeal, fire resistance, all while maintaining or improving flexibility.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and are not limited in the accompanying figures.

FIG. 1 includes an illustration of a fabric according to an embodiment of this disclosure.

FIG. 2 includes an illustration of another fabric according to an embodiment of this disclosure.

FIG. 3 includes an illustration of yet another fabric according to an embodiment of this disclosure.

FIG. 4 includes an illustration of an architectural assembly according to an embodiment of this disclosure.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the invention.

DETAILED DESCRIPTION

The following description in combination with the figures is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the teachings. This focus is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other embodiments can be used based on the teachings as disclosed in this application.
The terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one, at least one, or the singular as also including the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing acts are conventional and may be found in textbooks and other sources within the fluoropolymer-containing fabric arts.
Conventional fabrics made from polyester or polyvinyl chloride do not meet stringent fire codes and may lose aesthetic appeal over time. On the other hand, while conventional fabrics made from self-cleaning materials can be color fast and meet fire codes, they are more expensive and do not meet the demanding flexing requirements of applications such as umbrella and retractable roofing systems. Surprisingly, embodiments of the fabric described herein can exhibit or exceed the best properties of both conventional materials described above. For example, embodiments of the fabric described herein can provide a combination of high flexibility, long term structural integrity, fire resistance, and long term aesthetic appeal. Moreover, the fabric can be manufactured at a relatively low cost. The concepts are better understood in view of the embodiments described below that illustrate and do not limit the scope of the present invention.
As illustrated in FIG. 1, the fabric 101 can include a reinforcement material 102 and a layer 204 disposed adjacent to the reinforcement material 102. The layer 104 can directly contact the reinforcement material 102, as illustrated, such as without intervening layers. Alternatively, the layer 104 can be separated from the reinforcement material 102 by intervening layers.
The reinforcement material 102 can include a fibrous reinforcement material, such as a woven or nonwoven fibrous reinforcement material. In certain embodiments, the fibrous reinforcement material can include a woven fabric or an intermeshing of random fibrous strands. In particular embodiments, the fabric can include a woven glass fabric. In other embodiments, the reinforcement material can include a mesh of ceramic, plastic, or metallic material or sheets of composite materials, among others.
The reinforcement material 102 can take the form of a substrate, typically a sheet. In certain embodiments, the reinforcement material can include high melting point thermoplastics, such as thermoplastic polyimides, polyether-ether ketones, polyaryl ketones, polyphenylene sulfide, and polyetherimides; thermosetting plastics, particularly of the high temperature capable thermosetting resins, such as polyimides; coated or laminated textiles based on the above thermoplastics or similar thermally stable resins and thermally stable reinforcement materials such as fiberglass, graphite, and polyaramid; plastic coated metal foil; and metallized or metal foil laminated plastic films.
Particular examples of the reinforcement material 102 include woven and non-woven materials formed of fibers selected from aramid, fluorinated polymer, fiberglass, graphite, polyimide, polyphenylene sulfide, polyketones, polyesters, or a combination thereof. In particular, the reinforcement material includes a fiberglass reinforcement material that has been cleaned or pretreated with heat. Alternatively, the fibrous reinforcement material can include a coated fiberglass reinforcement material. In a particular example, each of the fibers, strands, yarns, or any combination thereof, of the fiberglass can be individually coated or impregnated with a polymeric coating, such as a fluoropolymer coating, for example, polytetrafluoroethylene (PTFE).
In certain embodiments, the reinforcement material 102 includes a woven fabric. The woven fabric can include, but is not limited to, a woven fabric having a plain weave, a satin weave, a twill weave, or a combination thereof.
In certain embodiments, the reinforcement material 102 can include a woven fabric having a weight of at least 100 grams per square meter (gsm), at least 150 gsm, at least 200 gsm, at least 225 gsm, or at least 250 gsm. In further embodiments, the woven fabric can have a weight of no greater than 1500 gsm, no greater than 1400 gsm, no greater than 1300 gsm, or no greater than 1200 gsm. In other embodiments, the woven fabric can have a weight in a range of any of the above minimum and maximum values, such as in a range of 100 to 1500 gsm, 150 to 1400 gsm, 200 to 1300 gsm, 225 to 1200 gsm, or 250 to 1200 gsm.
In certain embodiments, the reinforcement material 102 can include a woven fabric having a thickness of at least 0.005 mm, at least 0.01 mm, at least 0.015 mm, or at least 0.02 mm. In further embodiments, the woven fabric can have a thickness of no greater than 5 mm, 4.5 mm, 4 mm, or 3.7 mm. In other embodiments, the woven fabric can have a thickness in a range of any of the above minimum and maximum values, such as in a range of 0.005 mm to 0.50 cm, 0.01 mm to 4.5 mm, 0.015 mm to 4 mm, or 0.02 mm 0.5 to 3.7 mm.
In certain embodiments, the reinforcement material 102 can include a woven fabric having a desirable openness factor. The openness factor of a fabric material describes the ratio of open space to fabric material in a weave, measured according to ASTM D4751. For example, the reinforcement material 102 can include a woven fabric having an openness factor of 0% or more, at least 1%, at least 2%, or at least 3%. In further embodiments, the reinforcement material 102 can include a woven fabric having an openness factor of no greater than 30%, no greater than 25%, no greater than 20%, or no greater than 15%. In other embodiments, the reinforcement material can include a woven fabric having an openness factor of no greater than 85%, no greater than 80%, no greater than 75%, or no greater than 70%. In particular embodiments, the reinforcement material 102 can include a woven fabric having an openness factor in a range of any of the above maximums and minimums, such as in a range of from 0% to 30%, 1% to 25%, 2% to 20%, or 3% to 15%, or such as in a range of 15 to 85%, 20 to 80%, 25 to 75%, or 30 to 70%.
In certain embodiments, the reinforcement material 102 can include a woven fabric having a desirable window size. The window size of a woven fabric is a measure of the area of the open space between the warp and weft of the weave. For example, the reinforcement material 102 can have a window size of at least 0.04 mm², at least 0.5 mm², at least 1 mm², at least 2 mm², or at least 4 mm². In further embodiments, the reinforcement material 102 can have a window size of no greater than 1000 mm², no greater than 900 mm², or no greater than 625 mm². In yet further embodiments, the reinforcement material 102 can have a window size in a range of any of the above minimum and maximum values, such as in a range of 0.04 to 1000 mm², 1 to 900 mm², or 4 to 625 mm². The fabric window can have a variety of shapes depending on the direction of the warp and weft. For example, the reinforcement material 102 can have a window shape that is rectangular, either square or non-square.
As stated previously, the layer 104 is disposed adjacent to the reinforcement material 102. The layer 104 can include a polymer such as a fluoropolymer, an elastomer, or a combination thereof.
In certain embodiments, the layer 104 can include a fluoropolymer. The fluoropolymer can include a homopolymer of fluorine-substituted monomers or a copolymer including at least one fluorine-substituted monomer. The fluorine-substituted monomer can include tetrafluoroethylene (TFE), vinylidene fluoride (VF2), hexafluoropropylene, chlorotrifluoroethylene (CTFE), perfluoroethylvinyl ether (PEVE), perfluoromethylvinyl ether (PMVE), and perfluoropropylvinyl ether (PPVE). In certain embodiments, the fluoropolymer can include a polytetrafluoroethylene (PTFE), a perfluoroalkylvinyl ether (PFA), a fluorinated ethylene-propylene copolymer (FEP), an ethylene tetrafluoroethylene copolymer (ETFE), a polyvinylidene fluoride (PVDF), a polychlorotrifluoroethylene (PCTFE), TFE copolymers with VF2 or hexafluoropropylene, or a combination thereof. In particular embodiments, the fluoropolymer can include a perfluoropolymer. The perfluoropolymer can be derived from a dispersion, such as an aqueous dispersion. Examples of the perfluoropolymer include a PTFE, a polyhexafluoropropylene (HFP), a fluorinated ethylene propylene (FEP), a perfluoroalkylvinyl (PFA), or any combination thereof. In a more particular embodiment, the perfluoropolymer can include a PTFE.
In certain embodiments, the layer 104 can include an elastomer. The elastomer can include a silicone elastomer, a fluoroelastomer, a perfluoroelastomer, or any combination thereof.
In certain embodiments, the silicone elastomer can include a polyalkylsiloxane, a phenylsilicone, a fluorosilicone, or any combination thereof. In an example, a polyalkysiloxane includes a polydimethylsiloxane, a polydipropylsiloxane, a polymethylpropylsiloxane, or any combination thereof. In particular, the silicone elastomer can include silicone elastomer derived from an aqueous dispersion of precured silicone elastomer. In an example, the silicone elastomer can include a silicone elastomer derived from an aqueous dispersion and can include precured silicone with terminal end groups that undergo condensation reaction during drying. In another example, the silicone polymer can include a silicone elastomer derived from an aqueous dispersion of precured silicone with terminal groups or additives, such as cross-linkers, that undergo a condensation reaction when dried. In yet another example, the silicone elastomer can include silicone elastomers selected from a silicone elastomer dispersion available from Wacker-Chemie GmbH, Munchen, Germany, such as the Wacker CT27E silicone rubber dispersion, available from Dow Corning, such as Additive 84, or available from Shin Etsu, such as Polon MF 56.
The layer 104 can include a polymer blend including the polymer and the elastomer discussed above. In certain embodiments, the polymer blend can include the elastomer in an amount of at least 2 wt %, at least 5 wt %, at least 10 wt %, or at least 15 wt %. In further embodiments, that polymer blend can include the elastomer in an amount of no greater than 50%, no greater than 40%, no greater than 30 wt %, no greater than 25 wt %, or no greater than 20 wt %. In other embodiments, the polymer blend can include the elastomer in an amount in a range of any of the above minimum and maximum values, such as in a range of 5 wt % to 30 wt %, 10 wt % to 30 wt %, 15 wt % to 40 wt %, 25 wt % to 50 wt %, or even 15 wt % to 20 wt %. The percentages discussed in this paragraph are based on the total weight of the polymer blend.
In addition, the polymer blend can include the fluoropolymer in an amount of at least 50%, at least 60%, at least 70%, at least 75%, or at least 80%. The polymer blend can include the fluoropolymer in an amount in a range of no greater than 98%, no greater than 90%, no greater than 85%, no greater than 80%, no greater than 75% or no greater than 70%. For example, the polymer blend can include the fluoropolymer in an amount in a range of any of the above minimum and maximum values, such as in a range of 70 wt % to 98 wt %, 75 wt % to 90 wt %, or even 80 wt % to 85 wt %. In particular embodiments, the polymer blend can include the fluoropolymer in an amount in a range of 50 wt % to 80 wt %. The percentages discussed in this paragraph are based on the total weight of the polymer blend.
In particular embodiments, the layer 104 can include a filler, a stabilizer including weathering, heat, moisture or light stabilizer, a pigment, a bonding aid, or any combination thereof. Exemplary fillers include talc, silica, and calcium carbonate. Exemplary stabilizers and pigments include TiO₂, Fe₂O₃, carbon black, and calcined mixed metal oxides. Such fillers can be included in the polymer blend in an amount not greater than 60 wt %, such as not greater than 40 wt %, not greater than 15 wt %, or even not greater than 5 wt %.
In more particular embodiments, the layer 104 can include a glycerin. The glycerin may be included in the polymer blend to improve the durability of the layer 104. The glycerin can be present in the polymer blend in an amount described above for the fillers. More particularly, the glycerin can be present in an amount of 0.25 wt % to 25 wt %, 0.25 wt % to 15 wt %, or 0.25 wt % to 5 wt %, based on the total weight of the polymer blend.
In certain embodiments, the layer 104 can have a thickness of at least 0.001 cm, at least 0.0025 cm, at least 0.0075 cm, at least 0.01 cm. In further embodiments, the layer 104 can have a thickness of no greater than 0.2 cm, no greater than 0.15 cm, no greater than 0.1 cm, no greater than 0.8 cm, or no greater than 0.65 cm. In other embodiments, the layer 104 can have a thickness in a range of any of the above minimum and maximum values, such as in a range of 0.001 cm to 0.2 cm, 0.0025 cm to 0.15 cm, 0.0075 cm to 0.1 cm, or even 0.01 cm to 0.8 cm.
In certain embodiments, the layer 104 can have a weight of at least 60 gsm, at least 75 gsm, at least 125 gsm, at least 205 gsm. In further embodiments, the layer 104 can have a weight of no greater than 2500 gsm, no greater than 2200 gsm, no greater than 1900 gsm, no greater than 1600 gsm, or no greater than 1300 gsm. In other embodiments, the layer 104 can have a weight in a range of any of the above minimum or maximum values, such as in a range of 60 gsm to 2500 gsm, 75 gsm to 1900 gsm, or 125 gsm to 1300 gsm.
As illustrated in FIG. 2, the fabric 201 can include the reinforcement material 102, the layer 104, and a layer 103 disposed between the reinforcement material 102 and the layer 104. The layer 103 can directly contact the reinforcement material 102, the layer 104, or both, without intervening layers, as illustrated. Alternatively, the layer 103 can be separated from the reinforcement material 102, the layer 104, or both, by one or more intervening layers.
The layer 103 can include a fluoropolymer, such as one or more of the fluoropolymers discussed above with respect to layer 104.
In certain embodiments, the layer 103 can have a weight of at least 15 gsm, at least 25 gsm, at least 35 gsm, or at least 45 gsm. In further embodiments, the layer 103 can have a weight of no greater than 300 gsm, no greater than 275 gsm, no greater than 250 gsm, or no greater than 225 gsm. In other embodiments, the layer 103 can have a weight in a range of any of the above minimum and maximum values, such as in a range of 15 gsm to 300 gsm, 25 gsm to 275 gsm, 35 gsm to 250 gsm, or 45 gsm to 225 gsm.
As illustrated in FIG. 3, the fabric 301 can include the reinforcement material 102, the layer 103, the layer 104, and a layer 105 disposed adjacent to the layer 104 opposite the layer 103. The layer 105 can directly contact the layer 104 without intervening layers, as illustrated. Alternatively, the layer 105 can be separated from the layer 104 by one or more intervening layers. Although not pictured in FIGS. 1 and 2, any of the embodiments of the fabric discussed above can include the layer 105 disposed adjacent to the layer 104. The layer 105 can directly contact the layer 104 without intervening layers.
The layer 105 can include a fluoropolymer, such as one or more of the fluoropolymers discussed above with respect to layer 103. The layer 105 can have a weight in a range discussed above with respect to the layer 103. In addition, the layer 105 can have a thickness in a range discussed above with respect to layer 103.
In any of the embodiments of the fabric discussed above, the reinforcement material 102 can have a first major surface and an opposing second major surface, and the one or more layers disposed adjacent to the reinforcement material 102 can be disposed adjacent to the first and second major surfaces of the reinforcement material 102. Each of the one or more layers disposed adjacent to the reinforcement material can include a laminate layer or a coating layer.
Furthermore, one or more additional layers can be provided which can impart surface functionality to the fabric. While each of the above embodiments illustrated in FIGS. 1-3 are symmetric about the reinforcement material 102, the layers disposed adjacent to the reinforcement material 102 can alternatively be applied in an asymmetric form, wherein one or more of the layers can be absent from one of the sides or each of the layers can be applied in different thicknesses on different sides. In certain embodiments, the layers can be applied as fused layer or semifused layers. Semifused layers can be adhered to semifused layers of other films, substrates, fabrics, or sheets, and fused to bond the fabric to the other material. In certain embodiments, the fabric is a laminate.
In particular embodiments, the fabric can have an outer surface coating that includes PTFE, FEP, PFA, or any combination thereof. In further embodiments, the fabric can have an outer surface coating that includes TiO₂.
In certain embodiments, the total weight of the fabric can be at least 135 gsm, at least 175 gsm, at least 200 gsm, at least 300 gsm. In further embodiments, the total weight of the fabric can be no greater than 2500 gsm, no greater than 2000 gsm, no greater than 1500 gsm, no greater than 1300 gsm, or no greater than 1100 gsm. In other embodiments, the total weight of the fabric can be in a range of any of the above minimum and maximum values, such as in a range of 135 gsm to 2000 gsm, 200 gsm to 1300 gsm, or 300 gsm to 1100 gsm, or 500 gsm to 2500 gsm.
In certain embodiments, the total thickness of the fabric can be at least 0.01 cm, at least 0.05 cm, or at least 0.1 cm. In further embodiments, the total thickness of the fabric can be no greater than 0.3 cm, no greater than 0.25 cm, or no greater than 0.2 cm. In other embodiments, the total thickness of the fabric can be in a range of any of the above minimum and maximum values, such as in a range of 0.01 cm to 0.3 cm, 0.05 cm to 0.25 cm, or 0.1 cm to 0.2 cm.
The fabric can exhibit retention of break strength when stressed through creasing or folding. In particular, the fabric can exhibit a Strength Retention after Flex Fold, defined as the warp or fill (weft) break strength according to ASTM 751 retained by a sample after undergoing a Flex Fold test, which is expressed as a percentage of the original warp or fill (weft) break strength prior to flexing test by which a 10-lbs roller is used to roll over folded fabric 10 times. In certain embodiments, the fabric can exhibit a Strength Retention after Flex Fold of at least 45%, at least 55%, at least 65%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95%. In certain embodiments, the fabric may exhibit a Strength Retention after Flex Fold of no greater than 99.5%, no greater than 99%, or no greater than 98%. Further, in particular embodiments, the Strength Retention after Flex Fold of the fabric can be in a range of any of the above minimum and maximum values, such as in a range of 45% to 99% or 75% to 98%.
The fabric can exhibit long-term structural integrity. In certain embodiments, the fabric can exhibit a desirable Strength Retention after Flex Fold after weathering. Strength Retention after Flex Fold can be measured after weathering according to ASTM D4329, and is expressed as a percentage of the Strength Retention after Flex Fold before weathering. For example, in certain embodiments, the fabric can have a Strength Retention after Flex Fold after weathering of at least 40%, at least 50%, at least 60%, at least 70%, at east 80%, at least 90%, or at least 95%. In further embodiments, the fabric can have a Strength Retention after Flex Fold after weathering of no greater than 99%, no greater than 97%, or no greater than 95%. In yet further embodiments, the fabric can have a Strength Retention after Flex Fold after weathering in a range of any of the above minimum and maximum values, such as in a range of 40% to 99%, 70% to 97%, or 80% to 95%.
Another measure of long-term structural integrity can include Creep Resistance, which refers to the resistance to distortion when under a load over an extended period and is expressed time to failure under the load. Creep Resistance is measured according to ASTM D6992, including mounting a length of 50 mm wide fabric including a seam on a load tester with a load equivalent to 30%, 40%, 50%, 60%, 70% or 80% of the fabric break strength (or within that range of 30-80%). In certain embodiments, the fabric can have a Creep Resistance of at least at least 50 hours, 100 hours, at least 150 hours, or at least 200 hours. In further embodiments, the fabric may have a Creep Resistance of no less than 2000 hours, no less than 1000 hours, no less than 500 hours, or no less than 400 hours.
The fabric can have a warp direction and a fill direction based on the reinforcement material used. The tensile strength of the fabric can be measured in the warp direction and the fill direction according to ASTM 751. The tensile strength in the warp direction, fill direction, or both can be at least 150 pounds per linear inch (pli), at least 200 pli, at least 250 pli, at least 500 pli, at least 750, or at least 1000 pli. In addition, the fabric can have a tensile strength in the warp or fill direction of no greater than 1500 pli, no greater than 1700 pli, no greater than 2000 pli, or no greater than 2500 pli. For example, the fabric can have a tensile strength in a range of any of the above minimum and maximum values, such as in a range of 150 pli to 2500 pli, 200 pli to 2000 pli, or 500 pli to 1000 pli, or even 300 pli to 1500 pli.
The fabric can exhibit a desired Break Strength Retention after Crease Fold, as measured according to ASTM 751. In certain embodiments, the fabric can have a Break Strength Retention after Crease Fold of at least 45%, at least 55%, at least 60%, at least 70%, at least 80%, or at least 90%. In further embodiments, the fabric can have a Break Strength Retention after Crease Fold of 100%, or no greater than 97%, or no greater than 95%. In yet further embodiments, the Break Strength Retention after Crease Fold of the fabric can be in a range of any of the above minimum and maximum values, such as in a range of from 45% to 100%, 55% to 97%, or 60% to 95%. In a particular embodiment, the fabric can have a Break Strength Retention after Crease Fold in a range of 75% to 100%.
The fabric can exhibit a resistance to combustibility and flame spread. Embodiments of the fabric can be non-combustible. As used herein, the term non-combustible refers to fabrics that have a Class A fire resistance rating. The Class A fire resistance rating is determined by the test procedures set forth in ASTM E 84.
Further, the fabric exhibits desirable trapezoidal tear strength in both the machine direction and the cross direction. The trapezoidal tear strength in both the machine and cross directions is more closely matched. In certain embodiments, the trapezoidal tear strength in the machine direction, cross direction, or both can be at least 10 lbs, at least 25 lbs, at least 60 pounds, at least 80 lbs, or even at least 100 lbs. In further embodiments, the trapezoidal tear strength in the machine direction, cross direction, or both can be no greater than 450 lbs, no greater than 400 lbs, no greater than 350 lbs, or no greater than 300 lbs. In yet further embodiments, the trapezoidal tear strength in the machine direction, cross direction, or both can be in a range of any of the above minimum and maximum values, such as in a range of 10 to 450 lbs, 60 to 400 lbs, or 100 to 350 lbs. Trapezoidal tear strength is measured in accordance with ASTM D 5587. The Tear Directional Ratio, defined as the ratio of the trapezoidal tear strength in the cross direction over the trapezoidal tear strength in the machine direction is at least 0.77. For example, the Tear Directional Ratio can be at least 0.81, such as at least 0.85.
While the value of trapezoidal tear strength can be influenced by the selection of a reinforcement material, the fabric exhibits an unexpected and desirable change in trapezoidal tear strength relative to fabrics of similar weight formed from similar reinforcement material and PTFE alone. For example, the trapezoidal tear strength can be at least 25% more than a PTFE coated fabric, such as at least 50% more, at least 70% more, or even at least 90% more. The increase in trapezoidal tear strength relative to the reinforcement material coated with PTFE alone is defined as the Tear Index.
In addition, the surface of the fabric can have a coefficient to friction of no greater than 0.4, no greater than 0.3, or no greater than 0.2. In certain embodiments, the surface of the fabric can have a coefficient of friction of at least 0.01, at least 0.03, or at least 0.05. For example, the coefficient for the surface of the fabric can be in a range of any of the above minimum and maximum values, such as in a range of 0.01 to 0.4, 0.03 to 0.3, or even 0.05 to 0.2.
Embodiments of the fabric can exhibit desired properties related to light energy. Visible Light Reflectance (VLR) represents the percent of total visible light (approximately 380 to 780 nm) that is reflected by the fabric. The lower the number, the less visible light reflected. Visible Light Transmittance (VLT) represents that percent of total visible light that is transmitted through the fabric. The lower the number, the less visible light transmitted. Infrared Light Reflectance (ILR) represents the percent of total infrared light (approximately 700 nm to 1 mm) that is reflected by the fabric. The lower the number, the less infrared light reflected. Infrared Light Transmittance (ILT) represents that percent of total infrared light (from approximately 380 to 780 nanometers) that is transmitted through the fabric. The lower the number, the less visible light transmitted.
The light energy properties described above can be measured on a spectrophotometer, characterized by the VLT at 550 nm, and calculated using Window6 and Optics6 software packages freely available from Lawrence Berkeley National Lab. The transmission from 300 nm to 2500 nm, the reflection on one side of the fabric from 300 nm to 2500 nm and the reflection on the other side of the fabric from 300 nm to 2500 nm are measured using a Perkin Elmer Lambda 950 spectrophotomer. The data is then input into the Optics6 software and an Optics file is created. The Optics file is then input into the Window6 software and the parameters are calculated using the environmental conditions NFRC 100-2001, a single layer, and a tilt of 90 degrees.
In certain embodiments, the fabric can limit the transmission of visible light such that it has a VLT of no greater than 30%, no greater than 25%, or no greater than 20%. Further, in certain embodiments, the fabric may allow the transmission of some visible light such that it has a VLT of at least 3%, or at least 5%, or at least 10%, or at least 20% or at least 30% or at least 40% or at least 50%. In particular embodiments, the fabric can have a VLT in a range of any of the above maximum and minimum values, such as 3 to 50%, 5 to 40%, or 10 to 30%. In more particular embodiments, the fabric can have a VLT in a range of 20 to 30%, 25 to 40%, or 30 to 50%.
In certain embodiments, the fabric can reflect visible light such that it has a VLR of at least 60%, at least 65%, or at least 70%. Further, in certain embodiments, the fabric can have a VLR of no greater than 95%, no greater than 90%, no greater than 85%, or no greater than 80%. In particular embodiments, the fabric can have a VLR in a range of any of the above maximum and minimum values, such as 60 to 90%, 65 to 85%, or 70 to 80%.
In certain embodiments, the fabric can limit the transmission of infrared light such that it has an ILT of no greater than 30%, no greater than 25%, or no greater than 20%. Further, in certain embodiments, the fabric may allow the transmission of some infrared light such that it has an ILT of 0%, or at least 1%, or at least 3%, or at least 5%. In particular embodiments, the fabric can have an ILT in a range of any of the above maximum and minimum values, such as 0 to 30%, 1 to 25%, or 3 to 25%.
In certain embodiments, the fabric can reflect infrared light such that it has an ILR of at least 40%, at least 45%, or at least 50%. Further, in certain embodiments, the fabric can have an ILR of no greater than 95%, no greater than 93%, or no greater than 90%. In particular embodiments, the fabric can have an ILR in a range of any of the above maximum and minimum values, such as 40 to 95%, 45 to 93%, or 50 to 90%.
The fabric can provide a cohesive structure that has a desirable Coating Adhesion, as determined by ASTM D4851-88 modified by heating and pressing for as much as 2 minutes to form test samples and performing tests on samples 1″ in width. In certain embodiments, the coating adhesion can be at least 5.5 lb/in, at least 8.5 lb/in, at least 9.5 lb/in, or at least 10 lb/in. In further embodiments, the coating adhesion can be no greater than 50 lb/in, no greater than 40 lb/in, no greater than 35 lb/in, or no greater than 30 lb/in. In yet further embodiments, the coating adhesion can be in a range of any of the above minimum and maximum values, such as in a range of 5.5 to 50 lb/in, 8.5 to 40 lb/in, or 9.5 to 35 lb/in.
Advantageously, embodiments of the fabric can exhibit improved break strength in the warp or machine direction relative to a comparable fabric formed of a similar reinforcement material and coated with an equivalent thickness of perfluoropolymer, such as PTFE. The Warp Strength Index, defined as the percent increase in warp break strength relative to the comparable fabric, is at least 8%, such as at least 10%, at least 12%, or even at least 15%.
In an additional example, the fabric also exhibits a desirable combination of cohesion and break strength. In contrast to other materials that exhibit a trade-off between cohesiveness (measured as coating adhesion) and break strength, the fabric can exhibit both improved break strength and coating adhesion. As such, embodiments of the fabric can exhibit a Cohesive Ratio, defined as the warp break strength divided by the coating adhesion, of not greater than 300, not greater than 100, not greater than 65, not greater than 50, or even not greater than 35.
In certain embodiments, the layer 104 of the fabric can be formed from a polymer blend dispersion. The polymer blend dispersion can be prepared including a blend of fluoropolymer, such as perfluoropolymer, particles and precured elastomer, such as silicone, particles. For example, the polymer blend dispersion can be an aqueous dispersion. In a particular example, a dispersion of perfluoropolymer, such as PTFE, is mixed with a dispersion of elastomer, such as a precured silicone polymer. The silicone polymer can form between 2 wt % and 30 wt % based on the solids of the dispersion. For example, the silicone polymer can form 5 wt % to 30 wt % of the solids of the dispersions, such as 10 wt % to 30 wt %, 10 wt % to 25 wt %, or even 15 wt % to 20 wt % of the solids of the dispersion. The perfluoropolymer can form the remainder of the solids of the dispersion. For example, the perfluoropolymer can form 70 wt % to 98 wt % of the solid content of the dispersion, such as 75 wt % to 90 wt % or even 80 wt % to 85 wt % of the solid content of the dispersion. Alternatively, a solid filler can be included in the dispersion. For example, the solid filler can form not greater than 60 wt % of the solids in the dispersion, such as not greater than 40 wt %, not greater than 15 wt %, or not greater than 5 wt %.
A carrier can be coated with the polymer blend dispersion through a process, such as dip coating, knife coating, or casting. Excess material can be wiped and the coating dried and sintered or fused. In certain embodiments, the carrier can be the reinforcement material 102, with or without the layer 103, which can be coated with the polymer blend dispersion. The reinforcement material 102 can be drawn through an aqueous dispersion.
To form layer 103 on the reinforcement material 102 prior to coating with the polymer blend dispersion, the aqueous dispersion can be a dispersion of perfluoropolymer absent the silicone. For example, the reinforcement material 102 can be drawn through an aqueous dispersion of PTFE. The reinforcement material 102 coated with the perfluoropolymer dispersion is passed through a wiping arrangement to remove excess perfluoropolymer dispersion and is passed through an oven. The oven can be, for example, a three zone tower oven. In particular, the three zone tower oven can fuse the coated material. For example, the first zone can dry the dispersion at a temperature in a range of 200° F. to 300° F. The second zone can heat the deposited perfluoropolymer to remove surfactants and other additives. In particular, the second zone can heat the deposited perfluoropolymer at a temperature in a range of 500° F. to 600° F. The third zone can melt, sinter, or fuse the perfluoropolymer. For example, the third zone can fuse the perfluoropolymer at a temperature in the range of 680° F. to 750° F.
In another example, the three zone tower can be set to semifuse the coated material. For example, the first zone can dry the dispersion at a temperature in a range of 200° F. to 300° F. The second zone can heat the deposited perfluoropolymer to remove surfactants and other additives. In particular, the second zone can heat the deposited perfluoropolymer at a temperature in a range of 500° F. to 600° F. The third zone can be set to a temperature lower than the melting point of the perfluoropolymer. For example, the third zone can be set to a temperature in the range of 550° F. to 600° F.
To deposit the polymer blend dispersion that includes fluoropolymer and elastomer, the process can be repeated. For example, the reinforcement material 102 can be drawn through a bath of the polymer blend dispersion. Excess dispersion can be removed using a wiping arrangement, such as a metering bar, a Bird bar, a wire-wound metering bar, a K bar, or other similar equipment or combinations thereof. The reinforcement material 102 coated with the polymer blend dispersion is heated. For example, the polymer blend dispersion can be heated to dry the dispersion, remove surfactants or other additives, and subsequently to melt the perfluoropolymer and cure the precured elastomer. In particular, the coated reinforcement material can pass through a three zone tower oven, including a first zone that dries the dispersion at a temperature in a range of 200° F. to 300° F. A second zone of the oven can remove surfactants and other additives from the deposited blend coating at a temperature in a range of 500° F. to 600° F. The third zone can be set to fuse the blend, for example, melt the fluoropolymer, or can be set to form a semifused layer. For example, the third zone can be set to a temperature in a range of 680° F. to 700° F. to fuse the material. In another example, the third zone can be set to a temperature in a range of 550° F. to 600° F. to semifuse the layer 104. Alternatively, the coating can be heating in an oven including one zone, two zones, or more. In a particular example, the coating can be dried and sintered in two stages.
In certain embodiments, the dispersion bath/pan can be covered to limit water evaporation from the dispersion thereby 1) reducing premature curing/skinning of the dispersion, 2) enabling longer processing runs, and 3) improving the coating quality.
In addition, particularly when the outer layer is a semifuse layer, the fabric can be pressed or calendered. In an example, the drums of the calender can be set to a temperature in a range of 275° F. to 400° F. and to a pressure between the drums in a range of 500 psi to 4000 psi. Subsequently, the calendered fabric including the semifused layer or layers can be subjected to fusing conditions, such as a temperature within a range of 680° F. to 750° F.
Further, the fabric can pass through a cooling plenum from which it can be directed to a subsequent dip pan to begin formation of a further layer of film, to a stripping apparatus, or to a roll for storage. In other embodiments, sheets of composite material are formed and subsequently layered over the reinforcement material. These sheets can be further processed to bond to the reinforcement material. For example, sheets of material can be laminated to the reinforcement material.
In a particular example, a reinforcement material can be passed through an emulsion of perfluoropolymer, such as PTFE, and fused. For example, the reinforcement material can be passed through the emulsion once. In another example, the reinforcement material can be passed through a second time, or optionally a third time, and fused. Each pass results in additional thickness referred to herein as a pass. Following the application of the perfluoropolymer layer, the fabric can be passed through an emulsion including a blend of perfluoropolymer and silicone. The fabric can be passed through the emulsion of the blend at least once. In particular, the fabric can be passed through the emulsion of the blend twice or can be passed through the emulsion three or more times. Following coating of the blend over the fabric, the blend layer can be fused. Alternatively, the blend layer can be semifused, as described above, and can be calendered, pressed, or further treated, and subsequently fused.
Optionally additional layers can be applied. For example, an additional layer or layers can be coated on the fabric by passing the fabric through an additional emulsion. In an example, the additional emulsion can be a perfluoropolymer emulsion. In another example, the additional emulsion can be a silicone emulsion. Passes underlying the additional layers can be fused or semifused when the additional layer is coated. The additional layer or layers can be fused, or can be semifused. The additional layer or layers can be calendered or otherwise treated.
In a particular example, a semifused layer, either the blend layer or an additional layer can be pressed into contact with another semifused layer of another fabric or film. In an example, the construct can be fused to bond the fabrics or fabric and film together. For example, an additional semifused PTFE outer layer can be pressed or calendered into contact with a semifused PTFE layer of a second fabric or film and subsequently fused. In another example, a semifused blend layer can be placed in contact with a semifused blend layer or semifused perfluoropolymer layer of a second fabric or film, and subsequently fused.
In particular embodiments, the fabric includes a reinforcement material coated with a single pass of perfluoropolymer, such as PTFE, that is coated with at least one pass and likely two passes of a blend. Each of the layers can be fused. Alternatively, the passes of the blend can be semifused, calendered, and subsequently, fused.
In other embodiments, the fabric includes the reinforcement material, a pass of fused perfluoropolymer, two passes of fused blend, and an outer layer. The outer layer can include at least one pass of a polymer, such as a perfluoropolymer or a silicone polymer.
The fabric or method of any one of the preceding claims, wherein at least one layer of the fabric includes an outer surface and the outer surface is treated to provide an added functionality. The added functionality includes enhanced self-cleaning properties, enhanced weldability, enhanced bondability, enhanced solar properties, enhanced coloration, or any combination thereof. For example, the fabric can include a photocatalytic topcoat, such as a photocatalytic topcoat including TiO₂. In another example, the surface treatment can include a fluoropolymer topcoat , such as a topcoat including FEP, PFA, or both. In particular embodiments, the fluoropolymer topcoat can include a silica dioxide. In a further example, the surface treatment can include a layer comprising infrared reflective particles.
In yet another example, the surface treatment can include a mechanical etching, a chemical etching, a corona treatment, a plasma treatment, or any combination thereof. In a particular example, the surface treatment can include a C-treatment
In a further example, the surface treatment can include a layer comprising a pigment. The pigment can include an organic pigment, an inorganic pigment, or both. The organic pigment can include a carbon and the inorganic pigment can include a metal oxide.
In an example, the outer layer is fused. In another example, the outer layer is semifused. In a further embodiment, an outer layer that is semifused or a blend layer that is semifused can be placed in contact with a film, such as a film including perfluoropolymer or silicone. In an example, the film is a defect free perfluoropolymer film, such as a PTFE film. In an example, a film has a more uniform consistency than a coating and lower variability in properties. An example of a film includes a skived film, a cast film, or an extruded film.
In certain embodiments, embodiments of the fabric can include an architectural fabric, as discussed in more detail below. The can be disposed adjacent to a support structure, such as in a stretched state, namely the architectural fabric can be stretched over a support structure to form an architectural assembly. The support structure can include a rigid frame. The support structure can include a coupling element and the architectural fabric can be coupled to the support structure via the coupling element.
In certain embodiments, the fabric can comprise an architectural fabric adapted to protect a defined area from environmental elements.
In certain embodiments, the fabric can comprise an architectural fabric adapted for a tension fabric structure. The tension fabric structure can comprise a reversibly collapsible tension fabric structure.
In certain embodiments, the fabric can comprise an architectural fabric adapted to fold from a central joint, such as an architectural umbrella.
In certain embodiments, the fabric can comprise an architectural fabric adapted for a retractable roofing system.
For example, FIG. 4 is an illustration of an architectural assembly 400 including a fabric as described herein. As illustrated in FIG. 4, the architectural assembly 400 can include the fabric 401 coupled to a support structure 420. The support structure 420 can include a rigid frame 423. The support structure 420 can include a coupling element 425 that can be used to couple the fabric 401 to the support structure 420.
In particular embodiments, the fabric 401 can be disposed adjacent to the support structure 420 in a stretched state. In a further embodiment, the fabric 401 can have a major surface 410 and an opposing major surface 415. The major surface 410 of the fabric can define a protected area where the architectural assembly provides protection from environmental elements, such as wind, rain, snow, hail, and the like.
The architectural assembly 400 can include a tension fabric building, such as an architectural umbrella, a retractable roofing system, and the like.
In other embodiments, the fabric described herein can be used in other applications for which one or more of its properties, such as the ability to withstand repeated folding, flexing, or both while in use, might be advantageous. Some examples include industrial release belts or sheets, expansion joints, transportable radomes, and the like.
Many different aspects and embodiments are possible. Some of those aspects and embodiments are described below. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the items as listed below.
Item 1. A fabric comprising:

- a reinforcement material; and
- a layer disposed adjacent to the reinforcement material,
- wherein the fabric has a Strength Retention after Flex Fold of at least 80%.

Item 2. A fabric comprising:

- a reinforcement material; and
- a layer disposed adjacent to the reinforcement material,
- wherein the fabric has a Class A fire rating and a Strength Retention after Flex Fold of at least 45%.

Item 3. A method of forming a fabric, the method comprising:

- providing a reinforcement material; and
- coating the reinforcement material with a layer disposed adjacent to the reinforcing material,
- wherein the fabric has a Strength Retention after Flex Fold of at least 80% or a Class A fire rating and a Strength Retention after Flex Fold of at least 45%.

Item 4. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material comprises a fluoropolymer, an elastomer, or a combination thereof.
Item 5. The fabric or method of item 4, wherein the elastomer is a silicone elastomer, a fluoroelastomer, perfluoroelastomer, or any combination thereof.
Item 6. The fabric or method of any one of the preceding items, wherein the reinforcement material has a first major surface and an opposing second major surface, and the layer disposed adjacent to the reinforcement material is disposed adjacent to the first and second major surfaces of the reinforcement material.
Item 7. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material includes a plurality of layers, at least one layer of the plurality of layers comprises a polymer blend comprising a fluoropolymer and an elastomer.
Item 8. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material includes a plurality of layers and the plurality of layers includes:

- a first layer disposed adjacent to the reinforcement material, the first layer comprising a fluoropolymer; and
- a second layer disposed adjacent to the first layer, the second layer comprising a polymer blend comprising a fluoropolymer and an elastomer.

Item 9. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material includes a plurality of layers and the plurality of layers includes:

- a first layer disposed adjacent to the reinforcement material, the first layer comprising a fluoropolymer;
- a second layer disposed adjacent to the first layer, the second layer comprising a polymer blend comprising a fluoropolymer and an elastomer; and
- a third layer disposed adjacent to the second layer, the third layer comprising a fluoropolymer.

Item 10. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material includes a layer comprising a polymer blend comprising a fluoropolymer and an elastomer, and the elastomer is present in the layer in an amount of at least 2 wt %, at least 5 wt %, at least 10 wt %, or at least 15 wt %.
Item 11. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material includes a layer comprising a polymer blend comprising a fluoropolymer and an elastomer, and the elastomer is present in the layer in an amount of no greater than 50%, no greater than 40%, no greater than 30 wt %, no greater than 25 wt %, or no greater than 20 wt %.
Item 12. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material includes a layer comprising a polymer blend comprising a fluoropolymer and an elastomer, and the elastomer is present in the layer in a range of 5 wt % to 30 wt %, 10 wt % to 30 wt %, 15 wt % to 40 wt %, 25 wt % to 50 wt %, or even 15 wt % to 20 wt %.
Item 13. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material includes a layer comprising a polymer blend comprising a fluoropolymer and an elastomer, and the elastomer is a silicone elastomer derived from a precured silicone polymer dispersion.
Item 14. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material includes a layer comprising a polymer blend comprising a fluoropolymer and an elastomer, and the elastomer is a condensation polymerized silicone.
Item 15. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material includes a perfluoropolymer.
Item 16. The fabric or method of any one of the preceding items, wherein the fluoropolymer in at least one layer of the fabric includes a polytetrafluoroethylene (PTFE), a hexafluoropropylene (HFP), a fluorinated ethylene propylene (FEP), a perfluoroalkyl vinyl ether (PFA), or any combination thereof.
Item 17. The fabric or method of any one of the preceding items, wherein at least one layer of the fabric includes an outer surface and the outer surface is treated to provide an added functionality.
Item 18. The fabric or method of item 17, wherein the added functionality includes enhanced self-cleaning properties, enhanced weldability, enhanced bondability, enhanced solar properties, enhanced coloration, or any combination thereof.
Item 19. The fabric or method of any one of the preceding items, wherein the fabric includes a photocatalytic topcoat, such as a photocatalytic topcoat including TiO₂.
Item 20. The fabric or method of any one of the preceding items, wherein the fabric includes a fluoropolymer topcoat, such as a topcoat including FEP, PFA, or both.
Item 21. The fabric or method of item 20, wherein the fluoropolymer topcoat includes a silica dioxide.
Item 22. The fabric or method of item 17, wherein the surface treatment includes a mechanical etching, a chemical etching, a corona treatment, a plasma treatment, or any combination thereof.
Item 23. The fabric or method of item 22, wherein the surface treatment includes a C-treatment
Item 24. The fabric or method of any one of the preceding items, wherein the fabric comprises infrared reflective particles.
Item 25. The fabric or method of any one of the preceding items, wherein the fabric comprises a pigment.
Item 26. The fabric or method of item 25, wherein the pigment includes organic pigments, inorganic pigments, or both.
Item 27. The fabric or method of item 26, wherein the organic pigment includes a carbon and the inorganic pigment includes a metal oxide.
Item 28. The fabric or method of any one of the preceding items, wherein the layer disposed adjacent to the reinforcement material includes a laminate layer or a coating layer.
Item 29. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric.
Item 30. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having a plain weave, a satin weave, a twill weave, or a combination thereof.
Item 31. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having a weight of at least 100 grams per square meter (gsm), at least 150 gsm, at least 200 gsm, at least 225 gsm, or at least 250 gsm.
Item 32. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having a weight of no greater than 1500 gsm, no greater than 1400 gsm, no greater than 1300 gsm, or no greater than 1200 gsm.
Item 33. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having a weight in a range of 100 to 2500 gsm, 150 to 1400 gsm, 200 to 1300 gsm, 225 to 1200 gsm, or 250 to 1200 gsm.
Item 34. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having a thickness of at least 0.005 mm, at least 0.01 mm, at least 0.015 mm, or at least 0.02 mm.
Item 35. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having a thickness of no greater than 5 mm, 4.5 mm, 4 mm, or 3.7 mm.
Item 36. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having a thickness in a range of 0.005 mm to 5 mm, 0.01 mm to 4.5 mm, 0.015 mm to 4 mm, or 0.02 mm to 3.7 mm.
Item 37. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having an openness factor, measured according to ASTM D4751, of at least 0%, at least 1%, at least 2%, or at least 3%.
Item 38. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having an openness factor, measured according to ASTM D4751, of no greater than 30%, no greater than 25%, no greater than 20%, or no greater than 15%.
Item 39. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having an openness factor, measured according to ASTM D4751, in a range of 0% to 30%, 1% to 25%, 2% to 20%, or 3% to 15%, or such as in a range of 15 to 85%, 20 to 80%, 25 to 75%, or 30 to 70%.
Item 40. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having a window size of at least 0.04 mm², at least 0.5 mm², at least 1 mm², at least 2 mm², or at least 4 mm².
Item 41. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having a window size of no greater than 1000 mm², no greater than 900 mm², or no greater than 625 mm².
Item 42. The fabric or method of any one of the preceding items, wherein the reinforcement material includes a woven fabric having a window size in a range of 0.04 to 1000 mm², 1 to 900 mm², or 4 to 625 mm².
Item 43, The fabric or method of any one of the preceding items, wherein the fabric is a laminate.
Item 44. The fabric or method of any one of the preceding items, wherein the fabric has a Strength Retention after Flex Fold of at least 45%, at least 55%, at least 65%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95%, based on the Warp Break Strength test according to ASTM 751/D4851 retained after undergoing a Flex Fold test.
Item 45. The fabric or method of any one of the preceding items, wherein the fabric has a Strength Retention after Flex Fold of no greater than 99.5%, no greater than 99%, or no greater than 98%, based on the Warp Break Strength test according to ASTM 751/D4851 retained after undergoing a Flex Fold test.
Item 46. The fabric or method of any one of the preceding items, wherein the fabric has a Strength Retention after Flex Fold in a range of 45% to 99% or 75% to 98%, based on the Warp Break Strength test according to ASTM 751/D4851 retained after undergoing a Flex Fold test.
Item 47. The fabric or method of any one of the preceding items, wherein the fabric has a Strength Retention after Flex Fold after weathering, measured according to ASTM D4329, of at least 40%, at least 50%, at least 60%, at least 70%, at east 80%, at least 90%, or at least 95%.
Item 48. The fabric or method of any one of the preceding items, wherein the fabric has a Strength Retention after Flex Fold after weathering, measured according to ASTM D4329, of no greater than 99%, no greater than 97%, or no greater than 95%.
Item 49. The fabric or method of any one of the preceding items, wherein the fabric has a Strength Retention after Flex Fold after weathering, measured according to ASTM D4329, in a range of 40% to 99%, 70% to 97%, or 80% to 95%.
Item 50. The fabric or method of any one of the preceding items, wherein the fabric has a Creep Resistance, measured according to ASTM D6992, of at least 100 hours, at least 150 hours, or at least 200 hours.
Item 51. The fabric or method of any one of the preceding items, wherein the fabric has a Creep Resistance, measured according to ASTM D6992, in a range of 100 to 600 hours, 150 to 500 hours, or 200 to 400 hours.
Item 52. The fabric or method of any one of the preceding items, wherein the fabric has a warp direction and a fill direction, and a tensile strength in the warp direction, fill direction, or both, of at least 150 pounds per linear inch (pli), at least 200 pli, at least 250 pli, at least 500 pli, at least 750, or at least 1000 pli.
Item 53. The fabric or method of any one of the preceding items, wherein the fabric has a warp direction and a fill direction, and a tensile strength in the warp direction, fill direction, or both, of no greater than 1500 pli, no greater than 1700 pli, no greater than 2000 pli, or no greater than 2500 pli.
Item 54. The fabric or method of any one of the preceding items, wherein the fabric has a warp direction and a fill direction, and a tensile strength in the warp direction, fill direction, or both, in a range of 150 pli to 2500 pli, 200 pli to 2000 pli, or 500 pli to 1000 pli, or even 300 pli to 1500 pli.
Item 55. The fabric or method of any one of the preceding items, wherein the fabric has a Crease Fold Retention of at least 80%, at least 85%, or at least 90%.
Item 56. The fabric or method of any one of the preceding items, wherein the fabric has a Visible Light Transmission (VLT) of no greater than 30%, no greater than 25%, or no greater than 20%.
Item 57. The fabric or method of any one of the preceding items, wherein the fabric has a VLT of at least 3%, or at least 5%, or at least 10%, or at least 20% or at least 30% or at least 40% or at least 50%.
Item 58. The fabric or method of any one of the preceding items, wherein the fabric has a VLT in a range of 3 to 50%, 5 to 40%, or 10 to 30%, or in a range of 20 to 30%, 25 to 40%, or 30 to 50%.
Item 59. The fabric or method of any one of the preceding items, wherein the fabric has a Visible Light Reflectance (VLR) of at least 60%, at least 65%, or at least 70%.
Item 60. The fabric or method of any one of the preceding items, wherein the fabric has a VLR of no greater than 95%, no greater than 90%, no greater than 85%, or no greater than 80%.
Item 61. The fabric or method of any one of the preceding items, wherein the fabric has a VLR in a range of 60 to 90%, 65 to 85%, or 70 to 80%.
Item 62. The fabric or method of any one of the preceding items, wherein the fabric has an Infrared Light Transmission (ILT) of no greater than 30%, no greater than 25%, or no greater than 20%.
Item 63. The fabric or method of any one of the preceding items, wherein the fabric has an ILT of at least 0%, or at least 1%, or at least 3%, or at least 5%.
Item 64. The fabric or method of any one of the preceding items, wherein the fabric has an ILT in a range of 0 to 30%, 1 to 25%, or 3 to 25%.
Item 65. The fabric or method of any one of the preceding items, wherein the fabric has an Infrared Light Reflectance (ILR) of at least 40%, at least 45%, or at least 50%.
Item 66. The fabric or method of any one of the preceding items, wherein the fabric has an ILR of no greater than 95%, no greater than 93%, or no greater than 90%.
Item 67. The fabric or method of any one of the preceding items, wherein the fabric has an ILR in a range of 40 to 95%, 45 to 93%, or 50 to 90%.
Item 68. The fabric or method of any one of the preceding items, wherein the fabric has a Coating Adhesion, as determined by ASTM D4851-88 modified by heating and pressing for as much as 2 minutes to form test samples and performing tests on samples 1 inch in width, of at least 5.5 lb/in, at least 8.5 lb/in, at least 9.5 lb/in, or at least 10 lb/in.
Item 69. The fabric or method of any one of the preceding items, wherein the fabric has a Coating Adhesion, as determined by ASTM D4851-88 modified by heating and pressing for as much as 2 minutes to form test samples and performing tests on samples 1 inch in width, no greater than 50 lb/in, no greater than 40 lb/in, no greater than 35 lb/in, or no greater than 30 lb/in.
Item 70. The fabric or method of any one of the preceding items, wherein the fabric has a Coating Adhesion, as determined by ASTM D4851-88 modified by heating and pressing for as much as 2 minutes to form test samples and performing tests on samples 1 inch in width, in a range of 5.5 to 50 lb/in, 8.5 to 40 lb/in, or 9.5 to 35 lb/in.
Item 71. The fabric or method of any one of the preceding items, wherein the fabric has a Class A fire rating.
Item 72. The fabric or method of any one of the preceding items, wherein the fabric is substantially impermeable to liquid water.
Item 73. The fabric or method of any one of the preceding items, wherein the fabric is a architectural fabric.
Item 74. The fabric or method of any one of the preceding items, wherein the fabric is an architectural fabric adapted to be disposed adjacent to a support structure.
Item 75. The fabric or method of item 74, wherein the fabric is an architectural fabric adapted to be disposed adjacent to the support structure in a stretched state.
Item 76. The fabric or method of items 74 or 75, wherein the support structure includes a rigid frame.
Item 77. The fabric or method of any one of items 74-76, wherein the support structure includes a coupling element and the architectural fabric is adapted to be coupled to the support structure via the coupling element.
Item 78. The fabric or method of any one of the preceding items, wherein the fabric is an architectural fabric adapted to protect a defined area from environmental elements.
Item 79. The fabric or method of any one of the preceding items, wherein the fabric is an architectural fabric adapted for a tension fabric structure.
Item 80. The fabric or method of item 79, wherein the tension fabric structure is reversibly collapsible.
Item 81. The fabric or method of any one of the preceding items, wherein the fabric is an architectural fabric adapted to fold from a central joint.
Item 82. The fabric or method of any one of the preceding items, wherein the fabric is an architectural fabric adapted for an architectural umbrella.
Item 83. The fabric or method of any one of the preceding items, wherein the fabric is an architectural fabric adapted for a retractable roofing system.
Item 84. The fabric or method of any one of the preceding items, wherein the fabric is an architectural fabric adapted to withstand repeated folding, flexing, or both while in use.
Item 85. The fabric or method of any one of the preceding items, wherein the fabric is adapted for industrial release belts or sheets.
Item 86. The fabric or method of any one of the preceding items, wherein the fabric is adapted for expansion joints.
Item 87. The fabric or method of any one of the preceding items, wherein the fabric is adapted for transportable radomes.
Item 88. The fabric or method of any one of the preceding items, wherein the polymer blend further comprises glycerin.
Item 89. The fabric or method of item 88, wherein the glycerin is present in the polymer blend in an amount of 0.25 wt % to 25 wt %, 0.25 wt % to 15 wt %, or 0.25 wt % to 5 wt %, based on the total weight of the polymer blend.

EXAMPLES

The concepts described herein will be further described in the following examples, which do not limit the scope of the invention described in the claims. Some of the parameters below have been approximated for convenience.

Example 1

Example 1 included a comparison between Comparative Sample 1, a conventional architectural fabric, and Sample 2, an architectural fabric according to an embodiment as described herein.
Comparative Sample 1 was manufactured by providing a plain woven glass fabric and coating the glass fabric with a fluoropolymer dip under a multistep coating process including heat cleaning, coating with a first fluoropolymer formulation, which is a blend of T30 [98%] and T121[2%] (both of which are available from E. I. du Pont de Nemours and Company at Deleware, USA), coating with a second fluoropolymer formulation, TE3879 (available from E. I. du Pont de Nemours and Company at Deleware, USA), and coating with a third fluoropolymer formulation, TE9568 (available from E. I. du Pont de Nemours and Company at Deleware, USA).
Sample 2 was manufactured by providing the same plain woven glass fabric used for Comparative Sample 1 and coating the fabric with the same multistep coating process used for Comparative Sample 1, except that the second fluoropolymer formulation of Comparative Sample 1 was replaced with a polymer blend including 80% by weight of a fluoropolymer, TE3879, and 20% by weight of a silicone polymer, CT-27E, (available from Wacker-Chemie GmBH at Munich, Germany).
The two samples were tested for Break Strength (ASTM 751/D4851), Strength Retention after Flex Fold (as described herein), and Average Trapezoidal Tear (ASTM D5587) in the warp direction, as well as Water Absorption (FED Test Method 191-5502). The results of the testing are provided in Table 1. As shown in Table 1, Sample 2, an embodiment of the architectural fabric according to this disclosure, provides vastly improved performance in the warp direction, especially the Strength Retention after Flex Fold, compared to Comparative Sample 1.

	TABLE 1

	Comparative Sample 1	Sample 2

Breaking strength - Warp (pli)	484 ± 15.5	449 ± 31.7
Flex Fold Resistance - Warp (%)	75%	97%
Average Trapezoidal Tear - Warp (lbs.)	31 ± 1.8	34 ± 1.0
Water Absorption (%) (0.5 MAX)	0.08 (0.09 MAX)	0.11 (0.15 MAX)

Example 2

Comparative Sample 3 was manufactured by providing a heavy plain woven glass fabric (30 osy) and coating the glass fabric with a fluoropolymer dip under a multistep coating process including heat cleaning, coating with a first fluoropolymer formulation (LA11501 M132), coating with a second fluoropolymer formulation (TE3859), and lamination with a 4 mil cast PTFE film.
Sample 4 was manufactured by providing the same heavy plain woven glass fabric (30 osy) used for Comparative Sample 3 and coating the fabric with the same multistep coating process used for Comparative Sample 3, except that the process used for Sample 4 further included coating with a polymer blend including 80% by weight of a fluoropolymer (TE3879) and 20% by weight of a silicone polymer (CT-27E) and coating with a third fluoropolymer formulation (TE3859) prior to lamination with a 4 mil cast PTFE film.
The two samples were tested for Ultimate Tensile (ASTM 751/D4851), Flex Fold Resistance (as described herein), and Trapezoidal Tear (ASTM D5587) in the warp and fill directions. The results of the testing are provided in Table 2. As shown in Table 2, Sample 4, an embodiment of the architectural fabric according to embodiments of this disclosure, provides increased performance compared to Comparative Sample 3, even though the two fabrics have a very similar weight and thickness.

	TABLE 2

	Comparative
	Sample 3	Sample 4

Weight (osy)	60	60.1
Thickness (mils)	52	51
Ultimate Tensile - Warp (pli)	1410	1677
Strength Retention after Flex Fold- Warp (pli)	70%	97%
Trapezoidal Tear -Warp (lbs.)	268	250
Ultimate Tensile - Fill (pli)	1054	1452
Flex Fold Resistance - Fill (pli)	70%	94%
Trapezoidal Tear - Fill (lbs.)	226	375

Example 3

Example 3 tested architectural fabrics according to embodiments of this disclosure having various reinforcement materials.
Sample 5 was prepared by providing a woven fabric reinforcement material having a satin weave (Style 7581) and coating the fabric with a polymer blend layer including 80% by weight of a PTFE and 20% by weight of a silicone polymer.
Sample 6 was prepared in the same manner as Sample 5, except that the reinforcement material for Sample 6 was a woven fabric having a twill weave (Style 92125).
Sample 7 was prepared in the same manner as Samples 5 and 6, except that the reinforcement material for Sample 7 was a woven fabric having a plain weave (Style 7526).
Sample 8 was prepared in the same manner as Samples 5-7, except that the reinforcement material for Sample 8 was a woven fabric having a plain weave (Style 1564).
Each of Samples 5-8 were tested for Coating Adhesion (ASTM D4851-88), Break Strength (ASTM 751), and Strength Retention after Flex Fold (as described herein). The results of the testing are provided in Table 3.

TABLE 3

Sample 5	Sample 6	Sample 7	Sample 8	Sample 9

Weave Type	Satin	Twill	Plain	Plain	Plain
Weave Style No.	Style 7581	Style 92125	Style 7526	Style 1564	Style 1564
Coating	1.6 ± 0.26	6.5 ± 0.44	4.1 ± 0.77	7.87 ± 0.88	13.6 ± 2.13
Adhesion (pli)
Break Strength -	409 ± 1.9	347 ± 3.4	496 ± 16	514 ± 4	590 ± 20
Warp (pli)
Strength	96%	82%	63%	95%	95%
Retention after
Flex Fold -
Warp (%)
Break Strength -	402 ± 3.4	n/a*	488 ± 6	432.9 ± 22	505 ± 38
Fill (pli)
Strength	86%	n/a*	66%	95%	88%
Retention after
Flex Fold -
Fill (%)

*n/a indicates value was well below desired levels

Samples 7 and 8 each have a plain weave type and the tighter weave of Sample 7 appears to contribute to the lower Strength Retention after Flex Fold. In addition, although Sample 5 has a high Strength Retention after Flex Fold, Sample 5 does not exhibit a high Coating Adhesion. Sample 9 maintains a high Strength and Strength Retention while providing an increased Coating Adhesion.
As described in the above description and example, embodiments of the architectural fabric according to this disclosure are suitable for the flexing and folding of an architectural umbrella or retractable roofing system. In particular, embodiments of the architectural fabric can provide the unexpected combination of high flexibility, long term structural integrity, fire resistance, and long term aesthetic appeal.
Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.
The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

Claims

What is claimed is:

1. A fabric comprising:

a reinforcement material; and

a layer disposed adjacent to the reinforcement material and comprising a fluoropolymer, an elastomer, or a combination thereof,

wherein the fabric has a Strength Retention after Flex Fold of at least 80%.

2. The fabric of claim 1, wherein the elastomer is a silicone elastomer, a fluoroelastomer, perfluoroelastomer, or any combination thereof.

3. The fabric of claim 1, wherein the layer disposed adjacent to the reinforcement material includes a plurality of layers, at least one layer of the plurality of layers comprises a polymer blend comprising a fluoropolymer and an elastomer.

4. The fabric of claim 3, wherein the plurality of layers includes:

a first layer disposed adjacent to the reinforcement material, the first layer comprising a fluoropolymer; and

a second layer disposed adjacent to the first layer, the second layer comprising a polymer blend comprising a fluoropolymer and an elastomer.

5. The fabric of claim 3, wherein the plurality of layers includes:

a first layer disposed adjacent to the reinforcement material, the first layer comprising a fluoropolymer;

a second layer disposed adjacent to the first layer, the second layer comprising a polymer blend comprising a fluoropolymer and an elastomer; and

a third layer disposed adjacent to the second layer, the third layer comprising a fluoropolymer.

6. The fabric of claim 1, wherein the layer disposed adjacent to the reinforcement material includes a layer comprising a polymer blend comprising a fluoropolymer and an elastomer, and the elastomer is present in the layer in an amount of at least 5 wt %.

7. The fabric of claim 6, wherein the polymer blend further comprises a glycerin.

8. The fabric of claim 7, wherein the glycerin is present in the polymer blend in an amount of 0.25 wt % to 25 wt %, 0.25 wt % to 15 wt %, or 0.25 wt % to 5 wt %, based on the total weight of the polymer blend.

9. The fabric of claim 1, wherein the fluoropolymer in at least one layer of the fabric includes a polytetrafluoroethylene (PTFE), a hexafluoropropylene (HFP), a fluorinated ethylene propylene (FEP), a perfluoroalkyl vinyl ether (PFA), or any combination thereof.

10. The fabric of claim 1, wherein the reinforcement material includes a woven fabric having a weight of at least 100 grams per square meter (gsm).

11. The fabric of claim 1, wherein the reinforcement material includes a woven fabric having a window size of at least 0.04 mm².

12. The fabric of claim 1, wherein the fabric has a Strength Retention after Flex Fold of at least 90%, based on the Warp Break Strength test according to ASTM 751/D4851 retained after undergoing a Flex Fold test.

13. The fabric of claim 1, wherein the fabric has a Strength Retention after Flex Fold after weathering, measured according to ASTM D4329, of at least 40%.

14. The fabric of claim 1, wherein the fabric has a Creep Resistance, measured according to ASTM D6992, of at least 100 hours.

15. The fabric of claim 1, wherein the fabric has a Crease Fold Retention of at least 80%.

16. The fabric of claim 1, wherein the fabric has a Coating Adhesion, as determined by ASTM D4851-88 modified by heating and pressing for as much as 2 minutes to form test samples and performing tests on samples 1 inch in width, of at least 5.5 lb/in.

17. The fabric of claim 1, wherein the fabric is substantially impermeable to liquid water.

18. The fabric of claim 1, wherein the fabric is an architectural fabric adapted to protect a defined area from environmental elements.

19. A fabric comprising:

a reinforcement material; and

a layer disposed adjacent to the reinforcement material,

wherein the fabric has a Class A fire rating and a Strength Retention after Flex Fold of at least 45%.

20. A method of forming a fabric, the method comprising:

providing a reinforcement material; and

coating the reinforcement material with a layer comprising a fluoropolymer,

an elastomer, or a combination thereof,

wherein the fabric has a Strength Retention after Flex Fold of at least 80% or a Class A fire rating and a Strength Retention after Flex Fold of at least 45%.