Laminated fabric:

Laminated fabric is layered structures with two or more fabrics fused together. Each layer
maintains its unique identity.
A laminated or more specially foam laminated usually consists of three layers adhered
together-
 A face fabric
 A middle foam layer (usually polyurethane foam)
 A backing fabric (usually nylon or acetate 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 half
inch thickness of foam layers.

Face fabric Face fabric

Foam Backing
Backing

Fig: foam laminated fabric Fig: foamback laminated fabric

Types of laminate:
1. Foam: 2 or 3 layers and are usually used for insulation.
2. Polymer film: film is laminated to knit or woven fabric. Ex. Neoprene.
Characteristics of Polymer Films
 Poor strength
 Repel water
 Resist soil
 Not air-permeable
 Poor drape
 Inexpensive
Methods of lamination:
Bonding with adhesives
Welding with fine frequency electric current
Slightly melting one layer of fabric by means of flame.

Materials for laminate:

 Polyurethane
 Polyester
 Polyether
 Polyura
 Lather, rubber etc

Properties of laminated fabric:

 It has wrinkled resistance
 Good tailoring properties
 Lower weight and better thermal insulation property
 Lower stability
  Less comfortable
 Stretch and recovery is very low

Factors of which and what type of adhesive to be used:

 Chemical nature of substrates to be joined, i.e. polyester, PVC, etc;
 Physical condition, i.e. texture, pile and surface nature – will it be damaged,
especially by hot melt processes?
 Fabric construction, open or relatively closed – will adhesive penetrate?
 Fabric stability – how it will affect handling – is stretching or shrinkage likely to
occur?
 Presence of fabric finish or residual lubricant and possible effect on adhesion;
 Temperature resistance required of the resultant laminate;
 Initial bond strength specified
 Bond durability, i.e. resistance to water, high relative humidity, etc;
 Plasticizer migration (of PVC components);
 UV and light resistance (if applicable);
 Possible effect on appearance, e.g. discoloration of face fabric

Factors considered evaluating the performance of a laminated fabric:

 Durability of bond
 Shrinkage behavior- should be no shrinkage
 Good crease resistant property
 Permissible disappearance of foam
 Good thermal insulation property
 Should not be dissolved in organic solvents
 Should not grow bacteria
 Should not hamper the elasticity of the component fabric

Suitability polyurethane foam sheet for lamination

 Weak solubility in organic solvent
 Resistance to elevated temperature
 Good thermal insulation
 High adhesiveness to practically all materials
 This may be given any degree of elasticity
 Lightness
 Resistance to creasing
 Good sound absorbance
 Does not support growth of bacteria
 Odorless or non odor retaining
 It is perspiration proof, non toxic and non allergic

Characteristics of various types of lamination:

Adhesive bonding:
Advantages:
 Good wrinkle recovery
Disadvantages:
 Less air permeability
 Problem with water soluble adhesive
 Layers may be separated due to rough handling
Welding:
Advantages:
 Good bonding property
Disadvantages
 Costly process
Melting:
Advantages:
 Easy process
Disadvantages:
 Less thermal insulation due to air packet
 Decrease D.P due to heat
 Strength may also decrease
 Stiffness may decrease

Different types of bonding agents:

1. Liquid bonding agents:
Natural adhesive, synthetic adhesive
2. Powdered thermoplastic substances:
It includes Co-polymer of P.V.C and P.V.A and polyethylene melted by infrared
radiation and bonding by calendaring and cooling.
3. Cold setting of water based rubber
4. High temperature curing rubber or resin

Maintenance of laminated fabric:

Polyether: sensitive to chemical cleaning, wash only with light detergent.
Polyester: washing or chemical cleaning
Polyurethane: washing or chemical cleaning

Recipe for washing:

Ionic detergent: 5 g/l conc. With optimum temperature of 40⁰ C
Natural fiber: hand wash with care
Synthetic fiber: mechanical (machine) wash
Dry temperature: 20⁰ C to 60⁰ C

Chemical cleaning recipe:

Percholoro ethylene or white spirit is used as chemical cleaning agent.
Washing temperature: 20 to 25⁰ C
Optimum drying temperature: 60⁰ C
Problems created by laminated fabric:
A common problem with laminated fabrics is ‘cracking’ which is caused when one or both
materials joined is not stretchy enough to allow the laminate to be curved in an arc. Use of
an excessive amount of adhesive or too much foam burnt off in flame lamination may cause
cracking.
Uses of laminated fabric:
Agriculture Geotextiles Home furnishings Industrial
Bulk containers Settling pond liners Upholstery Conveyor belts
Fencing Irrigation liners and fill Trim Filtration
Seed/crop covers liners & covers Carpet backing Barrier materials
Bags Soil stabilizers Drapery backing Field covers
Shade materials Erosion barriers Bedding Abrasive backing
Irrigation systems Artificial leather Mechanical rubber
Pond liners goods
Irrigation
Hoses
Constructions Clothing Medical Transportation
Safety fencing Shoe uppers and linings Barrier materials Seating/Trim for
Wind covers Artificial leather/bags Bandages automotive, trucks,
Concrete curing Rainwear Prosthetic devices Hoses/Belts
Safety vests Garment linings Gloves Tires
Hoses Backing/stiffeners Incontinence Headlining
Conveyer Belting Water/stain repellants materials Seating
Drainage ditches Gloves Upholstery Carpeting
Architectural Hats Body bags Airbags
structures Hygiene products Truck covers

Sports/leisure Packaging Protective material

Athletic shoes Bulk containers Gloves
Artificial House Wrap Cut/slash resistant
leather/bags/belt Lumber Wrap materials
s Gas holding Aprons
Rainwear Barrier packaging Clean room
Backpacks Liquid bulk Chemical/haz-mat
Tents storage/hauling suits
Exercise mats Waterproof materials Footwear
Exercise Space suits
equipment
Balls
Seating
Field Covers
Bonded fabric:
Bonded Fabrics are the types of fabrics made by joining a nonwoven fabric with a
woven / knitted fabric or by joining 2 nonwoven fabrics or bonding 2 different fabrics .

Types of bonding:
 Thermal bonding
 Mechanical bonding
 Chemical bonding

Thermal bonding:
Thermal bonding is a two stage process in which the bonding agent is softened at a high
temperature and then cooled at a low temperature for solidification of the bond.
 For thermoplastic fibers
 Heat causes these fibers to melt and fuse
Methods of thermal bonding:
 Hot calendering
 Belt calendering
 Through-air thermal bonding
 Ultrasonic bonding
 Radiant-heat bonding

Mechanical bonding:
A variety of mechanical methods are used which entangle the fibers of the web together by
some form of physical action.
 Needle punching
 Stitch bonding

Chemical bonding:
 The fibers are sprayed with a dilute chemical solution and then heated
 Chemicals dissolve and evaporate, fibers resolidify.
In chemical bonding, bonding adhesives are used in the form of polymer dispersion (latex)
or polymer solutions, chemically bonded fabrics are produced in the following integrated
steps-
 Web formation
 Binder application
 Drying
 Curing
The binder can be applied in the following methods
 Padding
 Spray bonding
 Print bonding
  Foam bonding
 Powder bonding

General properties of bonded fabric:

 They give strength to sheer fabric
 They improve the useful life of loose – structured fabrics such as lace
 They can be made up into reversible two faced fabrics for special designs
 Tailoring property not good
 Less comfortable to wear
 Higher stability property
 Low wrinkle resistance
 Stretching and good recovery property
 Higher weight and not so good thermal insulation property

Uses of bonded fabric:

 They make good backing fabrics for suits or coats
 They have furnishing applications, such as for seating and cushions
 They have household applications, such as for bed mattresses, pads and pillows and
underlay’s for carpets
 They have industrial applications, such as padding and cushioning for cars and
aircrafts and packaging for the shipment of fragile products

Problems in using of bonded fabric:

 The fabrics may be separated by abrasion
 In laundering, one fabric may shrink more than the other due to poor
stabilization, causing fabric ripples and pucker
 In dry-cleaning, some solvents may dissolve the adhesive, thus separating the
fabrics