The manufacturing process used to apply the PE coating to Oxford fabric involves several precise and controlled steps designed to enhance the fabric’s waterproofing, strength, and durability while maintaining its flexibility and texture. Polyethylene (PE) coating is one of the most practical and cost-effective ways to improve Oxford cloth for outdoor, industrial, and protective applications. Below is a detailed explanation of how the process works:
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1. Fabric Preparation
The process begins with preparing the base Oxford fabric, typically woven from polyester or nylon yarns in a basket or plain weave pattern. The raw fabric is carefully cleaned and dried to remove dust, oils, and other impurities that could interfere with coating adhesion. This step ensures that the PE coating bonds uniformly to the fabric surface.
2. Extrusion Coating Process
The most common method used for applying PE to Oxford fabric is extrusion coating. In this process:
- Polyethylene pellets are melted in an extruder at a controlled temperature, typically between 250°C and 300°C.
- The molten PE is then extruded through a flat die and spread evenly onto the surface of the moving Oxford fabric.
- As the coating is applied, the molten layer adheres tightly to the fibers, forming a continuous protective film that enhances the fabric’s waterproof and tear-resistant properties.
This process creates a uniform, smooth coating and provides excellent bonding strength between the polyethylene layer and the textile base.
3. Cooling and Solidification
After extrusion, the coated fabric passes over chilled rollers or through a cooling chamber. The rapid cooling solidifies the polyethylene layer, locking it in place on the textile surface. This stage helps control the thickness and glossiness of the final coating.
4. Surface Treatment and Finishing
Once the PE coating has hardened, the fabric may undergo additional surface finishing treatments to improve its performance and appearance. These may include:
- Calendering, which presses the coated fabric between heated rollers to achieve a smooth or matte finish.
- Embossing, which adds a textured pattern to improve grip or reduce glare.
- Corona or flame treatment, which modifies the surface energy to improve printability or lamination adhesion.
5. Quality Inspection and Testing
Before packaging, the PE Coated Oxford Cloth is tested for thickness consistency, coating adhesion, water resistance, and tensile strength. Manufacturers often perform hydrostatic pressure tests or peel strength tests to ensure the coating meets required standards.
6. Optional Lamination or Dual-Side Coating
In some cases, manufacturers apply PE coating on both sides of the Oxford fabric or laminate an additional PE film layer to achieve superior waterproofing and chemical resistance. This dual-side process is commonly used for heavy-duty applications like tarpaulins, outdoor covers, and industrial packaging.
Summary
The PE coating process for Oxford fabric primarily relies on extrusion coating technology, where molten polyethylene is evenly spread onto a woven polyester or nylon base. This method produces a durable, water-resistant, and flexible fabric with enhanced performance for outdoor gear, covers, bags, tents, and industrial applications. By precisely controlling coating thickness, cooling rate, and surface finish, manufacturers can tailor the fabric’s characteristics to meet various mechanical and environmental requirements.
