Guide to the Different Types of Coated Fabrics

A Guide to the Different Types of Coated Fabrics

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Coated fabrics are used in a diverse range of industries, from automotive, transportation, and aerospace to marine, healthcare, sports and leisure, and industrial sectors. They serve a vital purpose in the furniture industry as well, assisting companies in safeguarding their clients and adhering to applicable codes and regulations. With over half a century of experience in crafting high-quality furniture for the hospitality sector, Falcon has maintained a deep understanding of the applications, attributes, and benefits of coated fabrics with dozens of coated fabric options.

The upholstery fabrics we offer often undergo different types of coatings to make them more suitable for specific uses. In this article, we introduce you to the world of coated fabrics, shedding light on their production process, their application, and the diverse types available on the market today.

What is a Coated Fabric?

The term &#;coated fabric&#; refers to a textile that has been chemically treated with a specialized coating to alter, enhance, or improve its properties. This treatment offers a broad range of benefits that are both aesthetic and functional. Primarily employed to strengthen durability, these coatings also produce other desirable qualities such as water and fade resistance, increased resilience to wear and tear, thermal and antimicrobial protection, as well as fire retardancy.

The process of creating coated fabrics involves the application of a layer of polymer or other coatings onto a base textile material, thereby enhancing its properties and imparting specific functionalities. Common types of coatings used for upholstery fabrics include vinyl, silicone, acrylic, and polyurethane. Textile manufacturers have the flexibility to tailor coatings to particular fabrics, catering to diverse needs and the requirements of specific applications or venues, such as hotels, restaurants and hospitals.

Different Types of Coated Fabrics

Vinyl Coated Fabrics

Vinyl coated fabrics are known for their durability, versatility and low cost. They consist of a base fabric, usually polyester or nylon, which is coated with polyvinyl chloride (PVC) or polyurethane. Coating the fabric with PVC creates a waterproof and durable material. Vinyl coated fabrics are available in different weights and thicknesses, offering varying degrees of strength and flexibility.

Pros:

Waterproof: Vinyl coated fabrics are highly resistant to water and provide excellent protection against rain, making them suitable for applications such as outdoor furniture.

Durable: They are incredibly robust and are resistant to corrosion, chemicals, abrasion, and impact, making them ideal for use as upholstery in public or heavily trafficked spaces.

Cost-Effective:  Vinyl is less expensive than many other plastic coatings, making it an economical choice for various projects.

Color and Design Options: Vinyl fabrics are available in a wide array of colors and designs, giving users ample choices for their specific needs. They are easily customizable, so they can be made to match virtually any color or texture.

Cons:

Environmental Concerns: Traditional PVC-coated fabrics raise environmental concerns due to the use of phthalates and other potentially harmful chemicals during production. In addition, they are not biodegradable and release harmful chemicals when incinerated.

Less Breathable: Vinyl fabrics tend to be less breathable, which may lead to discomfort in hot and humid conditions.

Susceptible to Cold Cracking: In extremely cold temperatures, vinyl fabrics can become stiff and susceptible to cracking.

Health Risks: PVC can release toxic chemicals which can be harmful to human health. Exposure to these chemicals have been known to cause developmental problems and other health issues.

Recycling Challenges: PVC coated fabrics are difficult to recycle because they are made up of several different components that are hard to separate. In addition, the recycling process can also release harmful chemicals into the environment.

When to Use Vinyl Coated Fabrics:

Vinyl coated fabrics are a great choice when waterproofing and durability are paramount, such as in health care environments and hotel lobbies.

Silicone Coated Fabrics

Silicone coated fabrics are extremely durable, and have a modern look and comfortable feel. They are engineered to withstand extreme temperatures and offer exceptional resistance to fire, water, and chemicals. They are considered an eco-friendly solution to seating because they remain free of solvents. These fabrics are created by applying a silicone polymer to a base fabric. Silicone coatings are applied using different techniques, such as knife coating or dip coating, to achieve the desired level of coverage and properties.  

Pros:

Temperature Resistance: Silicone coated fabrics can handle high temperatures without degrading, making them suitable for applications such as car seats and indoor environments that lack air conditioning. 

Chemical Resistance: They are highly resistant to chemicals, oils, and solvents, making them ideal for withstanding exposure to harsh substances, such as the disinfectants and cleaners used in a health care setting.

Weather Resistance: Silicone coated fabrics perform well in outdoor settings and have excellent UV resistance.

Cons:

Cost: Silicone coated fabrics are more expensive to produce than other coated fabric types due to the high-performance properties of silicone polymers.

Less Flexible: While highly durable, silicone coatings can be less flexible than other coatings, which might limit their suitability for certain applications, such as draped upholstery.

Slow Production: Their production speed is 40% slower than conventional coated textiles.

When to Use Silicone Coated Fabrics:

Silicone coated fabrics are best suited for environments that have extreme temperature or the presence of chemicals such as harsh cleaning solutions. They are ideal for use in outdoor furniture.

Polyurethane Coated Fabrics:

Polyurethane (PU) coated fabrics are lightweight and flexible, combining the benefits of durability and water resistance. These fabrics are created by applying a layer of polyurethane to a base fabric such as polyester or nylon. PU coatings can vary in thickness, resulting in different levels of water repellency and breathability.

Pros:

Water Resistance: PU coated fabrics are water-resistant, providing a good amount of protection against rain and moisture.

Flexibility: They are more flexible than some other coated fabrics, making them suitable for applications requiring movement and drape, such as furniture upholstery.

Breathability: PU coated fabrics offer better breathability than vinyl, providing more comfort in warm and humid conditions.

Eco-Friendly Options: Some PU coated fabrics are made using eco-friendly processes, addressing environmental concerns associated with traditional PVC coatings.

Cons:

Durability: While durable, PU coatings may not be as robust as vinyl or silicone coatings, limiting their use in heavy-duty applications.

UV Resistance: PU coatings might not have the same level of UV resistance as silicone or vinyl, making them less suitable for prolonged exposure to sunlight.

When to Use Polyurethane Coated Fabrics:

Polyurethane coated fabrics are used extensively in public settings, where a balance of water resistance, breathability, and flexibility is essential.

Acrylic Coated Fabrics

Acrylic coated fabrics are known for their excellent UV resistance and color retention properties. These fabrics are produced by applying an acrylic coating to a base fabric such as polyester or cotton. The acrylic coating helps enhance the fabric's durability and resistance to fading.

Pros:

UV Resistance: Acrylic coated fabrics are the material of choice in applications where prolonged exposure to sunlight is a concern, such as outdoor furniture, or on indoor items that are not protected from the sun&#;s glare.

Color Fastness: They retain their color well, even after prolonged exposure to the elements, ensuring a vibrant appearance over time.

Mold and Mildew Resistance: Acrylic coatings often have mold and mildew-resistant properties, making them suitable for humid environments, as well as hospital settings.

Cons:

Water Resistance: While acrylic coatings offer some level of water resistance, they might not be as effective as other coated fabrics such as vinyl or PU.

Stiffness: Acrylic coated fabrics can be stiffer compared to other coated fabrics, negatively affecting their flexibility and drape.

For more information, please visit Pu Coated Fiberglass Fabric.

When to Use Acrylic Coated Fabrics:

Acrylic coated fabric is an excellent choice for heavily trafficked and outdoor applications that require UV resistance and color fastness.  

By understanding the differences among these coated fabric types and evaluating their pros and cons, you can make an informed decision about the best material for your specific needs. Consider factors like weather conditions, temperature requirements, durability, and flexibility to select the most suitable coated fabric for your project, ensuring optimal performance and longevity.

Polyurethane Fabric

Polyurethane (PU) is a composite material made of: (1) one or more layers of polymer resins joined by urethane links; and (2) a woven or non-woven textile backing such as polyester, cotton, nylon, or ground leather. The PU coating is applied to a single side of the base fabric and then treated to look more like animal hide. This makes the fabric water resistant, light weight and flexible. This fabric provides the most realistic imitation of leather when it comes to its soft supple hand. When stitched, gathered, or tufted it actually &#;breaks&#; or wrinkles like real leather.

PU resins are made of a soft polymer and unlike vinyl don&#;t need added plasticizers. Because no plasticizers are used in PU upholstery there is no cracking or peeling, and it remains soft and supple for the duration of time it remains on the furniture. PU fabrics are also easier to decorate. PU is considered greener than vinyl because it does not create dioxins. PU costs less than real leather, but it can be more expensive to produce than vinyl.

Polyurethane Resin Systems

All polyurethane coated fabrics are made from polymer resins. There are three basic types of resins used in making polyurethane coated fabrics.

1. Polycarbonate (PC) &#; The best resin available. It is very durable with high resistance to humidity, heat and light. PC resins are suitable for high traffic commercial upholstery applications.

2. Polyether (PET) - Good resistance to humidity, heat and light. PET resins are suitable for most commercial applications.

3. Polyester (PES) - Low resistance to humidity, heat and light. PES resins are only suitable for low activity commercial applications (e.g., headboards and pillows).

These resins can be used individually or in combination, such as:

&#;          Polycarbonate

&#;          Polyether &#; Polycarbonate

&#;          Polyether- Polyester

The cost of the PU upholstery fabric is directly correlated to the quality of the resin that is used, as well as other performance additives that are required to consider a PU fabric suitable for commercial use. Colorfastness and stain resistance are achieved through the skin layer and/or top finish of the fabric. Chemical additives can improve the performance of abrasion resistance, hydrolysis resistance, flame retardation, lightfastness, and cleanability.

Polyurethane Coated Fabric Manufacturing Process

There are two processes available for manufacturing polyurethane coated fabrics, referred to as &#;Wet&#; and &#;Dry.&#;

Wet PU Process

The Wet PU manufacturing process consists of coating a coagulated base on a substrate backing. An adhesive layer is then applied to the base and another layer, or top coat is decorated with color and design. The wet process can use any of the resin system combinations described previously. The wet process is used in the vast majority of PU upholstery on the market today.

Dry PU Process

In the Dry PU manufacturing process, the coagulate base is totally eliminated. The PU is coated directly on the face of the backing. The chemical reaction in the dry process provides enhanced strength and performance.  The resin system can be either: two-component reactive polyether-polycarbonate; or high solid polycarbonate. The high quality resins are processed in a cleaner and more environmentally sound manufacturing environment. Over 99% of solvents are recaptured and recycled. The dry manufacturing process uses about 25% less energy than the wet process.

Timeline of Polyurethane Applications

Dr. Otto Bayer discovers the basic polyurethane chemistry at the I.G. Farben Laboratories, a subdivision of Bayer Corporation, in Leverkusen, Germany.

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The practical application of polyurethane dates to the beginning of World War II where it is was first developed as a replacement for rubber. The versatility of this new organic polymer and its ability to substitute for scarce materials, spurred numerous applications. During World War II, polyurethane coatings were used for the impregnation of paper and the manufacture of mustard gas resistant garments, high-gloss airplane finishes, and chemical and corrosion resistant coatings to protect metal, wood and masonry.

The first commercially available polyurethane was introduced by DuPont Corporation in . The material was rigid foam used in the insulation of beer barrels. Dow Chemical, BASF, and Mobay Corporation introduced polyurethane materials.

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Shoe soles for sneakers introduced synthetic polyurethane leather. Flexible foam cushions for seating were introduced with the first commercial production in Europe and soon thereafter in the United States. In just a few years flexible polyurethane foam became the material of choice for furniture upholstery and car seats.

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Polyurethane made its way into apparel with DuPont&#;s Spandex fiber renamed Lycra. The fiber soon ended up in men's and women's figure-flattering swimwear and then hit the ski slopes in in the Lycra garments of the French Olympic ski team. In the mid-60s polyurethane was being used in automobile upholstery.

The first all plastic automobile (made from polyurethanes..!) introduced in by Bayer AG Corporation in Dusseldorf, Germany.

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In the s, cyclists traded in their woolen shorts for "aerodynamic" spandex shorts, and the versatile fiber began to find its way into dancewear, tights, and stretch jeans.

Polyurethane used as a spray building insulation as rising energy costs drove down the use of PVC, one of the most common synthetic building materials in the world.

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By the s, spandex had a commanding presence in hosiery. As pop singer Madonna started a trend in the '80s to wear innerwear as outerwear and sports-looks translated into new street-wear fashions, Chanel couture skirts set fashion trends with the use of spandex in leggings.

Energy absorbing polyurethane foams began being used in automobiles for passenger safety.

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Thin wall medical hoses (i.e. catheters) are made with polyurethane.

CFCs no longer added to polyurethane products and are replaced by alternative substances (hydrocarbons, HCFCs, CO2, etc.) that are environmentally-friendly.

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Beginning in the early s, industry efforts to become more environmentally friendly created polyurethanes made from vegetable oil polyols, most notably soy-based polyurethane used by Ford Motor Company in recent automobile interiors (dashboards, side-panels, etc.). A significant development in that evolution of luggage came in , when Rimowa introduced the first suitcase made of polycarbonate. Lighter than aluminum and highly durable, polycarbonate set the stage for the hard-shell cases that are now made by many major players in the luggage industry.

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In , The Mitchell Group introduces Sta-Kleen®, the first dry erase ink and stain resistant polyurethane upholstery fabric.

In , The Mitchell group introduces Sta-Kleen Polycarbonate&#;, a PU made from 100% polycarbonate resins.

Today an amazing number of products are made from polyurethane. They include bowling balls, surf boards, roller coaster wheels, soccer balls, housing insulation, bandages, denim jeans, running track and roofing tiles.

In , polyurethane accounted for about 1.1 billion dollars in sales in the United States from all applications. The end use of polyurethane can be segmented as follows:

Shoes               32%

Furniture         26%

Automobile     13%

Clothes            05%

Other               24%

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