Silicone coated fabrics are widely used in industrial applications such as insulation, fire protection, and flame resistance due to their outstanding heat resistance and durability.
Silicone-Coated Fabrics are produced by applying liquid silicone to one or both sides of a base fabric, significantly improving base fabric's fire resistance, airtightness, waterproofing, chemical resistance, and overall performance. Heaterk offers a range of base fabrics, including woven fiberglass, high-silica fabrics, knitted fabrics, non-woven fabrics, mesh fabrics, and laminated materials.
The available silicone coating options include peroxide-cured, addition-cured, and condensation-cured types. Through precise formulation adjustments, performance can be further enhanced by incorporating functional additives such as reinforcing fillers, reaction retarders, heat stabilizers, flame retardants, and colorants. These tailored enhancements allow silicone-coated fabrics to meet the rigorous demands of high-performance industrial environments while maintaining superior reliability and versatility.
The knife coating process applies liquid silicone evenly onto fabric surfaces by precisely controlling the blade-to-substrate gap, forming a dense and uniform coating after curing. The process involves four key steps: coating preparation, application, curing, and post-treatment.
In preparation, coating viscosity (5000–10000 mPa·s), solid content (30%–60%), and leveling properties must be optimized to prevent sagging or uneven coverage. During application, blade angle (20°–60°), gap size, and substrate tension are carefully adjusted to ensure uniform coating. Curing occurs at 150°C–180°C for 2–5 minutes using segmented temperature-controlled dryers, ensuring complete curing without distorting the substrate. Final treatments, such as calendaring or slitting, are performed as needed.
The knife coating process's Critical performance metrics include coating thickness (0.1mm–2mm), uniformity, adhesion, and physical properties like abrasion resistance, waterproofing, and tear strength. Achieving these requires advanced precision equipment: adjustable blades, stable tension control systems (5–30 m/min), segmented hot-air curing systems (temperature variation within ±2°C), and high-shear mixing to eliminate impurities. Automatic winding systems maintain substrate stability, and stainless steel blades ensure smooth, consistent coating.
The impregnated coating process involves fully submerging the fabric into liquid silicone coating, followed by squeezing and curing to form a uniform layer. The process consists of three key steps: coating preparation, impregnation, and curing.
During preparation, the silicone coating must maintain an optimal viscosity (1000–5000 mPa·s) and stable solid content (20%–50%). In the impregnation stage, the fabric passes through a coating bath under controlled tension, ensuring thorough silicone penetration. Excess coating is removed using precision squeeze rollers to achieve uniform thickness. Curing is performed at 120°C–160°C for 3–8 minutes, enhancing adhesion between the coating and the substrate.
The impregnated coating process emphasizes uniform penetration and strong adhesion, making it ideal for applications requiring high flexibility. Coating thickness is regulated by controlling coating viscosity, immersion speed, and squeeze roller pressure. Key equipment includes a coating bath (to maintain stable liquid levels and prevent contamination), a squeeze roller system (for precise thickness control), and a drying system (with segmented temperature control, maintaining a temperature variance within ±2°C). Operating speeds typically range from 3–20 m/min, accommodating varying thickness requirements.
The roller coating process applies liquid silicone evenly onto the fabric surface using coating rollers, with coating thickness controlled by the pressure between rollers and their rotational speed. The process includes three key steps: coating preparation, application, and curing.
During preparation, the silicone coating is optimized for viscosity (2000–8000 mPa·s) and flowability to ensure smooth application. In the coating stage, the fabric passes through the coating rollers under controlled tension, where silicone is uniformly applied. The gap between rollers and their rotation speed determine the final coating thickness. Curing is performed at 140°C–170°C using drying equipment designed for rapid curing to ensure stable adhesion of the coating.
The roller coating process is ideal for applications requiring high uniformity and lightweight coatings. It delivers thin coatings with a typical thickness of 0.05mm to 0.5mm, controlled by roller pressure and speed. Surface smoothness is another key metric, with coatings expected to be free of bubbles or scratches.
Equipment requirements include high-precision rollers with smooth, wear-resistant surfaces, a tension control system to ensure stable fabric movement, and drying equipment capable of rapid heating and segmented temperature control. The process operates at high speeds, typically 10–50 m/min, making it suitable for large-scale production.
This method ensures exceptional coating uniformity, thin layers, and a smooth finish, meeting the demands of industries prioritizing lightweight and precision-engineered silicone-coated fabrics.
The spray coating process utilizes specialized equipment to atomize silicone coating, which is then evenly sprayed onto the fabric surface through nozzles or air pressure, forming a thin and uniform layer. The process involves three main steps: coating preparation, application, and curing.
During preparation, the silicone coating is formulated with a low viscosity (500–3000 mPa·s) to ensure excellent flowability and atomization. In the application stage, the coating is evenly sprayed onto the substrate using high-pressure or air-assisted nozzles. The coating thickness is controlled by adjusting spray pressure, nozzle diameter, and spraying speed. Curing is then performed at 120°C–150°C using drying equipment to rapidly solidify the coating and ensure adhesion.
The spray coating process is particularly advantageous for achieving ultra-thin, uniform coatings and is ideal for substrates with complex shapes or requiring high breathability. Key performance metrics include:
Coating Thickness: Typically 0.01mm to 0.3mm, precisely controlled through adjustments to spray pressure, nozzle size, and application speed.
Surface Uniformity: The coating must be evenly distributed, with no buildup, sagging, or pinholes.
Spray Coating Process is well-suited for applications demanding thin and highly consistent coatings, offering exceptional flexibility and adaptability for diverse industrial needs.
The casting coating process involves evenly spreading liquid silicone onto the substrate surface or forming an independent film that is later laminated onto the substrate. Using precision rollers and casting devices, the coating thickness is precisely controlled to meet exact specifications. The process consists of three main steps: coating preparation, film casting, and curing (with optional lamination for composite products).
During preparation, the silicone coating is optimized for viscosity (3000–8000 mPa·s) and leveling properties to ensure smooth application. In the casting stage, the coating is extruded onto the casting machine and uniformly spread, creating a layer with precise thickness. Curing takes place at 130°C–170°C, ensuring uniform solidification of the coating. For composite products, the cured film is laminated onto the fabric substrate.
The casting coating process is distinguished by its ability to deliver highly precise coating thickness and a smooth surface finish, making it ideal for high-performance products. Key performance metrics include:
Environmental control is crucial to the coating process， Workshop temperature (20°C–30°C), humidity (50%–70%), and ISO Class 100,000 air cleanliness prevent contamination. Exhaust systems ensure compliance with emission standards, while anti-static devices address coating irregularities. Fire protection, explosion-proof measures, and proper PPE (masks, gloves) ensure operational safety.
The performance of silicone coated fabrics is significantly influenced by the coating process, affecting key properties such as thickness, adhesion, surface smoothness, abrasion resistance, waterproofing, breathability, high-temperature resistance, and flame retardancy.
Knife coating and casting processes are ideal for thick coatings, achieving thicknesses of 100–2,000 µm (0.004–0.08 in). These methods offer exceptional high-temperature resistance (-60°C to 250°C / -76°F to 482°F) and superior flame retardancy (LOI ≥ 30%). Adhesion strength reaches ≥5B (ASTM D3359 standard), with peel strength up to ≥10 N/cm (57 oz/in) and excellent tear resistance, making them suitable for industrial applications. In contrast, the impregnation process enhances the bond between the coating and the fabric fibers, providing superior flexibility for lightweight fabrics, although its high-temperature performance is slightly lower than knife and casting methods.
Roller coating and spray coating produce thinner layers, with thicknesses of 50–500 µm (0.002–0.02 in) and 10–300 µm (0.0004–0.012 in), respectively. These processes focus on improving breathability and surface smoothness, making them ideal for decorative and lightweight applications. Flame retardancy for these processes is moderate, achieving an LOI of 28%–30%.
In terms of high-temperature resistance, casting and knife coating processes excel, making them suitable for applications like high-temperature conveyor belts and industrial protective fabrics. Conversely, the thinner coatings produced by spray and roller processes are better suited for decorative products used in ambient temperature conditions. Flame retardancy is largely determined by coating density, with casting and knife coating delivering outstanding performance (LOI ≥ 30%), meeting UL 94 V-0 standards for industrial fire-resistant materials. Meanwhile, spray and roller coatings are better suited for products with standard fire-resistance requirements.
| Process Type | Coating Thickness | Adhesion (ASTM D3359) | Peel Strength | Abrasion Resistance | Waterproofing | Breathability | High-Temperature Resistance | Flame Retardancy |
| Knife Coating | 100–2,000 µm (0.004–0.08 in) | ≥5B | ≥8 N/cm (45.7 oz/in) | ≥150 cycles | ≥2,000 mm H₂O (78.7 in H₂O) | ≤50 g/m²/24h | -60°C to 250°C (-76°F to 482°F) | LOI ≥ 30% |
| Impregnation | 50–1,000 µm (0.002–0.04 in) | ≥4B | ≥6 N/cm (34.3 oz/in) | ≥100 cycles | ≥1,500 mm H₂O (59.1 in H₂O) | 100–200 g/m²/24h | -50°C to 180°C (-58°F to 356°F) | LOI ≥ 28% |
| Roller Coating | 50–500 µm (0.002–0.02 in) | ≥4B | ≥6 N/cm (34.3 oz/in) | ≥120 cycles | ≥1,500 mm H₂O (59.1 in H₂O) | 50–100 g/m²/24h | -50°C to 200°C (-58°F to 392°F) | LOI ≥ 28% |
| Spray Coating | 10–300 µm (0.0004–0.012 in) | ≥3B | ≥5 N/cm (28.6 oz/in) | ≥80 cycles | ≥1,000 mm H₂O (39.4 in H₂O) | 200–300 g/m²/24h | -40°C to 150°C (-40°F to 302°F) | LOI ≥ 28% |
| Casting | 10–2,000 µm (0.0004–0.08 in) | ≥5B | ≥10 N/cm (57 oz/in) | ≥200 cycles | ≥3,000 mm H₂O (118 in H₂O) | ≤50 g/m²/24h | -60°C to 250°C (-76°F to 482°F) | LOI ≥ 30% |
Technical Parameters Explanation
Silicone-coated fabrics exhibit diverse thickness ranges, performance characteristics, and application areas depending on the coating process used.
| Coating Process | Thickness Range | Coating/Product Type | Application Areas |
| Knife Coating | 100–500 µm (0.004–0.02 in) | Waterproof protective fabric, high-strength outdoor fabric | Outdoor tents, waterproof materials, protective clothing |
| 500–2,000 µm (0.02–0.08 in) | Fire blankets, welding blankets, removable insulation covers, high-temperature sealing pads | Industrial welding protection, high-temperature operations, fireproof systems | |
| Impregnation | 50–200 µm (0.002–0.008 in) | Medical fabrics, protective clothing, lightweight flexible protective fabrics | Healthcare, flexible fabrics, breathable protective materials |
| 200–1,000 µm (0.008–0.04 in) | Fire pit mats, flexible fireproof fabrics, tear-resistant protective fabrics | Outdoor fire pit mats, fire-resistant barriers, industrial flexible protective fabrics | |
| Roller Coating | 50–200 µm (0.002–0.008 in) | Decorative fabrics, outdoor shading fabrics, lightweight industrial fabrics | Decorative materials, outdoor products, lightweight protective applications |
| 200–500 µm (0.008–0.02 in) | Welding habitat systems (tents, covers), lightweight functional protective fabrics | Industrial welding environments, protective and isolation systems | |
| Spray Coating | 10–100 µm (0.0004–0.004 in) | Ultra-thin protective films, highly breathable medical dressings | Highly flexible lightweight materials, medical dressings, breathable protective materials |
| 100–300 µm (0.004–0.012 in) | Flexible decorative fabrics, lightweight protective fabrics, breathable fireproof materials | Healthcare, lightweight protective clothing, flexible decorative materials | |
| Casting | 10–200 µm (0.0004–0.008 in) | High-smoothness industrial films, high-temperature-resistant thin films | High-temperature protective materials, high-smoothness industrial applications, functional coatings |
| 200–2,000 µm (0.008–0.08 in) | High-temperature conveyor belts, airtight materials, fire blankets, removable insulation covers, welding blankets | High-temperature conveyors, fireproof protection systems, high-temperature protection for welding environments, insulation covers |
At Heaterk, we offer a wide range of silicone-coated fabrics tailored to meet diverse industrial needs. Whether your application requires high-temperature resistance, direct flame contact, chemical resistance, or superior abrasion performance, our extensive expertise and industry knowledge provide proven solutions. Let Heaterk's experts guide you with professional recommendations on coating processes and customized solutions. Contact us today to discuss your requirements!
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