A method to manufacture a textile product, a use thereof and a device for applying the method
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Solution Overview
Problem
Existing methods for manufacturing textile products with polymer yarns face challenges such as inefficient heat distribution, mechanical stress on the backing sheet, and uneven melting, leading to inhomogeneous products and increased energy consumption.
Innovation Solution
A method using a stationary, curved, rigid heating plate with a surface roughness above 1 µm, allowing for even contact and heat distribution, and optional features like variable contact length, pressure elements, and a calendering nip to ensure consistent melting and binding of yarns, while minimizing mechanical stress and optimizing heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a conventional heating roller is used to melt the yarns, then the yarns are heated and anchored to the sheet, but the heat distribution is inefficient and energy consumption is high
Solution Approach 1:
The heating element is designed as a curved plate rather than a conventional cylindrical roller. This curved geometry provides optimal contact surface area with the textile sheet while maintaining structural rigidity, enabling more efficient heat distribution across the heating zone and reducing energy consumption.
Solution Approach 2:
The invention replaces the conventional rotating heating roller with a stationary curved heating plate. This substitution eliminates the mechanical complexity of rotation while maintaining effective heat transfer through optimized geometric contact, improving both energy efficiency and heat distribution reliability.
2Manufacturing precision
If pressure is applied to press the sheet against the heating element, then the contact between sheet and heating element is improved, but mechanical stress on the backing sheet increases
Solution Approach 1:
The curved geometry of the heating plate naturally conforms to the sheet, creating uniform contact across the heating zone without requiring excessive pressing force. This geometric adaptation ensures consistent thermal contact while minimizing mechanical stress on the backing sheet.
3Device complexity
If the heating element is a flat plate, then the structure is simple, but the contact with the sheet is uneven leading to inhomogeneous heating
Solution Approach 1:
The heating element employs a curved plate design that provides optimal contact surface area and uniform pressure distribution across the textile sheet. This curved geometry ensures homogeneous heating throughout the treatment zone while maintaining relatively simple structural construction.
4Use of energy by moving object
If a stationary curved heating plate is used, then heat distribution is improved and energy consumption is reduced, but the device complexity increases
Solution Approach 1:
The curved plate geometry achieves superior heat distribution and energy efficiency through its optimized contact surface, while remaining a stationary component that does not require complex mechanical systems for actuation or control.
Solution Approach 2:
By replacing the rotating roller mechanism with a stationary curved plate, the invention eliminates mechanical complexity associated with rotation while achieving improved thermal performance through geometric optimization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a more efficient, scalable, and durable textile product with improved anchoring of yarns, reduced energy consumption, and enhanced surface texture homogeneity, suitable for various textile applications.
Implementation Method 1
heating the second surface with the heating element to at least partly melt the loops of the yarns to fasten the yarns to the sheet
Implementation Method 2
melt the loops of the yarns to fasten the yarns to the sheet
Implementation Method 3
transporting the sheet in contact with the heating element... heating the second surface with the heating element
Data Source
Figure 1~2
Figure 3
AI summary
The present invention pertains to a method to manufacture a textile product comprising a first sheet having a width and a length, and polymer yarns fastened to this sheet to form a pile thereon, the method comprising providing the sheet, stitching the polymer yarns through the sheet to form the pile on a first surface of the sheet and loops of the yarns at a second surface of the sheet, transporting the sheet in a direction parallel to its length along a heating element, the heating element being directed to the second surface of the sheet, heating the second surface with the heating element to at least partly melt the loops of the yarns to fasten the yarns to the sheet, wherein the method comprises transporting the sheet in contact with the heating element, wherein the heating element is a stationary rigid plate-like element having a width corresponding to the width of the sheet, and a length that extends parallel to the length of the sheet, the plate being curved in its length direction, wherein the outer circumference of the plate is contacted with the sheet. The invention also pertains to a method to use a textile product obtained with the new method and a device for applying the said method.