Adhesive Thread Drawing Process for Flat Fabric Attachment
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Solution Overview
Problem
Conventional fabric attachment methods, such as gluing or sewing, result in uneven surfaces and increased manufacturing costs due to the need for manual application of adhesives, which can lead to bumps and inefficiencies in attaching fabrics to objects.
Innovation Solution
A thread drawing process involving thermoplastic polyurethane particles mixed with a resin and crosslinker coupler, which are extruded, stretched, and dried to create adhesive threads that can be woven into fabrics, allowing for attachment to objects without additional adhesives through baking or blow baking, ensuring a flat and neat surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional gluing method is used to attach fabric to objects, then attachment is achieved, but the surface becomes uneven with bumps and manufacturing cost increases
Solution Approach 1:
The patent merges the adhesive function with the thread structure itself by incorporating adhesive particles into the thread during manufacturing. This integration eliminates the need for separate glue application steps, ensuring uniform adhesive distribution throughout the fabric while maintaining surface flatness and reducing manufacturing costs.
Solution Approach 2:
The adhesive particles are pre-mixed with the threads during thread manufacturing, performing the adhesive preparation action in advance. This preliminary action ensures that when the fabric is later attached to objects, the adhesive is already uniformly distributed and ready for application, eliminating surface bumps caused by uneven glue application.
2Productivity
If manual glue application is used to attach fabric, then attachment is achieved, but manufacturing time increases
Solution Approach 1:
By combining the adhesive material with the thread structure during manufacturing, the patent eliminates the separate steps of glue application and drying. The adhesive is already integrated into the threads, so when fabric is attached to objects, the adhesive is immediately available for bonding without requiring additional drying time.
Solution Approach 2:
The threads themselves provide the adhesive function through the incorporated adhesive particles, making the threading system self-sufficient. The adhesive is built into the thread structure, allowing the fabric to attach to objects directly without requiring external glue application and subsequent drying periods.
3Manufacturing precision
If multiple fabric pieces are connected by gluing or sewing, then fabric assembly is achieved, but bumps and uneven surfaces appear at boundaries
Solution Approach 1:
The patent merges the adhesive function into the thread structure itself, allowing multiple fabric pieces to be connected through the adhesive threads rather than separate gluing or sewing operations. This integration ensures uniform adhesive distribution across all fabric boundaries, eliminating bumps and surface irregularities while simplifying the assembly process.
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
The process enables fabric attachment to objects without the need for extra glue or sewing, maintaining a flat and neat surface, thereby reducing manufacturing costs and time while enhancing attachment strength and aesthetics.
Implementation Method 1
melting the thermoplastic polyurethane particles
Implementation Method 2
extruding yarns from an outlet of the thread drawing machine, the thermoplastic polyurethane particles being melted and coated to the outer periphery of the yarn
Implementation Method 3
passing the preliminary thread through a cooling tank so as to shape the surface of the preliminary thread
Implementation Method 4
passing the cooled preliminary thread through a stretching area to perform a stretch extension, wherein the stretching area includes a plurality of rollers, the rollers are disposed with an interval apart from each other and arranged in rows, and the preliminary thread is driven by each roller, so that the preliminary thread is stretched
Implementation Method 5
entering the preliminary thread processed by the step of stretch extension into an cooling area which is located next to the stretching area, and the preliminary thread being cooled to reduce surface deformation and to fix the interior of the preliminary thread
Implementation Method 6
drying the thermoplastic polyurethane particles to remove excess water by a dryer
Data Source
AI summary
The adhesive thread drawing processes include the steps of feeding, mixing and stirring, first drying, hot melt extrusion, first cooling, stretch extension, second cooling, winding-strands-into-roll, and second drying. The threads made by the processes are woven into fabric which has a certain level of stickiness so as to be attached onto objects without using glue and adhesive, and the fabric is flat and neat when it is attached to an object.