Bidirectional Low Tearing Spacer Textile via Warp Knitting
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Solution Overview
Problem
Conventional 3D warp knitting products used in airbag deployment lines face issues with uneven tearing properties in longitudinal and transverse directions, leading to difficulty in achieving required tearing strength and excessive adhesive consumption due to large loop gaps.
Innovation Solution
A spacer textile with a surface and rear textile layer connected by a spacer thread, featuring open loops in the main thread for longitudinal direction and closed loops with mono yarn for transverse direction, allowing for easy rupture and reduced adhesive usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional 3D warp knitting structure is used, then cushioning feeling is achieved, but tearing strength is insufficient in both longitudinal and transverse directions
Solution Approach 1:
The textile structure is segmented into two functional components: main threads forming open loops for longitudinal direction and additional monofilament threads forming closed loops for transverse direction. This segmentation allows each component to specialize in providing strength in its respective direction without compromising the cushioning properties of the overall structure.
Solution Approach 2:
The invention uses a composite thread system combining different thread types (main threads and additional monofilament threads) with distinct structural characteristics. The main threads provide open loop structure for longitudinal flexibility, while additional threads provide closed loop structure for transverse strength, creating a composite textile with balanced bidirectional tearing resistance.
2Loss of substance
If conventional warp knitting with large loop gaps is used, then manufacturing is simplified, but adhesive consumption increases due to excessive adhesive seeping through gaps
Solution Approach 1:
The textile structure implements local quality by creating regions with different loop characteristics. The closed loops formed by additional monofilament threads in specific areas reduce adhesive seepage locally, while maintaining the overall simplicity of the warp knitting manufacturing process. This localized structural modification targets adhesive consumption without complicating the entire manufacturing system.
3Strength
If uniform thread structure is used in both longitudinal and transverse directions, then manufacturing is simplified, but tearing properties become uneven between directions
Solution Approach 1:
The invention deliberately introduces asymmetry in the thread structure by using different thread configurations for longitudinal and transverse directions. Main threads with open loops dominate the longitudinal structure, while additional monofilament threads with closed loops reinforce the transverse structure. This asymmetric design creates uniform bidirectional tearing strength despite the structural differences.
Solution Approach 2:
The solution adds a dimensional aspect to the thread structure by introducing additional threads that cross-connect wales in the transverse direction. This creates a three-dimensional reinforcement system where the additional threads form closed loops that intersect with main threads, adding structural complexity only where needed for transverse strength.
Data Source
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AI summary
The present invention relates to a bidirectional low tearing strength spacer textile using warp knitting, more particularly, relates to a spacer textile comprising a surface textile layer, a rear surface textile layer, and a spacer thread connecting the textile layers, wherein the surface textile layer and the rear surface textile layer include a main thread provided with a plurality of open loops formed with openings in a longitudinal direction.