Biopolyamide Bielastic Fabric With Low-Temperature Heat-Setting
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Solution Overview
Problem
The textile industry faces challenges in reducing environmental impact and energy consumption while maintaining excellent fabric qualities, particularly in the production of elastic fabrics.
Innovation Solution
A bielastic fabric comprising biopolyamide yarn derived from castor seed and elastane yarn, produced through a process involving circular knitting and heat-setting at reduced temperatures, achieving high elasticity and dimensional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If conventional heat-setting temperatures and processes are used, then fabric dimensional stability is achieved, but energy consumption increases
Solution Approach 1:
The patent modifies the heat-setting parameters by using reduced temperatures (100-150°C instead of conventional higher temperatures) and extended time periods (5-30 minutes instead of shorter durations). This parameter change allows achieving dimensional stability while significantly reducing energy consumption in the heat-setting process.
Solution Approach 2:
The patent applies preliminary mechanical pre-setting through controlled tensioning and stretching of the fabric before the heat-setting process. This preliminary action prepares the fabric structure to require less thermal energy to achieve final dimensional stability, thereby reducing overall energy consumption.
2Object-generated harmful factors
If biopolyamide yarn is used instead of conventional yarn, then environmental impact is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent modifies manufacturing parameters including reduced heat-setting temperatures (100-150°C), adjusted moisture content (4-12%), and controlled tensioning forces during knitting. These parameter changes make the processing of biopolyamide yarn more manageable and less complex while maintaining environmental benefits.
Solution Approach 2:
The biopolyamide yarn exhibits self-setting properties during the knitting process itself, where the mechanical action of knitting contributes to dimensional stabilization. This self-service characteristic reduces the complexity of additional processing steps required for conventional yarns.
3Use of energy by stationary object
If reduced heat-setting temperature is used, then energy consumption is reduced, but elastic properties may be compromised
Solution Approach 1:
The fabric undergoes preliminary mechanical pre-setting through controlled tensioning and stretching at low temperatures before heat-setting. This preliminary action prepares the elastane fibers to achieve optimal elastic recovery without requiring high thermal energy, thus preserving elastic properties while reducing energy consumption.
Solution Approach 2:
The patent employs dynamic control of the heat-setting process with gradual temperature increase and maintained tensioning throughout the treatment. This dynamic approach ensures elastic properties are properly set even at reduced temperatures, preventing compromise of fabric elasticity.
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 bielastic fabric exhibits excellent elastic properties and high dimensional stability with reduced energy consumption and environmental impact, suitable for clothing and furniture items.
Implementation Method 1
contacting the circular knit, elastic, single jersey fabric with a continuous phase aqueous solution under conditions of temperature and pressure and for a period of time sufficient to substantially set the elastomeric material
Implementation Method 2
a bielastic fabric comprising biopolyamide yarn and elastane yarn, having excellent elastic properties and high dimensional stability
Data Source
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AI summary
There are described a bielastic fabric comprising biopolyamide yarn and elastane yarn, having excellent elastic properties and high dimensional stability, and a cost-effective, efficient process for obtaining it.