Engineered Non-Woven Textile With Bonded Yarns for Load Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional textile manufacturing methods result in suboptimal material properties for functional apparel and footwear, leading to increased material usage, waste, and weight due to the need for secondary reinforcement to meet specific performance requirements, which are not adequately addressed by generic yarn structures.
Innovation Solution
The development of engineered textiles with oriented yarn strands bonded by a polymeric material, allowing for tailored directional elasticities and strengths to meet specific functional demands, reducing the need for additional reinforcement and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional woven or knitted fabric structures are used to provide sheet integrity, then the fabric maintains structural stability, but the material usage increases and waste is generated due to suboptimal structural arrangement for functional demands
Solution Approach 1:
The fabric structure is segmented into discrete functional elements (yarn strands, stitches, knots) that can be independently optimized. Instead of using a uniform woven or knitted structure throughout, the invention applies specific structural elements only where needed to provide sheet integrity, allowing other areas to use minimal material configurations that meet functional demands.
Solution Approach 2:
The invention applies different structural qualities to different locations within the fabric. High-strength yarn strands and dense stitching are concentrated in areas requiring structural support, while areas requiring flexibility or elasticity use minimal or no traditional fabric structure. This local optimization eliminates the need for uniform over-engineering throughout the entire fabric sheet.
2Strength
If secondary structure (reinforcing cables, additional fabric sections) is applied to meet functional strength and elasticity requirements, then the performance demands are satisfied, but the weight and material usage increase
Solution Approach 1:
The invention merges the functions of primary fabric structure and secondary reinforcement into a single integrated system. The yarn strands that form the basic fabric structure are simultaneously optimized to provide the necessary strength and elasticity properties, eliminating the need for separate reinforcing cables or additional fabric sections. The bonding agent integrates multiple structural elements into a unified load-bearing system.
Solution Approach 2:
The invention uses composite material structures combining different types of yarns (elastic, non-elastic, varying deniers) bonded together with adhesive agents. This composite approach allows the fabric to achieve required strength and elasticity properties through the synergistic combination of materials rather than adding weight through separate reinforcement layers.
3Ease of manufacture
If generic yarn structures are used in pre-produced fabrics, then the manufacturing process is simplified, but the specific performance requirements for functional apparel cannot be adequately met
Solution Approach 1:
The invention introduces dynamic adaptability into the fabric structure by allowing yarn strand characteristics (type, orientation, density, elasticity) to vary throughout the fabric based on functional demands. Rather than using a static, uniform yarn structure, the system can be configured with different yarn properties in different regions to meet specific performance requirements while maintaining a relatively simple bonding process.
Solution Approach 2:
The invention changes key parameters of the yarn structure (orientation, density, elasticity, denier) to optimize performance for specific functional requirements. By varying these parameters within the bonding framework, the fabric can be tailored for different applications (compression, flexibility, strength) without fundamentally changing the manufacturing process or adding complex secondary structures.
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 enables lighter, more optimized textile structures with reduced material usage and waste, providing enhanced design freedom and improved performance in functional apparel and footwear by aligning yarn strands with expected load paths.
Implementation Method 1
adjacent ones of the plurality of arranged yarn strands are bonded together with an overlaid bonding material to form a bound plurality of arranged yarn strands
Data Source
AI summary
A method of creating an engineered textile includes placing a yarn-wound jig on an upper surface of a substrate, selectively printing or extruding a bonding material across the plurality of arranged yarn strands, solidifying the bonding material to bond adjacent ones of the plurality of arranged yarn strands together and form a bound plurality of arranged yarn strands, and removing the bound plurality of arranged yarn strands from the substrate and the frame.