Conjugate Yarn Fleece Fabric Segmentation for Handling
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Solution Overview
Problem
Fleece fabrics are bulky, difficult to handle, and have issues with the longevity of their nap, which affects their appearance and functionality, with existing production processes being expensive and inefficient.
Innovation Solution
A woven fabric is created using conjugate yarns made of splittable filaments, where the sub-filaments are woven to form loops that can be broken to create a fleece effect, providing improved thermal insulation and a softer, more versatile fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional fleece fabric with deep pile is used, then thermal insulation is improved, but fabric bulkiness increases making it difficult to handle
Solution Approach 1:
The patent segments the pile structure by using cut piles instead of continuous deep nap, creating shorter, discrete fiber segments that reduce bulkiness while maintaining insulation properties through increased surface area and air trapping capability
Solution Approach 2:
The patent changes the pile length parameter from deep continuous nap to shorter cut piles, and modifies the weave structure from traditional tight weaves to open weaves, creating a balance between insulation performance and fabric flexibility for easier handling
2Temperature
If deep pile is used to enhance fleece appearance, then insulating properties are improved, but nap wear resistance deteriorates
Solution Approach 1:
The patent divides the continuous pile into shorter cut pile segments, which reduces the leverage and stress on individual fibers during wear, thereby improving nap durability while maintaining adequate insulation through the distributed pile structure
Solution Approach 2:
The patent uses a higher density of shorter piles rather than fewer long piles, creating an excessive number of fiber endpoints that collectively provide both insulation and wear resistance through redundancy and distributed load bearing
3Quantity of substance
If traditional fleece production process is used, then fleece fabric is produced, but production cost increases and efficiency decreases
Solution Approach 1:
The patent incorporates the pile formation and cutting steps directly into the weaving process itself, performing preliminary actions during fabric construction rather than requiring separate post-weaving operations, thereby streamlining production and reducing overall manufacturing time and cost
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 fabric achieves a natural and uniform fleece appearance, enhanced thermal insulation, and a higher specific surface area, allowing for better allergen barrier properties and efficient delivery of cosmetic or drug microcapsules, while being easier and less expensive to produce.
Implementation Method 1
the filaments are split, so that they provide a fleece on the side of the fabric where the loops are located
Implementation Method 2
The fleece fabrics have insulating air space and are relatively light
Data Source
Figure 1~2
Figure 2A~2F
Figure 3~4B
AI summary
A fabric (1) having a first side (1a) and a second side (1b) and comprising weft yarns (2, 3) and warp yarns (4) woven together in pattern; at least some of the weft, or warp, yarns (2, 3, 4) float over a number of warp yarns (4), or weft yarns (2, 3), and below a number of warp yarns (4), or weft yarns, (2, 3) to provide weft, or warp, over portions (2a, 3a) in said first side and under portions (2b, 3b) in said second side (1b). The under portions (2b, 3b) and/or over portions (2a, 3a) of the yarns provide loops (5), and at least some of said yarns (2, 3, 4) providing loops (5) are conjugate yarns (2) comprising a plurality of filaments (6) splittable into sub-filaments (6a) and in that said loops (5) of the conjugated yarns (2) extend for a length of at least three adjacent warp, or weft, yarns.