Differential Tenter Frame for Balanced Shifted-Angle Fabric
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Solution Overview
Problem
Conventional methods for producing shifted angle fabrics result in unbalanced crimp and elongation properties, with variations across the fabric width, and require expensive custom-made equipment, limiting their applicability.
Innovation Solution
A differential tenter frame with opposed, constant path rails and a variable speed differential drive is used to advance fabric edges at different speeds, combined with a high velocity, low heat drying range to shift the weft angle and dry the fabric simultaneously, producing a balanced crimp and elongation in both warp and weft directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional angled and tapered rollers are used to shift the fabric, then the fabric can be shifted to a different angle, but the crimp and elongation properties become unbalanced and vary across the fabric width
Solution Approach 1:
The fabric width is divided into multiple zones with different rail speeds. The differential drive system segments the fabric handling into distinct velocity zones, allowing precise control of weft yarn shifting in different fabric regions to achieve balanced crimp distribution
Solution Approach 2:
The system uses variable speed differential drive to dynamically adjust the speed of opposing rails during fabric processing. This dynamic speed variation allows the fabric to be shifted to the desired angle while maintaining balanced crimp and elongation properties throughout the fabric width
2Manufacturing precision
If custom-made tenter frame with curved rails is used, then balanced crimp can be achieved, but the equipment cost increases significantly and cannot process other fabric types
Solution Approach 1:
The differential tenter frame system is designed to process multiple fabric types and configurations by adjusting rail speeds and differential drive parameters. The same equipment can handle various fabric widths, materials, and desired shift angles without custom modification, providing universal applicability
Solution Approach 2:
The system achieves different fabric shifting angles and crimp patterns by changing operational parameters such as rail speed ratios, differential drive settings, and processing velocities. This parameter-based control allows a single equipment configuration to produce multiple fabric outcomes
3Shape
If fabric is shifted using conventional methods, then the angle can be changed, but variations in crimp and elongation occur at different points across the fabric width
Solution Approach 1:
Different sections of the fabric width are subjected to different rail speeds, creating local quality variations in the shifting process. This allows each fabric region to achieve the optimal crimp and elongation characteristics while maintaining the overall desired fabric angle
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 solution achieves a shifted angle fabric with balanced crimp and elongation properties, reducing variations across the fabric width and eliminating the need for custom-made equipment, enhancing the fabric's performance and versatility.
Implementation Method 1
A high velocity, low heat drying range adjacent to the differential tenter frame simultaneously dries the fabric as the fabric travels the length of the differential tenter frame
Data Source
AI summary
An apparatus and method for producing a shifted angle fabric and the product produced thereby. The apparatus includes a supply of fabric and a differential tenter frame. The differential tenter frame includes a frame, a pair of opposed, constant path rails and a differential drive. The differential tenter frame is located downstream from the supply of fabric for receiving the opposing edges of the fabric and advancing the opposing edges at different speeds to shift the weft angle of the fabric as the fabric travels the length of the differential tenter frame. A high velocity, low heat drying range adjacent to the differential tenter frame simultaneously dries the fabric as the fabric travels the length of the differential tenter frame. A take-up roll downstream from the differential tenter frame then takes up the dried fabric.