Interwoven Double-Layer Turf Backing for Wrinkle-Free Tufting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing artificial grass carpets with double primary backing layers often result in variable tension and fabric differences between layers, leading to dimensional instability and wrinkles during the tufting and adhesive coating processes, and require multiple process steps and energy consumption.
Innovation Solution
A weaving process that simultaneously interweaves two layers of polypropylene primary backing fabric on a single loom, eliminating tension differences and reducing process steps by producing a composite double layer woven product in one step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If two separate layers of primary backing are used and held together during tufting, then increased carpet strength and dimensional stability are achieved, but variable tension and fabric differences between layers cause wrinkles and dimensional instability
Solution Approach 1:
The patent merges two separate primary backing layers into a single integrated woven fabric structure. The fabric is constructed with first and second sets of warp threads interwoven with weft threads to form a unified double-layer structure, eliminating the interface between separate layers and preventing tension differential issues while maintaining enhanced strength properties.
2Reliability
If two separate primary backing layers are used, then higher tuft anchorage is achieved, but multiple process steps and energy consumption increase
Solution Approach 1:
The patent combines the function of two separate primary backing layers into a single woven fabric produced in one manufacturing process. The integrated structure provides enhanced tuft anchorage through its construction with multiple sets of warp threads, while eliminating the need for separate layer handling, alignment, and bonding processes that would increase device complexity and energy consumption.
3Stability of the object's composition
If two separate primary backing layers are used, then increased dimensional stability is achieved, but tension differences between layers cause wrinkles during production
Solution Approach 1:
The patent integrates two layers into a single woven fabric where first and second sets of warp threads are interwoven together with weft threads during the weaving process. This unified construction ensures uniform tension distribution throughout the fabric, preventing wrinkles while maintaining enhanced dimensional stability, as there is no interface between separate layers where tension differential could occur.
Data Source
Figure 1~5
Figure 6~7
Figure 8(a)~8(b)
AI summary
There is disclosed a woven product (5) adapted to be used as a primary backing layer for a surface, ground or floor covering comprising artificial or synthetic grass or turf. The woven product (5) comprises at least a first woven layer (10) and a second woven layer (15), wherein the first and second woven layers (10, 15) are interwoven, the first woven layer (10) comprises a plurality of warp tapes/threads (25) and a plurality of weft tapes/threads (30), the warp tapes/threads (25) and the weft tapes/threads (30) of the first woven layer (10) being substantially perpendicular to one another. The second woven layer (15) comprises a plurality of warp tapes/threads (35) and a plurality of weft tapes/ threads (40), the warp tapes/threads (35) and the weft tapes/threads (40) of the second woven layer (15) being substantially perpendicular to one another. The warp tapes/threads (25, 35) of the first and second woven layers (10, 15) are substantially parallel to one another. The weft tapes/threads (30, 40) of the first and second woven layers (10, 15) are substantially parallel to one another. Each interwoven portion or area comprises one or more of: a weft tape(s)/thread(s) (40) of the first woven layer (10) and a transversely coincident weft tape(s)/thread(s) (40) of the second woven layer (15) which are passed over both a warp tape(s)/thread(s) (25) of the first woven layer (10) and a longitudinally coincident warp tape(s)/thread(s) (35) of the second woven layer (15); and an adjacent weft tape(s)/thread(s) (35) of the first woven layer (10) and an adjacent and transversely coincident weft tape(s)/thread(s) (40) of the second woven layer (15) which are passed under both said warp tape(s)/thread(s) (25) of the first woven layer (10) and said longitudinally coincident warp tape(s)/thread(s) (35) of the second layer (15).