Elastic Needled Belt Structure for Smooth Textile Compacting
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Solution Overview
Problem
Existing textile machine belts used for compacting knitted fabrics face issues with surface irregularity and reduced durability due to alternating compressing and stretching, leading to marking on processed cloths and shorter service life, especially when wrapped around rolls of varying diameters and exposed to chemical residues.
Innovation Solution
A multi-base needled belt with an elastic base layer constructed from flat-woven elastic fibers, coated with polymeric resin, and reinforced with batt fibers on both sides, allowing for consistent stretching and compressing without surface irregularity, and protected from damage through composite yarn construction and polymeric coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the belt is made thick to provide durability and structural integrity, then strength is improved, but the belt becomes prone to surface irregularity and marking when wrapped around rolls of varying diameters
Solution Approach 1:
The patent applies parameter changes by incorporating elastic fibers (such as spandex or elastane) into the belt construction, changing the material properties from rigid to elastic. This allows the belt to dynamically adjust its thickness and surface characteristics during operation, maintaining surface consistency while wrapped around rolls of varying diameters while still providing the necessary strength and durability.
Solution Approach 2:
The patent uses composite materials by combining elastic fibers with traditional belt materials. This creates a multi-component structure where the elastic fibers provide flexibility and surface consistency, while the base materials provide structural integrity and strength, resolving the contradiction between durability and surface quality.
2Adaptability or versatility
If the belt undergoes alternating compressing and stretching to wrap around rolls, then adaptability is improved, but the external product side surface becomes irregular and cracked
Solution Approach 1:
The patent changes the material parameters by incorporating elastic fibers that can dynamically adjust their physical state during compression and stretching. These fibers maintain their integrity through repeated cycles of deformation, preventing surface irregularity and cracking while allowing the belt to adapt to varying roll diameters and operational conditions.
Solution Approach 2:
The elastic fibers act as a cushioning mechanism that anticipates and absorbs the stresses of alternating compression and stretching. By incorporating these fibers beforehand, the belt is pre-equipped to handle the mechanical stresses without developing surface defects, maintaining reliability during repetitive use.
3Strength
If the belt is made from traditional materials like polyamide and polyester, then strength is improved, but the belt loses surface smoothness and develops cracks under repetitive stress
Solution Approach 1:
The patent applies composite materials by integrating elastic fibers into the traditional polyamide and polyester construction. This creates a hybrid structure where the conventional materials provide baseline strength and the elastic fibers provide fatigue resistance and surface stability, extending service life while maintaining strength requirements.
Solution Approach 2:
The patent changes the material composition parameters by adding elastic components to the traditional belt materials. This modification allows the belt to maintain its strength while gaining the ability to withstand repetitive stress without developing cracks or losing surface smoothness, thereby extending operational lifespan.
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 belt maintains surface consistency and flexibility, reducing marking on textiles and extending service life by accommodating repetitive stress and chemical exposure, while being producible through various textile methods.
Implementation Method 1
the elasticity of the instant belt derives from the use of elastic fibers in the flat woven elastic base layer. Hence, the instant belt can be produced using a variety of textile methods... the elastic base layer of the instant belt is flat woven with elastic fibers... the belt maintains surface consistency and flexibility, reducing marking on textiles and extending service life by accommodating repetitive stress
Implementation Method 2
batt fibers that are needled from an exterior surface of each base layer, into both base layers
Implementation Method 3
constructed from flat-woven elastic fibers, coated with polymeric resin, and reinforced with batt fibers on both sides, allowing for consistent stretching and compressing without surface irregularity, and protected from damage through composite yarn construction and polymeric coatings
Data Source
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AI summary
A multi-base needled belt having an elastic surface comprising a conventional base layer (14), an elastic base layer (16) and at least two batt layers (18, 20) needled into both base layers in order to join the base layers to each other, wherein the belt's elasticity derives from elastic fibers that are used to construct the elastic layer.