Industrial Two-Layered Fabric Warp Diameter Balance
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Solution Overview
Problem
Industrial two-layered fabrics face challenges in maintaining surface smoothness and durability due to imbalanced warp and weft diameters, leading to wear resistance issues and potential cutting of warps, which deteriorate the fabric's performance.
Innovation Solution
The fabric is designed with all upper surface side warps having the same diameter, and all lower surface side warps having the same larger diameter, with some upper surface side warps woven with lower surface side wefts as binding yarns to improve balance and prevent warp cutting, while maintaining uniform surface smoothness and marking characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the diameter of lower surface side wefts is increased to improve wear resistance, then wear resistance is improved, but the balance of the lower surface side fabric layer is worsened
Solution Approach 1:
The patent applies local quality by differentiating the diameter specifications between upper surface side yarns and lower surface side yarns. Specifically, lower surface side warps and wefts have larger diameters (0.15-0.30mm) compared to upper surface side yarns (0.05-0.20mm), optimizing each layer for its specific functional requirements while maintaining overall fabric balance
2Duration of action of stationary object
If the diameter of lower surface side warps is increased to improve wear resistance and prevent cutting, then durability is improved, but the surface smoothness is deteriorated due to undulation
Solution Approach 1:
The patent implements local quality by assigning different diameter characteristics to different fabric layers. The lower surface side warps have larger diameters (0.15-0.30mm) for enhanced durability and cut resistance, while the upper surface side warps have smaller diameters (0.05-0.20mm) to maintain surface smoothness and prevent undulation
Solution Approach 2:
The patent applies asymmetry by creating an intentional diameter difference between the two fabric layers. The lower surface side yarns are systematically designed with larger diameters than the upper surface side yarns, creating an asymmetric structure that optimizes each layer for its specific function while maintaining overall fabric performance
3Manufacturing precision
If the number of yarns is increased and diameter is reduced to improve surface smoothness, then surface smoothness is improved, but the fabric strength and durability are reduced
Solution Approach 1:
The patent applies segmentation by dividing the fabric into two distinct layers with different yarn diameter characteristics. The upper surface side layer uses finer yarns for smoothness, while the lower surface side layer uses coarser yarns for strength, allowing each layer to be optimized independently for its specific functional requirements
4Manufacturing precision
If the diameters of upper surface side warps and wefts are reduced to improve surface smoothness, then surface smoothness is improved, but the hydration property is decreased
Solution Approach 1:
The patent implements local quality by creating different yarn diameter specifications for upper and lower surface sides. The lower surface side yarns with larger diameters (0.15-0.30mm) provide the necessary hydration property and structural support, while the upper surface side yarns with smaller diameters (0.05-0.20mm) deliver the required surface smoothness
Data Source
AI summary
[Task] The object of the present invention is to provide an industrial two-layered fabric with a long durability which exhibits an excellent surface smoothness and excellent marking characteristics, while at the same time improving wear resistance characteristics to balance warps and wefts.[Solution to the Task] An industrial two-layered fabric formed by binding yarns, diameters of all of the upper surface side warps are set to be the same, diameters of all of the lower surface side warps are set to be the same, diameters of the lower surface side warps are set to be larger than diameters of said upper surface side warps, and at least one, or more than one of said upper surface side warps are woven with said lower surface side wefts to constitute binding yarns binding said at least one upper surface side fabric and said at least one lower surface side fabric.