Lightweight Compounded Uni-Directional Cloth by Selective Adhesive Removal
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Solution Overview
Problem
Existing uni-directional cloths used in safety protection applications have insufficient weft-direction strength due to excessive adhesive film layers, making it difficult to reduce product weight and enhance strength.
Innovation Solution
A method involving hot pressing two uni-directional cloths with non-parallel yarn layers and peeling off one adhesive film layer, followed by heating and pressing multiple layers to fuse the yarns, while removing additional adhesive film layers to form a lightweight compounded uni-directional cloth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple layers of uni-directional cloths are laid up and compounded to strengthen the product, then the strength in various directions is improved, but the number of adhesive film layers increases excessively, making it difficult to reduce the weight of the product
Solution Approach 1:
The invention extracts and removes the adhesive film layer from one side of the compounded uni-directional cloth after hot pressing. This selective removal reduces the total adhesive content and product weight while maintaining the structural integrity and strength benefits of the multi-layer compounding process
Solution Approach 2:
The invention changes the physical state of the adhesive film layer by heating the semi-finished product to a temperature where the adhesive becomes soft or melts, enabling the adhesive film to be peeled off easily without damaging the yarn layers, thus facilitating weight reduction
2Ease of manufacture
If a single uni-directional cloth is used with yarn layer and adhesive film layer, then the manufacturing process is simple, but the weft-direction strength is insufficient
Solution Approach 1:
The invention merges multiple uni-directional cloths with different yarn directions through hot pressing compounding. By combining layers with orthogonal or non-parallel yarn orientations, the product achieves enhanced strength in multiple directions while maintaining manufacturing efficiency through a integrated hot pressing process
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 method significantly reduces product weight and enhances strength and toughness, improving practicability and competitiveness by reducing adhesive usage and maintaining high strength.
Implementation Method 1
hot pressing the two uni-directional cloths with the yarn layers facing each other to form a semi-finished product
Implementation Method 2
heating the semi-finished product, and peeling off the adhesive film layer on one side of the semi-finished product
Implementation Method 3
the semi-finished product may be conveyed through a stripping roller, so that the adhesive film layer on one side of the semi-finished product is peeled off by the stripping roller
Implementation Method 4
the semi-finished product may be conveyed through a space between a hot glue roller and a guide roller, so that one side of the semi-finished product is heated by the hot glue roller
Implementation Method 5
overlapping and conveying a plurality of lightweight compounded uni-directional cloths through a heating area to heat and press the plurality of lightweight compounded uni-directional cloths in the heating area, and then conveying the lightweight compounded uni-directional cloths through a cooling area so as to discharge a pressed product after cooling
Data Source
AI summary
A method for manufacturing a lightweight compounded uni-directional cloth is presented, includes: providing two uni-directional cloths, and each of the uni-directional cloths has a yarn layer and an adhesive film layer; hot pressing the two uni-directional cloths with the yarn layers facing each other to form a semi-finished product, the yarn directions of the two yarn layers being not parallel; and heating the semi-finished product, and peeling off the adhesive film layer on one side of the semi-finished product to obtain a lightweight compounded uni-directional cloth. A system for implementing the above-mentioned method is also presented.