Metal Element Textile Widthwise Stability via Knit Binding
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Solution Overview
Problem
Conventional metal element based textile products face issues with stability and impregnation during processing, leading to inferior performance in reinforced articles due to the shielding effect of added yarns, which reduces adhesion and impact resistance.
Innovation Solution
A textile product with elongate metal elements held in a parallel array by stitches that encase each metal element between the legs and underlap of the stitch, providing widthwise stability and improved integration, and optionally incorporating additional fiber layers bound by the same or separate stitches, using techniques like mono-axial warp knitting or bi-axial warp knitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a parallel roving or higher tex value yarn is added to bind metal cords, then the preload tension and widthwise stability are improved, but the free reachable surface of metal cord is reduced, resulting in inferior impregnation, less adhesion and reduced impact resistance
Solution Approach 1:
The patent introduces a knit fabric as an intermediary binding mechanism between metal cords. The knit fabric acts as a mediator that provides widthwise stability through its elastic recovery properties while maintaining open spaces between metal cords, thus preventing the shielding effect and ensuring good impregnation quality without requiring additional parallel rovings.
Solution Approach 2:
The patent employs a knit fabric (thin film structure) to bind metal cords. The knit fabric provides flexible binding that maintains the metal cords in a parallel arrangement while allowing polymer impregnation to reach between the cords effectively, avoiding the blocking effect caused by traditional parallel rovings.
2Force
If a parallel roving or higher tex value yarn is added to bind metal cords, then the preload tension is increased, but the impact resistance is reduced due to the shielding effect
Solution Approach 1:
The knit fabric serves as an intermediary that distributes preload tension across multiple metal cords through its elastic network, maintaining adequate tension without creating a shielding effect that would block polymer impregnation and reduce impact resistance.
Solution Approach 2:
The flexible knit fabric structure provides tension distribution while maintaining open spaces, allowing impact forces to be distributed effectively and enabling polymer to reach between metal cords for proper adhesion and impact resistance.
3Stability of the object's composition
If metal cords are held firmly to prevent movement, then widthwise stability is improved, but the integration with polymer matrix is reduced, affecting adhesion
Solution Approach 1:
The knit fabric acts as an intermediary that holds metal cords in position while maintaining open spaces between them. This allows polymer to penetrate and bond with metal cords effectively, achieving both position stability and good adhesion without the metal cords being overly constrained.
Data Source
AI summary
A textile product and a method of making the same is described wherein the textile product includes a layer of metal elements, an array of stitches, and wherein the metal elements are encased between the legs of the stitch and the underlap of the stitch. Preferably, the overlaps and/or underlaps span between at least two stitch lines. This provides an improved metal element based textile product for preparing reinforced articles. The metal element based textile product of the present invention allows improved processing and improved performance as compared to conventional metal element based textile products.