Method for manufacturing cleaning cloth
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional cleaning cloths made of knitted cotton shrink upon drying and form tangled hair balls, making them difficult to dry and lay flat, leading to reduced aesthetic quality and increased replacement costs.
Innovation Solution
A method involving high-density weaving, scouring, sanforizing, brushing, calendering, and applying polyurethane-based waterproof agents to create a substrate with improved water resistance, breathability, and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If knitted cotton substrate is used for cleaning cloth, then the substrate can be washed, but it shrinks after drying and cannot be dried properly
Solution Approach 1:
The substrate undergoes sanforizing treatment before final assembly, which pre-shrinks the fabric at high temperature to eliminate subsequent shrinkage during washing and drying. This preliminary action ensures the substrate maintains its shape stability throughout the product's lifecycle.
Solution Approach 2:
The substrate is treated with waterproof agents and undergoes calendering at high temperature to change its physical parameters, including fiber arrangement and density. These parameter changes make the substrate resistant to water and heat, enabling it to withstand high-temperature drying without shrinking or deforming.
2Ease of operation
If knitted cotton substrate is used for cleaning cloth, then the substrate can be washed, but tangled hair balls form on the substrate due to frequent friction
Solution Approach 1:
The invention uses high-density weaving cloth as the substrate material instead of conventional knitted cotton. This composite structure with tighter weave and higher density resists fiber entanglement and hair ball formation during frequent washing and friction, maintaining surface integrity over time.
3Reliability
If conventional cleaning cloth is made, then waterproof and breathable functions are provided, but the cleaning cushion cannot be laid flat due to tangled hair balls
Solution Approach 1:
The substrate undergoes sanforizing and calendering treatments before final assembly. These preliminary actions pre-shrink and pressurize the fabric to eliminate future shrinkage and ensure the cleaning cushion can be laid flat without deformation or hair ball interference during use.
4Shape
If high-density weaving cloth is used with multiple treatment steps, then the cleaning cloth can be washed and dried at high temperature without shrinking, but the manufacturing process becomes more complex
Solution Approach 1:
The substrate undergoes sanforizing treatment early in the manufacturing process to pre-shrink the fabric. This preliminary action eliminates the need for complex post-washing adjustments and ensures shape stability at high temperature, simplifying the overall manufacturing workflow despite the additional initial step.
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 enables the cleaning cloth to be washed and dried at high temperatures, maintaining its shape and extending its lifespan while reducing replacement frequency and costs.
Implementation Method 1
a scouring step including scouring the substrate to remove oil, sizing agent, and dirt from the substrate
Implementation Method 2
a sanforizing step including sanforizing the substrate at a high temperature so that the substrate has a determined amount of shrinkage in a warp direction and a weft direction, to reduce a water shrinkage
Implementation Method 3
a water repelling treatment step including applying a water repellent on the substrate to fully blend the water repellent into fibers of the substrate
Implementation Method 4
a calendering step including performing a calendering treatment to pressurize the substrate at a high temperature, to shorten a gap between the fibers of the substrate
Implementation Method 5
a waterproof treatment step including applying a waterproof agent on the substrate to form cleaning cloth
Data Source
AI summary
A method includes a preparing step including providing a substrate made of high-density woven cloth, a scouring step including scouring the substrate, a sanforizing step including sanforizing the substrate at a high temperature, a brushing step including brushing the substrate to form a layer of fluff on the substrate, a water repelling treatment step including applying a water repellent on the substrate to fully blend the water repellent into fibers of the substrate, a calendering step including performing a calendering treatment to pressurize the substrate at a high temperature, to shorten and fill a gap between the fibers of the substrate by the fluff, and a waterproof treatment step including applying a waterproof agent on the substrate to form the cleaning cloth.