Multi-ply woven gauze
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Solution Overview
Problem
Conventional multi-ply woven gauze fabrics lack sufficient bulkiness, heat-retaining properties, soft touch feel, transparency prevention, and lightness, limiting their application in clothing and bedding due to poor structural strength and breathability.
Innovation Solution
A multi-ply woven gauze fabric structure featuring a surface and back layer in plain weave construction and a middle layer in honeycomb weave, with differential shrinkage between twisted and non-twisted yarns creating wrinkles for enhanced bulkiness, and using a combination of twisted and non-twisted yarns to maintain strength and improve softness and lightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the number of gauze fabrics is increased to improve heat-retaining property, then heat retention improves, but lightness is spoiled remarkably
Solution Approach 1:
The fabric is divided into three distinct layers (surface layer, middle layer, back layer) with different weave constructions. The middle layer uses honeycomb weave to create air pockets for heat retention, while the surface and back layers use plain weave to maintain lightness. This segmentation allows each layer to contribute different functional properties without requiring multiple thick gauze fabrics.
Solution Approach 2:
Different regions of the fabric have different weave constructions tailored to specific functions. The middle layer has honeycomb weave with larger mesh sizes and air pockets optimized for heat retention, while the surface and back layers have plain weave optimized for lightness and breathability. This local differentiation resolves the contradiction by placing heat-retaining structures only where needed.
2Object-affected harmful factors
If yarn with large diameter or high density gauze is used to prevent skin visibility, then transparency preventing property improves, but breathability and lightness are spoiled remarkably
Solution Approach 1:
The fabric structure is segmented into three layers where the middle layer with honeycomb weave provides transparency prevention through its convoluted structure and air pockets, while the surface and back layers with plain weave maintain breathability through their open mesh structures. This segmentation allows transparency prevention without sacrificing breathability.
Solution Approach 2:
The honeycomb weave in the middle layer creates a three-dimensional convoluted structure with air pockets, adding vertical dimensionality to the fabric. This 3D structure effectively blocks skin visibility through the fabric while the overall open mesh structure of all layers maintains breathability by allowing air flow through the fabric thickness.
3Strength
If conventional multi-ply woven gauze fabric structure is used, then fabric strength is maintained, but bulkiness and softness are poor
Solution Approach 1:
The fabric uses different weave constructions in different layers: plain weave in surface and back layers for strength, and honeycomb weave in the middle layer for bulkiness and softness. This local quality differentiation allows each layer to contribute its optimal properties, resolving the contradiction between strength and bulkiness.
Solution Approach 2:
The fabric is a composite structure combining three different weave constructions (two plain weave layers and one honeycomb weave layer) into a single multi-ply fabric. This composite approach integrates the strength-providing plain weave structures with the bulkiness-providing honeycomb weave structure, achieving both properties simultaneously.
Data Source
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AI summary
Provided is multi-ply woven gauze that has loft, a soft texture, and superior heat retention, permeation resistance, and lightness of weight. The multi-ply woven gauze comprises a front surface layer formed with a plain-weave structure, an intermediate layer formed with a waffle-weave structure, and a rear surface layer formed with a plain-weave structure. The front surface layer and the intermediate layer are joined together, and the rear surface layer and the intermediate layer are joined together. Wrinkles form at the connections between the front surface layer and the rear surface layer due to the difference in contraction between the plain-weave structures and the waffle-weave structure. The intermediate layer is formed from at least one layer. The weave density of a single layer in the intermediate layer is equal to or half the weave density of the front surface layer and the rear layer.