Nonwoven Textile With Non-Linear Entangled Seams for Recyclable Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional insulating garments are costly and time-intensive to produce, with high energy costs and carbon footprints due to the use of multiple materials and processes like spinning, weaving, and stitching. Additionally, they have limited recyclability and often result in material waste to maintain uniform visual arrangements.
Innovation Solution
A composite nonwoven textile with non-linear entangled seams is produced using an entanglement system that forms seams by engaging entanglement needles or jets of fluid with stacked layers of nonwoven material and fill, reducing the need for adhesives, stitching, and heat pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods using multiple materials and processes (spinning, weaving, stitching) are used to form insulating garments, then the garment structure and insulation performance are achieved, but manufacturing cost and energy consumption increase
Solution Approach 1:
The patent combines multiple traditional manufacturing steps (spinning, weaving, stitching, adhesive application, heat pressing) into a single hydroentanglement process. Water jets simultaneously bond fabric layers and secure insulation material in one continuous operation, eliminating the need for separate spinning, weaving, and stitching processes, thereby dramatically reducing energy consumption while maintaining garment structure
Solution Approach 2:
The invention extracts and eliminates unnecessary intermediate processes from the traditional manufacturing chain. By using hydroentanglement, the patent removes the need for separate adhesive application and heat pressing steps, as well as eliminating the need for pre-spun and pre-woven fabrics, directly forming the final garment structure from loose fibers in one process
2Strength
If traditional stitching and adhesive methods are used to form seams, then the panels are securely joined, but manufacturing time and complexity increase
Solution Approach 1:
The hydroentanglement process merges seam formation with panel bonding in a single operation. Water jets simultaneously penetrate through multiple fabric layers and insulation material, creating strong mechanical bonds without requiring separate stitching or adhesive application steps, thereby doubling or tripling manufacturing speed while maintaining seam strength
Solution Approach 2:
The patent replaces traditional mechanical stitching systems with a hydrodynamic system. Instead of using needles and threads to create seams, high-pressure water jets are used to erode and bond fibers together, forming seams through hydroentanglement. This substitution eliminates the need for complex stitching machinery and significantly accelerates the manufacturing process
3Reliability
If multiple disparate materials are used in traditional garment construction, then the desired insulation and structural properties are achieved, but recyclability decreases
Solution Approach 1:
The patent employs homogeneity by using the same polymer material for both the fabric layers and the insulation material. This allows the entire garment to be composed of a single material type that can be easily separated and recycled together, eliminating the complexity of sorting and processing multiple disparate materials while maintaining the required insulation performance through proper fiber selection and arrangement
4Shape
If repeating visual arrangements of elements are applied to textile panels, then uniform appearance is achieved, but material waste increases
Solution Approach 1:
The patent introduces dynamics by enabling variable positioning of visual elements during the continuous hydroentanglement process. The entanglement system can adjust the location, spacing, and pattern of seams and decorative elements in real-time based on the specific garment design requirements, eliminating the need to cut and discard excess material to achieve uniform visual arrangements across multiple garments
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 reduces manufacturing costs and energy consumption, enhances recyclability by using materials of the same polymer class, and minimizes material waste while allowing for complex visual arrangements of entangled seams for varied aesthetic and insulation properties.
Implementation Method 1
A composite nonwoven textile with non-linear entangled seams is produced using an entanglement system that forms seams by engaging entanglement needles or jets of fluid with stacked layers of nonwoven material and fill
Data Source
AI summary
Aspects herein are directed to a composite nonwoven textile that includes non-linear entangled seams and method and systems for producing the same. The composite nonwoven textile includes at least a first nonwoven layer, a second layer, and a fill material positioned between the first nonwoven layer and the second layer. When the composite nonwoven textile is formed into a garment, the regions between the non-linear entangled seams may help store and retain heat to provide insulation, and the non-linear entangled seams may help prevent shifting or drift of the fill material.