Nonwoven Yarn Twisting for Versatile Weaving Materials
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Solution Overview
Problem
The textile industry faces challenges in producing threads for weaving, particularly in nonwoven materials, where the mechanical strength of fibers is crucial during the spinning process, making it difficult to bypass the need for considering physical characteristics like strength and stress.
Innovation Solution
A method involving the use of nonwoven materials, which are slit into threads and then twisted to create yarns with enhanced mechanical characteristics, allowing for various functionalities in textiles without requiring specific fiber strength considerations, and can be woven using techniques like tatting, knitting, or mesh weaving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional spinning process is used to produce threads, then fiber mechanical strength must be considered and controlled, but this increases process complexity and limits material source diversity
Solution Approach 1:
The invention segments the nonwoven fabric into narrow strips (slitting process) to create thread-like structures directly from the bonded fiber web, bypassing the traditional spinning process that requires fiber strength control. This segmentation approach transforms the material form without requiring complex spinning equipment or fiber property considerations.
Solution Approach 2:
The invention extracts the essential thread-forming function from the traditional spinning process by directly slitting nonwoven fabric into strips. This extraction eliminates the need for fiber preparation, carding, and spinning operations, thereby reducing process complexity while maintaining thread production capability.
2Strength
If nonwoven materials are slit into threads and twisted to create yarns, then mechanical properties and functionality are improved, but additional processing steps are required
Solution Approach 1:
The invention merges multiple functions into the slitting process itself: cutting the nonwoven into strips, creating edge fringes for interlocking, and forming twistable structures all in one operation. The subsequent twisting process then simultaneously creates yarn structure and enhances mechanical properties, reducing the need for separate processing steps.
Solution Approach 2:
The invention changes the physical parameters of the nonwoven material through controlled slitting width and twisting degree. By adjusting these parameters, the material transforms from a flat bonded web to a three-dimensional yarn structure with enhanced mechanical strength and desired functionality, optimizing both properties and production efficiency.
3Ease of manufacture
If nonwoven threads are used for weaving without considering fiber strength, then material selection is simplified, but ensuring adequate thread strength becomes challenging
Solution Approach 1:
The invention performs preliminary bonding of fibers into a nonwoven web with controlled strength characteristics before slitting. This preliminary action ensures that the resulting strips have adequate base strength, and the subsequent twisting process further reinforces the threads, guaranteeing sufficient strength while maintaining manufacturing simplicity.
Solution Approach 2:
The invention creates composite thread structures by twisting multiple slitted strips together, combining the bonded fiber web material with the twisted yarn structure. This composite approach enhances thread strength and reliability while maintaining the simplicity of using nonwoven materials as the base material.
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
This approach enables the production of textiles with varied functionalities and appearances, including water-resistant properties, by utilizing nonwoven yarns made from different materials, such as polymers and metals, while simplifying the manufacturing process and eliminating the need to assess fiber strength.
Implementation Method 1
the nonwoven is slit, and a plurality of nonwoven threads are obtained
Implementation Method 2
the nonwoven threads are subjected to a twisting process, and a plurality of nonwoven yarns are obtained
Data Source
AI summary
The present invention provides a method for producing thread using nonwoven, which discloses that nonwoven having different materials is slit first to get a plurality of nonwoven threads and then the nonwoven threads are used for performing a twisting process to get a plurality of nonwoven yarns. In the twisting process, each of the nonwoven threads has different materials, so that the nonwoven yarns have good mechanical characteristic and can be added for producing textiles with various functionalities.