Polyamide monofilament
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Solution Overview
Problem
The increased number of weft yarn insertions in the weaving process of thin and dense screen gauze fabrics leads to yarn cast-off and loom stoppages, resulting in fabric defects, which existing polyamide monofilament technologies fail to adequately address.
Innovation Solution
A polyamide monofilament with a deposited oil containing a hydrocarbon and fatty acid alkyl ester, where the weight average molecular weight of these components is 500 or less, and their rate is 40% or less of the total oil weight, is used to stabilize the yarn and prevent cast-off, while maintaining excellent weaving properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of weft yarn insertions is increased to achieve weight reduction and thinning of screen gauze fabric, then fabric quality and density are improved, but yarn cast-off and loom stoppages occur during weaving
Solution Approach 1:
The patent applies parameter changes by precisely controlling the molecular weight distribution of oil components deposited on the yarn surface. By limiting the rate of low molecular weight components (≤500) to 40% or less and controlling the total deposited oil amount to 0.1-1.5% by weight, the yarn's friction and electrostatic properties are optimized, preventing cast-off during high-frequency insertions
Solution Approach 2:
The deposited oil acts as an intermediary substance between the yarn and the weaving environment. This oil layer with controlled composition serves as a mediator that reduces excessive friction and static electricity, enabling smooth yarn insertion without cast-off while maintaining the required fabric density and quality
2Ease of operation
If the molecular weight of oil components is reduced to improve yarn smoothness, then weaving properties are enhanced, but yarn cast-off occurs due to insufficient friction control
Solution Approach 1:
The patent optimizes the molecular weight parameter distribution of oil components. By controlling the rate of components with molecular weight ≤500 to be 40% or less of the total oil, and setting the total deposited oil at 0.1-1.5% by weight, the yarn achieves balanced smoothness and friction control, preventing both excessive resistance and cast-off during weaving
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 solution effectively reduces yarn cast-off and loom stoppages, improving fabric quality and productivity by controlling the deposition of the oil components on the yarn surface, thereby enhancing the smoothness and stability of the weaving process.
Implementation Method 1
A polyamide monofilament containing a deposited oil, an amount of the deposited oil being 0.1 to 1.5% by weight, the deposited oil containing a component containing a hydrocarbon having a weight average molecular weight of 500 or less and a fatty acid alkyl ester having a weight average molecular weight of 500 or less
Implementation Method 2
a rate of the component being 40% by weight or less based on a total weight of the deposited oil
Data Source
Figure 1
AI summary
Provided is a polyamide monofilament which prevents thread shedding in a weaving process and provides excellent weaving properties and fabric quality. This polyamide filament is characterized in that the amount of oil deposition is 0.1-1.5% by weight, and components comprising hydrocarbons and fatty acid alkyl esters having a weight average molecular weight of 500 or less in the deposited oil account for 40% by weight or less of the total components of the oil.