Ultra-Fine Polyester Cleansing Fabric That Protects Delicate Surfaces
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Solution Overview
Problem
Existing cleansing polyester fabrics are either ineffective in removing cosmetics without damaging surfaces or are too harsh, due to issues with yarn fineness and texture.
Innovation Solution
A cleansing polyester fabric is developed using ultra-fine yarns (0.001 to 0.1 deniers) as warp and weft, combined with a high shrinkage polyester multifilament, woven with a sea-island type conjugated yarn and treated with an aqueous alkaline solution to enhance softness and stability, preventing surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a split type conjugated yarn having a triangle shape of cross-section after splitting is used, then the fabric has good structure, but the fabric is hard to the touch and damages the surface of products to be cleansed
Solution Approach 1:
The patent changes the key parameter of yarn cross-sectional shape from triangle (in prior art) to circle. This parameter change transforms the harmful sharp edges into smooth surfaces, making the fabric soft to the touch and preventing surface damage to cleansed objects while maintaining good fabric structure
Solution Approach 2:
The patent applies different local qualities to different parts of the yarn structure. The circular cross-section provides smooth contact surfaces for gentle cleansing, while the conjugated yarn structure (sea-island type) provides structural integrity and shrinkage control, creating localized functional zones within the yarn
2Strength
If monofilament denier of warp and weft is larger than 0.3 deniers, then the fabric has good strength, but the cleansing performance and feel are deteriorated
Solution Approach 1:
The patent changes the monofilament denier parameter from >0.3 dtex (prior art) to 0.001-0.1 dtex (ultra-fine). This parameter change creates ultra-fine yarns that provide superior softness and cleansing performance while the conjugated yarn structure compensates for the reduced individual fiber strength
Solution Approach 2:
The patent uses composite material structure through sea-island type conjugated yarns, where fine denier monofilaments (island) are embedded in a matrix of other fibers (sea). This composite structure allows the ultra-fine monofilaments to provide softness and cleansing performance while the surrounding matrix provides structural support and strength
3Object-affected harmful factors
If ultra fine yarns of 0.001 to 0.1 deniers are used as warp and weft, then the fabric is soft to the touch and provides excellent cleansing performance, but the fabric requires complex processing to achieve stability
Solution Approach 1:
The patent applies preliminary action by performing false twisting and shrinkage control treatments during the fabric manufacturing process. This preliminary treatment pre-establishes the dimensional stability and structural integrity of the ultra-fine yarn fabric, preventing excessive complexity in subsequent processing and finishing stages
Solution Approach 2:
The patent changes the shrinkage rate parameter of the conjugated yarn to 10-50% in boiling water. This parameter change allows controlled shrinkage that stabilizes the ultra-fine yarn structure, reducing the need for complex post-processing while maintaining softness and cleansing performance
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 fabric achieves excellent cleansing performance while being soft to the touch and maintaining surface integrity, suitable for precision products and optical devices.
Implementation Method 1
a high shrinkage polyester multifilament with 10 ̃50% of shrinkage rate in boiling water
Implementation Method 2
the heat-set fabric being treated in an aqueous alkaline solution for extracting the sea component in the fabric
Data Source
AI summary
The cleansing polyester fabric of the present invention (AAA). The cleansing fabric of the present invention is useful as a makeup cleansing fabric or as a wiping fabric for precision products and optical devices since it exhibits excellent cleansing performance, is soft to the touch and does not damage the surface of a products to be cleansed.