Polyester Core-Outer Yarn for Solar Heat Screening
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Solution Overview
Problem
Existing screening fabrics for buildings, made from glass fiber and PVC yarn, suffer from shape and size changes, bad odor, short lifespan, and high weight, making them difficult and costly to install, while lacking a natural appearance.
Innovation Solution
A yarn composed of a polyester core yarn and a lower-melting-point polyester outer yarn, wound and processed to maintain specific temperatures and pressures, is developed, along with a manufacturing method that includes a double weft weaving technique to create a stable, odor-free, long-lasting fabric with a natural appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If glass fiber and PVC yarn are used to manufacture screening fabric, then solar heat prevention and light transmission are achieved, but the fabric changes shape and size over time
Solution Approach 1:
The invention uses a composite yarn structure consisting of a polyester core yarn and a polyester outer yarn with different melting temperatures. This composite structure provides both the heat prevention functionality and the dimensional stability, replacing the problematic glass fiber and PVC combination with a fully polyester-based composite that maintains shape while blocking solar heat.
2Temperature
If glass fiber and PVC yarn are used to manufacture screening fabric, then solar heat prevention is achieved, but bad odor is formed under environmental conditions
Solution Approach 1:
The invention extracts and eliminates the PVC component from the yarn composition, using only polyester materials for both core and outer yarns. This removal of the harmful PVC substance prevents the formation of bad odors under environmental conditions while maintaining the solar heat prevention functionality through the polyester outer yarn's properties.
3Temperature
If glass fiber and PVC yarn are used to manufacture screening fabric, then solar heat prevention is achieved, but the fabric has short lifespan
Solution Approach 1:
The invention changes the material parameters by replacing PVC with polyester, specifically using a polyester outer yarn with a melting temperature lower than the core yarn. This parameter change creates a more durable, environmentally stable fabric that resists degradation over time while maintaining effective solar heat blocking capabilities.
4Temperature
If glass fiber is used to manufacture screening fabric, then solar heat prevention is achieved, but the fabric weight becomes high
Solution Approach 1:
The invention replaces heavy glass fiber with a lightweight polyester composite yarn structure. The polyester core yarn provides structural integrity while the polyester outer yarn delivers solar heat prevention, creating a fabric that is significantly lighter than glass fiber-based alternatives while maintaining equivalent thermal blocking performance.
5Temperature
If glass fiber and PVC yarn are used to manufacture screening fabric, then solar heat prevention is achieved, but the fabric lacks natural appearance
Solution Approach 1:
The invention removes the artificial-looking PVC coating and glass fiber components, using entirely polyester yarns that can be textured and colored to achieve a natural, aesthetic appearance. The polyester material properties allow for surface treatments and dyeing that create a natural look while maintaining the solar heat prevention functionality.
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 resulting fabric maintains shape and size, prevents solar heat while transmitting light, has a natural appearance, and is long-lasting, reducing installation challenges and costs.
Implementation Method 1
The melting temperature of the outer yarn (5) is lower than the melting temperature of the core yarn (2)
Implementation Method 2
increasing the temperature of the bobbin (7) to a temperature between 80 to 90° C., preferably 85° C., in 15 minutes
Implementation Method 3
placing the bobbin (7) in a fixing machine (105) keeping the bobbin (7) under −700 mmHg relative pressure between 10 to 20 minutes
Data Source
AI summary
The invention relates to a yarn (1) for screening applications, especially for screening applications preventing solar heat while transmitting solar light, a fabric obtained from the yarn, and a manufacturing method thereof. The yarn (1) consists of at least one polyester outer yarn (5) wound on a polyester core yarn (2). The manufacturing method keeps the core and outer yarns at certain temperatures for certain durations after the core and outer yarns have been twisted.