Isotactic Polypropylene Knitted Sheet Polychrome Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current outdoor sheets with screening and sunbreak functions are limited by monochromatic designs, lack of durability, and inability to feature polychrome patterns due to textile technology constraints, and face challenges in continuous processing over large lengths.
Innovation Solution
The development of an outdoor sheet using isotactic polypropylene yarns for jacquard or interlay knitting, which allows for polychrome graphics and enhanced durability, combined with U.V. stabilizers and flame retardant treatments, and a modified knitting machine capable of handling high tenacity yarns for continuous processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyethylene monofilament fabrics are used for outdoor sheets, then durability and resistance to bad weather are improved, but the ability to create polychrome patterns and graphic decorations is lost
Solution Approach 1:
The patent changes the material parameter from polyethylene monofilament to isotactic polypropylene continuous filament yarn, which has different properties that enable both outdoor durability and polychrome knitting capabilities. This parameter change resolves the contradiction by finding a material that satisfies both requirements simultaneously.
Solution Approach 2:
The patent uses composite yarns made of isotactic polypropylene with different colorations (monochromatic, bicolor, multicolor) to create polychrome patterns while maintaining the durability required for outdoor use. The composite approach combines material strength with color variety.
2Ease of manufacture
If traditional textile technology is used for outdoor sheets, then monochromatic designs are achieved, but the aesthetic value and added value through polychrome patterns are lost
Solution Approach 1:
The patent modifies the yarn parameter to include continuous filament isotactic polypropylene available in multiple colorations, enabling jacquard and interlay knitting techniques that create polychrome patterns. This transforms the manufacturing capability from simple monochromatic production to versatile polychrome pattern creation.
Solution Approach 2:
The patent employs continuous filament yarns that allow uninterrupted knitting processes for creating complex polychrome patterns across large sheet areas. The continuity enables consistent coloration and pattern formation throughout the entire fabric structure.
3Reliability
If yarns with high resistance features for outdoor exposure are used, then durability is improved, but continuous processing over considerable lengths becomes difficult
Solution Approach 1:
The patent specifies isotactic polypropylene continuous filament yarns with particular structural parameters that provide both high resistance to outdoor exposure and suitability for continuous knitting processes over considerable lengths. The molecular structure and filament continuity enable both durability and processability.
4Ease of manufacture
If printing techniques are used to add drawings to sheets, then graphic representation is achieved, but the drawing durability under atmospheric exposure is insufficient
Solution Approach 1:
The patent incorporates coloration directly into the yarn structure during manufacturing, before the fabric is produced. This preliminary action of embedding pigments in the continuous filament yarns ensures that the graphic patterns are intrinsic to the material and will not fade or deteriorate under atmospheric exposure, unlike surface printing.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Outdoor sheet (1), suitable for exposure in outer environments with a screening and/or sunbreak function, comprising a fabric made of isotactic polypropylene yarns having a graphic representation on its surface which is made through jacquard or interlay weaving of yarns of different colour.