PTFE Fabric Weave for Large Umbrella Strength and Foldability
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Solution Overview
Problem
Large umbrella constructions require a fabric that balances high tensile strength with ease of folding, resistance to aging and weathering, and excellent waterproofness, which existing fabrics fail to achieve effectively, especially for diameters or side lengths of 10 meters and more.
Innovation Solution
A fabric with a symmetrical two-layer construction, using PTFE yarns for both warp and weft threads, with a thread density of 50-90 threads per cm, providing a thickness of 0.8-1 mm, and a balanced number of warp and weft threads to ensure strength, foldability, and water resistance without coatings, and optionally using twisted yarns for enhanced softness and water repellency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fabric with high tensile strength is used for large umbrella constructions, then the fabric can withstand high tension forces, but the fabric becomes difficult to fold without excessive stress
Solution Approach 1:
The fabric is constructed with a specific weave pattern featuring 81 warp threads and 77 weft threads per cm, creating a segmented structure that distributes tension forces across multiple threads while maintaining flexibility. This segmentation allows the fabric to achieve high tensile strength without compromising foldability, as each thread can independently bend during folding while collectively resisting tension.
Solution Approach 2:
The fabric parameters are precisely optimized: thread density is set at 81 warp and 77 weft threads per cm, thickness is controlled at 1 mm or less, and the weave pattern is specifically designed. These parameter changes create a fabric that achieves the optimal balance between strength and flexibility, allowing large umbrella constructions to be both strong and easily foldable.
2Ease of operation
If the fabric thickness is reduced to improve foldability, then the fabric becomes easier to fold, but water resistance decreases
Solution Approach 1:
The fabric thickness is precisely controlled at 1 mm or less to ensure easy folding, while the thread density is simultaneously optimized at 81 warp and 77 weft threads per cm. This combination of parameter changes creates a dense weave pattern that provides effective water resistance even at reduced thickness, eliminating the need for additional coatings while maintaining both foldability and waterproofness.
3Strength
If the number of warp threads is increased to improve strength, then the fabric becomes stronger, but the fabric becomes more difficult to fold
Solution Approach 1:
The warp thread count is set at 81 threads per cm and weft thread count at 77 threads per cm, creating a balanced density that provides high tear resistance while maintaining flexibility. The specific weave pattern and 1 mm thickness further optimize this balance, ensuring the fabric achieves maximum strength without excessive stiffness that would hinder folding operations.
Data Source
AI summary
The invention relates to a woven fabric for textile constructions or covers having warp threads and weft threads of PTFE yarn. According to the invention, the woven fabric is woven in two or more layers having a weft thread count that substantially corresponds to the warp thread count, and the woven fabric is formed identically on a top side and on a bottom side.