PVA Nonwoven Base Fabric for Stable, Soft Chemical Lace Embroidery
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Solution Overview
Problem
Current chemical lace base fabrics are expensive, prone to needle breakage during embroidering, and face challenges in achieving high dimensional stability and low dissolution temperature while preventing dye transfer from colored polyester yarn.
Innovation Solution
A chemical lace base fabric produced by impregnating a random web of water-soluble PVA-based fibers with a foamy binder solution containing a PVA-based resin, followed by drying, which reduces water adherence and energy consumption, and preferentially supplies binder resin to fiber-intertwined portions for enhanced stability and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If woven fabric is used as base fabric, then dimensional stability and accurate embroidery motif reproduction are improved, but production cost increases and needle breakage occurs
Solution Approach 1:
The invention changes the physical and chemical parameters of the nonwoven fabric by controlling the degree of polymerization of PVA (1,000-3,000) and the amount of binder resin (5-20 parts by mass per 100 parts of random web), achieving optimal dimensional stability without the high costs associated with woven fabrics
Solution Approach 2:
The invention creates a composite structure combining PVA-based random web with binder resin, where the binder resin bonds the fibers to provide dimensional stability comparable to woven fabrics while maintaining the cost advantages of nonwoven construction
2Stability of the object's composition
If woven fabric is used as base fabric, then dimensional stability is improved, but needle breakage during embroidering occurs
Solution Approach 1:
The invention optimizes the softness parameter by controlling binder resin content (5-20 parts by mass) and degree of polymerization (1,000-3,000), achieving bending resistance that prevents needle breakage while maintaining sufficient dimensional stability for accurate embroidery
Solution Approach 2:
The binder resin is selectively applied to bond fibers at critical locations within the nonwoven fabric structure, providing localized dimensional stability in areas requiring it while leaving other areas soft and flexible to prevent needle breakage
3Ease of manufacture
If nonwoven fabric is used to reduce cost, then production cost decreases, but dimensional stability during embroidering deteriorates
Solution Approach 1:
The binder resin acts as an intermediary substance that bonds the PVA fibers in the random web, providing the dimensional stability typically associated with woven fabrics while maintaining the cost advantages of nonwoven construction. The binder resin content is optimized at 5-20 parts by mass per 100 parts of random web
Solution Approach 2:
The invention achieves dimensional stability in nonwoven fabric by precisely controlling the degree of polymerization of PVA (1,000-3,000) and the binder resin content, transforming the typical nonwoven fabric properties to match the dimensional stability requirements for embroidery applications
4Stability of the object's composition
If binder resin amount is increased to improve dimensional stability, then dimensional stability is improved, but softness deteriorates
Solution Approach 1:
The invention identifies the optimal parameter range for binder resin content (5-20 parts by mass per 100 parts of random web) where dimensional stability is sufficiently improved without excessive binder resin that would cause hardening and needle breakage. This precise parameter control resolves the trade-off between stability and softness
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 method results in a soft, easy-to-handle base fabric with high dimensional stability and low dissolution temperature, preventing skips and non-uniformity in embroidery motifs, and is produced at a lower cost, ensuring accurate and durable chemical lace production.
Implementation Method 1
impregnating a random web of water-soluble PVA-based fibers with a foamy binder solution containing a PVA-based resin
Implementation Method 2
followed by drying
Data Source
AI summary
A base fabric for producing chemical lace of the present invention is fabricated from dyed embroidery yarn and nonwoven fabric formed of a water-soluble poly (vinyl alcohol)-based fiber random web, which base fabric satisfies the following conditions: (1) a binder to be adhered onto the nonwoven fabric is formed of a foamy aqueous solution containing a poly (vinyl alcohol)-based resin, and the binder is deposited onto the nonwoven fabric in an amount of 2 to 20 mass% with respect to the total mass of the nonwoven fabric; (2) the nonwoven fabric has a 10% modulus strength in the widthwise direction of 15 to 80 N/50·mm width; and (3) the nonwoven fabric has a bending resistance of 40 to 150 mm. The base fabric for producing chemical lace is soft and easy to handle, has high dimensional stability and low dissolution temperature, prevents skips and non-uniformity in embroidery motifs, and is produced at low cost.