Stitched Multi-Layer Fabric with Melted Barrier Seal
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Solution Overview
Problem
Textile manufacturers face challenges in creating products that simultaneously offer high levels of air permeability, breathability, water resistance, and stretch, making it difficult to achieve a high level of comfort in consumer products.
Innovation Solution
A stitched multi-layer fabric is developed, comprising an interior layer, a barrier layer with a meltable adhesive and a membrane or film, and a face layer, where the yarn is stitched through all layers to secure them together, allowing the adhesive to fill stitch holes and enhance bonding, while maintaining stretchability and breathability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a product is made to be water resistant or waterproof, then water resistance is improved, but breathability deteriorates
Solution Approach 1:
The fabric is divided into multiple functional layers: a water-resistant barrier layer and a breathable interior layer. This segmentation allows each layer to perform its specific function independently, with the barrier layer blocking water while the interior layer maintains breathability, thus resolving the contradiction between water resistance and breathability.
Solution Approach 2:
The fabric combines different materials with complementary properties: a water-resistant membrane or film bonded to a breathable fabric substrate. This composite structure integrates the water-blocking capability of the membrane with the breathability of the fabric, simultaneously achieving both water resistance and breathability.
2Object-generated harmful factors
If a product is made to be breathable, then breathability is improved, but water resistance deteriorates
Solution Approach 1:
The fabric is divided into multiple functional layers: a water-resistant barrier layer and a breathable interior layer. This segmentation allows each layer to perform its specific function independently, with the barrier layer blocking water while the interior layer maintains breathability, thus resolving the contradiction between water resistance and breathability.
Solution Approach 2:
The fabric combines different materials with complementary properties: a water-resistant membrane or film bonded to a breathable fabric substrate. This composite structure integrates the water-blocking capability of the membrane with the breathability of the fabric, simultaneously achieving both water resistance and breathability.
3Strength
If layers are bonded tightly to improve bonding strength, then bonding strength is improved, but stretchability deteriorates
Solution Approach 1:
The barrier layer incorporates a flexible membrane or film that can stretch and recover. This flexible component maintains strong bonding between layers while allowing the fabric to stretch, thus resolving the contradiction between bonding strength and stretchability.
Solution Approach 2:
The fabric combines different materials with complementary properties: a water-resistant membrane or film bonded to a breathable fabric substrate. This composite structure integrates the water-blocking capability of the membrane with the breathability of the fabric, simultaneously achieving both water resistance and breathability.
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 good breathability, wind and water resistance, and stretch, providing a high level of comfort in various applications, such as outdoor garments and medical bandages, by effectively bonding layers while allowing moisture vapor transfer.
Implementation Method 1
a barrier layer, where the yarn is stitched through all layers to secure them together, allowing the adhesive to fill stitch holes and enhance bonding
Data Source
AI summary
A stitched multi-layer fabric including a face layer, a barrier layer disposed over the face layer, where the barrier layer is configured to inhibit fluid flow, a batting layer disposed over the barrier layer, a first yarn disposed over the batting layer, and a second yarn securing the first yarn to the batting layer, securing the face layer, the barrier layer, and the batting layer together, and forming stitch holes in the barrier layer. A melted portion of the barrier layer fills a portion of the stitch holes in the barrier layer.