Suspended Multi-Layer Fiber Structure Without Adhesive Lamination
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Solution Overview
Problem
Existing fiber structures, such as double russel meshes, face challenges in laminating layers with different functions, leading to weight increase, peeling issues, and complex manufacturing processes when using adhesives.
Innovation Solution
A fiber structure comprising parallel layers with suspension layers made of weaving or knitting yarns between each pair of fiber layers, allowing for lightweight, reliable, and easy manufacturing with adjustable properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If double russel meshes are laminated with adhesive to laminate layers having different functions, then the desired layer structure with different functions is achieved, but weight increases and peeling may occur
Solution Approach 1:
The patent extracts and eliminates the adhesive layer from the laminated structure. Instead of using adhesive to bond fiber layers, the invention uses a continuous yarn that physically interconnects multiple fiber layers, removing the need for adhesive and thereby preventing weight increase and peeling issues associated with adhesive bonding.
Solution Approach 2:
The patent introduces a continuous yarn as an intermediary element that serves as a mechanical connector between fiber layers. This yarn acts as a mediator that physically links multiple fiber layers together, replacing the adhesive's bonding function with a mechanical interconnection that avoids the drawbacks of adhesive-based lamination.
2Adaptability or versatility
If double russel meshes are laminated with adhesive to laminate layers having different functions, then the desired layer structure with different functions is achieved, but the manufacturing process becomes complicated
Solution Approach 1:
The patent merges the functions of multiple separate components (adhesive application system, layer alignment system, bonding system) into a single integrated continuous yarn that performs all bonding functions. This consolidation simplifies the manufacturing process by eliminating multiple complex steps required for adhesive-based lamination.
Solution Approach 2:
The patent extracts and removes the adhesive application process entirely from the manufacturing workflow. By using a continuous yarn for lamination, the complex steps of adhesive coating, application, and curing are eliminated, significantly simplifying the manufacturing process.
3Device complexity
If a single layer structure is used, then the structure is simple, but it is difficult to laminate layers having different functions
Solution Approach 1:
The patent segments the fiber structure into multiple distinct fiber layers (first fiber layer, second fiber layer, third fiber layer) that can have different functions. Each layer can be optimized for specific purposes while the continuous yarn provides the connection, enabling functional differentiation without excessive complexity.
Solution Approach 2:
The continuous yarn serves multiple functions simultaneously: it connects the first fiber layer to the second fiber layer, connects the second fiber layer to the third fiber layer, and provides structural integrity to the entire laminated assembly. This multi-functionality enables complex layer structures without proportionally increasing complexity.
Data Source
AI summary
To provide a fiber structure 100 at least part of which has a layer structure including a first fiber layer 110, a second fiber layer 120, and a third fiber layer 130 that are arranged parallel to one another, a first suspension layer 140 that is composed of a weaving yarn or a knitting yarn stretched between the first fiber layer 110 and the second fiber layer 120, and a second suspension layer 150 that is composed of a weaving yarn or a knitting yarn stretched between the second fiber layer 120 and the third fiber layer 130. The fiber structure 100 can be adopted particularly as a material of shoes, clothing items, bags, and the like required to have various functions.