Tearable Polyester Cloth with Pre-Formed Separation Portions
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Solution Overview
Problem
Existing cloths made from polyester fiber textiles are difficult to tear, leading to complex production and packaging processes for manufacturers and inconvenient use for consumers.
Innovation Solution
The cloth is designed with separation portions formed by heating and melting the material to reduce tear strength, allowing easy tearing into independent units, facilitated by ultrasonic heating and compressing, with optional recesses or grooves to enhance brittleness and stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cloth is made from polyester fiber textile material with base layer and looped pile, then the cloth has good durability and cleaning ability, but the cloth is difficult to tear and requires complex cutting processes for production and packaging
Solution Approach 1:
The patent applies preliminary action by pre-forming separation portions during the cloth manufacturing process. These separation portions are created with reduced tear strength through controlled heating and melting of the polyester material, allowing the cloth to be easily torn later without requiring complex cutting operations during production or packaging
Solution Approach 2:
The patent applies local quality by creating distinct separation portions with different properties from the rest of the cloth. These portions have reduced tear strength and defined thickness (0.01mm-2mm) compared to the adjacent cloth material, allowing selective tearing at specific locations while maintaining the overall integrity and strength of the cloth body
2Reliability
If the cloth is produced as large continuous material and then cut into individual pieces, then the cloth has consistent quality, but the packaging process becomes complex requiring stacking and individual packaging
Solution Approach 1:
The patent applies segmentation by dividing the continuous cloth into separable units through pre-formed separation portions. These portions create natural break points that allow the cloth to be easily divided into individual pieces or smaller bundles, simplifying the packaging process while maintaining quality consistency across all pieces
Solution Approach 2:
The patent applies preliminary action by pre-defining separation portions during manufacturing that facilitate later division and packaging. This preliminary structuring allows the cloth to be easily segmented into manageable units for packaging without requiring complex cutting equipment or manual operations
3Ease of operation
If separation portions are formed by heating and melting the material, then the tear strength at separation portions is reduced for easy tearing, but the material structure is altered through phase change
Solution Approach 1:
The patent applies phase transitions by utilizing the melting behavior of polyester material to form separation portions. The material is heated to melt and then cooled to solidify, creating a structural change that reduces tear strength at these portions while maintaining the overall stability and integrity of the cloth material
Solution Approach 2:
The patent applies parameter changes by modifying the temperature and physical state of the polyester material during separation portion formation. The material is heated above its melting point and then cooled, creating permanent structural changes that reduce tear strength without compromising the stability of the surrounding cloth material
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
Enables easy separation of cloth units by tearing, improving user convenience and facilitating centralized storage, while maintaining fabric integrity and preventing fraying.
Implementation Method 1
The heating and melting is performed ultrasonically, e.g., via high frequency ultrasonic
Implementation Method 2
the material of which has been heated and melted, e.g., forming molten masses, to decrease the tear strength of the separation portions
Implementation Method 3
the separation portions are formed by heating, melting and compressing the meltable material of the separation portions
Data Source
AI summary
A continuous cloth comprising a meltable material comprises one or more cloth units having separation portions therebetween, wherein cloth material of the separation portions has been hot melted, facilitating separation of adjacent cloth units at the respective separation portion therebetween.