A method to manufacture a textile product, a use thereof and a device for applying the method
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Solution Overview
Problem
Existing methods for manufacturing textile products with polymer yarns fail to account for variations in environmental conditions and material changes, leading to inconsistent surface texture and durability when adhered to secondary surfaces, which affects wear and adherence.
Innovation Solution
A method that measures the surface roughness of the second surface after melting and adapts the manufacturing process to achieve a predetermined surface roughness, using in-line measurement and adjusting parameters such as heating time and pressure to ensure durable adherence, potentially incorporating a resilient intermediate layer for mitigating internal strain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If environmental conditions and material changes are not accounted for in the manufacturing process, then production is simpler and faster, but surface texture consistency and durability deteriorate
Solution Approach 1:
The patent implements a feedback mechanism where the actual surface roughness is measured during manufacturing and compared to the target roughness value. Based on this comparison, the system automatically adjusts manufacturing parameters (heating temperature, pressure, speed) to compensate for environmental variations and material changes, ensuring consistent surface texture without requiring complex manual monitoring
Solution Approach 2:
The system dynamically changes manufacturing parameters (temperature, pressure, transport speed) based on real-time feedback from roughness measurements. This allows the process to adapt to environmental conditions and material variations while maintaining precise control over surface texture, resolving the contradiction between simplicity and precision
2Strength
If heating temperature and time are increased to improve yarn adhesion, then bond strength improves, but energy consumption and risk of material degradation increase
Solution Approach 1:
The system optimizes heating parameters by using feedback from surface roughness measurements to determine the minimum necessary temperature and time required to achieve the desired surface texture and adhesion. This prevents excessive heating while ensuring adequate bond strength, balancing energy consumption with performance requirements
Solution Approach 2:
The patent replaces purely thermal bonding with a combination of mechanical spreading (via the heated roller's surface speed differential) and thermal softening. This mechanical assistance allows lower heating temperatures to achieve the same adhesion strength, reducing energy consumption while maintaining bond quality
3Strength
If a heated roller is used to melt and spread yarn loops, then yarn adhesion improves, but control over surface roughness becomes difficult
Solution Approach 1:
The system measures the actual surface roughness after the heating and spreading process and uses this feedback to adjust heating parameters and roller speed for subsequent processing. This closed-loop control ensures that the desired surface roughness is achieved while maintaining adequate yarn adhesion, resolving the contradiction between these two requirements
Solution Approach 2:
The system dynamically adjusts the heated roller's surface speed relative to the sheet transport speed to control the spreading action. By varying this speed differential, the system can optimize both the mechanical spreading (for adhesion) and the resulting surface roughness, providing dual control over these previously conflicting parameters
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
This approach ensures consistent and durable textile products with optimized surface texture for adherence, adaptable to changing conditions and materials, reducing wear and internal strain issues.
Implementation Method 1
heating the second surface of the sheet to at least partly melt the loops of the yarns to fasten the yarns to the sheet
Implementation Method 2
heating the second surface of the sheet to at least partly melt the loops of the yarns
Implementation Method 3
measuring a roughness of the second surface with the at least partly molten loops of the yarns thereon
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention pertains to a method to manufacture a textile product comprising a first sheet having polymer yarns fastened to this sheet to form a pile thereon, the method comprising providing the sheet, stitching the polymer yarns through the sheet to form the pile on a first surface of the sheet and loops of the yarns at a second surface of the sheet, heating the second surface of the sheet to at least partly melt the loops of the yarns to fasten the yarns to the sheet, wherein the method comprises measuring a roughness of the second surface with the at least partly molten loops of the yarns thereon, after the at least partly molten loops have solidified and, if the roughness differs from a predetermined surface roughness, adapting the method to manufacture the textile product, in order to obtain a second surface roughness that differs from the measured surface roughness. The invention also pertains to a device for applying this method.