Textile mesh-like structure for repelling insects
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing insect protection nets made from polymer fibers face issues with thermal shrinkage, energy consumption, formaldehyde residues from melamine resin, and recyclability challenges due to non-pure textile composition.
Innovation Solution
A textile grid-like structure composed of polyester threads with different melting temperatures, where multifilament polyester threads with varying melting points are used to achieve rigidity and restoring force without melamine resin, reducing energy requirements and formaldehyde presence, and enabling easier recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If melamine resin is applied to achieve stiffness and resilience, then the desired mechanical properties are achieved, but formaldehyde residues remain and energy consumption increases
Solution Approach 1:
The invention extracts and removes the harmful melamine resin component from the textile treatment process entirely. Instead of applying external resin coatings, the patent uses a dual-polymer yarn system where one polymer component (polyester with low melting point) is melted to bind the other component (polyester with normal melting point), creating stiffness and resilience without formaldehyde-containing resins.
Solution Approach 2:
The invention changes the physical state parameter of the low-melting-point polyester component from solid to liquid by heating it above its melting point (140-150°C). This phase change allows the polymer to flow and coat the textile structure, providing binding and mechanical properties without requiring chemical resin applications.
2Strength
If melamine resin is applied and heated to 190°C for curing, then stiffness and resilience are achieved, but energy consumption increases due to evaporation and high temperature
Solution Approach 1:
The invention changes the processing temperature parameter from the conventional 190°C (required for melamine resin curing) to a lower range of 140-150°C (sufficient for melting polyester). This parameter change reduces energy consumption while achieving the same mechanical property enhancement through polymer melting and binding rather than resin curing.
Solution Approach 2:
The invention replaces the chemical curing mechanism of melamine resin with a physical melting and binding mechanism of polyester. Instead of relying on chemical reactions that require high temperatures and evaporation, the patent uses the physical phase change of polyester to achieve binding, eliminating the need for high-energy evaporation processes.
3Strength
If melamine resin is used for setting, then the desired stiffness is achieved, but machine cleaning becomes difficult and time-consuming
Solution Approach 1:
The invention extracts and eliminates the melamine resin substance from the manufacturing process. By using only polyester components that can be melted and applied, the patent removes the substance that causes machine contamination and cleaning difficulties, while still achieving the required stiffness through polymer binding.
Solution Approach 2:
The invention uses homogeneous polyester material throughout the yarn structure (both components are polyester with different melting points), eliminating the need for separate resin application steps. This homogeneity simplifies the manufacturing process and eliminates the cleaning issues associated with applying and removing foreign resin substances from machinery.
4Strength
If the textile structure contains melamine resin, then stiffness and resilience are achieved, but recyclability is compromised due to non-pure textile composition
Solution Approach 1:
The invention creates a homogeneous textile structure composed entirely of polyester materials (two components with different melting points). This purity and homogeneity enable the textile to be recycled through standard polyester recycling processes, unlike conventional treated textiles that contain mixed materials and chemical resins difficult to separate and recycle.
Solution Approach 2:
The invention extracts and removes foreign substances (melamine resin) from the textile composition, leaving only pure polyester components. This extraction enables the textile to maintain its recyclability as a pure polymer material while still achieving the required mechanical properties through the dual-polymer melting and binding mechanism.
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 solution provides a more energy-efficient, formaldehyde-free, and recyclable insect protection net with sufficient rigidity and resilience, overcoming the limitations of prior art by using a pure textile structure formed through a specific production process involving different melting temperature polyester threads.
Implementation Method 1
the 30% polyester component can then be melted at relatively low melting temperatures of 140-150°C, so that it then forms a polyester film over the entire surface of the textile structure
Implementation Method 2
fixing the textile structure at a temperature that is above the melting temperature of the lower-melting polyester component and below the normal-melting component
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The patent application relates to a textile grid-like structure for insect repellency made of polymer threads with defined openings for air passage, whereby the polymer threads are formed from two polymers with differing melting points. The object of the invention is to create a new textile grid-like structure that can be processed into high-quality insect screens and offers sufficient stiffness and resilience. This object is achieved by forming the polymer threads from two polymers with differing melting points.