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 surface texture, which affects durability and adherence to secondary surfaces, leading to inconsistent product quality over time due to environmental and material changes.
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 non-contact methods to ensure consistent and durable adherence, incorporating a resilient intermediate layer to mitigate internal strain in laminated products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the manufacturing process does not control surface roughness, then the production process is simpler and faster, but the product quality and adherence consistency deteriorates
Solution Approach 1:
The patent applies preliminary action by measuring surface roughness immediately after the melting process while the material is still hot and pliable. This allows detection and correction of surface texture variations before they become permanent defects, ensuring consistent adherence properties without requiring complex post-processing control systems
Solution Approach 2:
The patent implements feedback control by continuously measuring surface roughness with a sensor and using this information to adjust manufacturing parameters in real-time. The measured roughness values are fed back to the control system, which modifies heating temperature, pressure, or speed parameters to maintain target surface texture and ensure consistent product quality
2Reliability
If environmental and material changes are not accounted for, then the manufacturing process is more stable and simpler, but the product quality consistency over time deteriorates
Solution Approach 1:
The patent uses feedback control to continuously monitor surface roughness and automatically adjust manufacturing parameters to compensate for environmental and material variations. This closed-loop system maintains reliable product quality despite changes in humidity, temperature, or material batches by detecting deviations and correcting them in real-time
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting manufacturing parameters such as heating temperature, pressure, and conveyor speed based on measured surface roughness and environmental conditions. This allows the process to adapt to varying materials and environmental factors while maintaining consistent product quality and adherence properties
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 method ensures consistent surface texture and improved durability of textile products by adjusting manufacturing parameters based on real-time surface roughness data, reducing internal strain and enhancing adherence to secondary surfaces.
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
Data Source
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.