Textilene Mesh Fabric Composition for Stable 3D Car Mat Molding
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Solution Overview
Problem
Conventional Textilene mesh fabrics face issues with tensile length restrictions in the warp and weft directions, leading to difficulties in 3D modeling and partial filament breakage when used for 3D car mats. Additionally, PVC threads exhibit high shrinkage and deformation problems after heating, resulting in uneven woven cloth and delamination.
Innovation Solution
A Textilene mesh fabric is developed with a mixed combination of 75% PVC threads and 25% polyester synthetic fibers, along with a three-stage heat treatment process to control thermal shrinkage. The thread production mechanism includes a raw material mixer, granulator, filament former, stretching machine, and winder to produce PVC threads with improved thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional Textilene mesh fabric is used with high-strength polyester filaments, then the fabric has sufficient tensile strength, but the tensile length is restricted leading to difficult 3D modeling and filament breakage
Solution Approach 1:
The patent changes the material parameter from conventional high-strength polyester filaments to polyester cutting-resistant fibers with specific linear density (50D-200D). This parameter change enables the fabric to achieve both sufficient tensile strength and adequate tensile length for 3D molding applications, resolving the contradiction between strength and extendability.
2Reliability
If PVC threads are used to weave Textilene mesh fabric, then the fabric has good aging and ultraviolet resistance, but high shrinkage and deformation occur after heating at 150°C-170°C
Solution Approach 1:
The patent creates a composite yarn structure by coating polyester cutting-resistant fibers with PVC material. This composite material combines the dimensional stability and heat resistance of polyester with the aging and UV resistance of PVC. The core polyester fiber resists thermal shrinkage while the PVC coating provides environmental resistance, resolving the contradiction between reliability and dimensional stability.
3Ease of manufacture
If traditional plastic thread extruding machine is used to extrude PVC threads, then the extrusion process is simple, but the threads have high shrinkage rate after heating causing uneven woven cloth and delamination
Solution Approach 1:
The patent modifies the extrusion process parameters by controlling the extrusion temperature, cooling rate, and drawing ratio during thread production. These parameter changes ensure that the PVC-coated polyester fibers are pre-stabilized against thermal shrinkage, maintaining dimensional accuracy while preserving the simplicity of the extrusion process.
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 achieves an elongation of more than 30% under high-temperature softening, significantly reducing thermal shrinkage and deformation issues. This results in stable 3D molded car mats with improved quality and reduced filament breakage.
Implementation Method 1
the stretching machine stretches and thermally contracts the monofilaments into filaments
Implementation Method 2
utilizes the plasticity and elongation of plastics to process molten PVC into thin threads by stretching and extruding
Implementation Method 3
the monofilaments are cooled in the cooling water bath, and the water temperature in the cooling water bath is controlled at 30-40° C.
Implementation Method 4
the extruder and the die core extrude monofilaments
Implementation Method 5
process molten PVC into thin threads by stretching and extruding
Implementation Method 6
Textilene mesh fabric must be baked at 150° C.-170° C. for softening before being processed to 3D molded car mats
Implementation Method 7
PVC monofilament has a high shrinkage rate after heating
Data Source
AI summary
The present invention discloses a Textilene mesh fabric and its application, which comprises warp yarns and weft yarns interwoven; the warp yarns comprise the first warp yarns and the second warp yarns, and the weft yarns comprise the first weft yarns and the second weft yarns; the first warp yarns and the first weft yarns are PVC threads, and the second warp yarns and the second weft yarns are polyester synthetic fibers. The present invention uses the polyester synthetic fiber to replace the traditional polyester yarn, and mixes with PVC thread prepared by the thread production mechanism to weave the Textilene mesh fabric that has an elongation ratio of more than 30% under high-temperature softening.