Tufted carpet primary base fabric
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing primary cloths for tufted carpets do not maintain the original properties and strength after the tufting step, as the continuous filaments are not adequately bonded and restricted, leading to potential damage from needles and inability to perform a second tufting step if defects are present.
Innovation Solution
A nonwoven fabric comprising continuous polyester filaments with a specific 'Y4' shape cross-section, made from a combination of low melting point and high melting point polyesters, where the low melting point polyester is used for bonding, providing enhanced rigidity and resistance to needle damage, and maintaining the original form and strength after the tufting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional nonwoven fabric is used as primary cloth, then the continuous filaments are bonded and restricted during tufting, but the original properties are not maintained after tufting step
Solution Approach 1:
The continuous filament is segmented into different functional regions along its length: a rigid upper portion (first region) that maintains structural integrity and a flexible lower portion (second region) that bonds during tufting. This segmentation allows the filament to simultaneously maintain original properties and endure the tufting process.
Solution Approach 2:
Different portions of the continuous filament are given different mechanical properties: the upper portion has high rigidity to maintain the primary cloth's original properties, while the lower portion has low rigidity to facilitate bonding and restriction during tufting. This local differentiation resolves the contradiction between maintaining original properties and withstanding tufting stresses.
2Strength
If continuous filaments are bonded and restricted in the tufting step, then the primary cloth resists strain, but the filaments may be damaged by needles
Solution Approach 1:
The continuous filament is designed with differentiated rigidity along its length: the upper portion maintains high rigidity to provide anti-strain capability, while the lower portion has reduced rigidity to allow needle penetration without damage. This local quality differentiation allows the fabric to resist strain while protecting filaments from needle damage.
Solution Approach 2:
The filament is divided into functional segments where the lower segment serves as a bonding zone that absorbs needle impact, while the upper segment maintains structural strength. This segmentation protects the main body of the filament from damage while still providing the necessary anti-strain properties.
3Adaptability or versatility
If the primary cloth maintains original properties after tufting, then a second tufting step can be performed, but requires specific filament structure
Solution Approach 1:
The filament structure incorporates local quality differentiation with a rigid upper portion and flexible lower portion, allowing the primary cloth to maintain its original properties after tufting. This enables adaptability for potential second tufting steps while using a relatively simple extrusion process to create the differentiated structure.
Solution Approach 2:
The filament's rigidity parameter is changed along its length, with the upper portion having high rigidity and the lower portion having low rigidity. This parameter variation is achieved through controlled extrusion and cooling processes, providing the necessary adaptability without excessive structural complexity.
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 primary cloth maintains its original rigidity and strength, effectively preventing deformation during dyeing and backing steps, and allows for the possibility of a second tufting step if defects are detected, ensuring the tufted carpet's stability and quality.
Implementation Method 1
the continuous filaments are bonded one another by melting the low melting point polyester
Implementation Method 2
the heated-embossing is performed in the lower temperature, that is, 25 degrees in temperature than the melting point of the bonding agent of the polyester
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The primary cloth is stabilized after a tufting step. The pr imary cloth is a nonwoven fabric of continuous filaments which are mor e than 10 dtex in fineness. The continuous filament is consisting of polyester which has a nearly 'V' part made of a low melting point pol yester and a nearly '+' part made of a high melting point polyester. The continuous filaments are one other bonded by melting or softening of the low melting point polyester to form the nonwoven fabric.