Two-Layer Fabric Warp Weft Arrangement for Unwoven Production
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Solution Overview
Problem
Conventional unwoven fabrics face issues with surface density uniformity, air permeability, fiber sticking, and curling due to inadequate lateral and diagonal rigidity, leading to manufacturing challenges during the production process.
Innovation Solution
A two-layer fabric structure with specific warp and weft arrangements, including binding yarns and overlapping warps, is designed to enhance surface density, air permeability, and rigidity while reducing fiber sticking, featuring a combination of plain weaving and carbon fibers to achieve improved sheet supportability and reduced tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If air permeability in the fabric is increased, then dehydration property is improved, but fiber is removed and vacuum effect is reduced
Solution Approach 1:
The patent applies parameter changes by precisely controlling the diameters of warps and wefts within specific ranges (0.25-0.40mm for warps, 0.35-0.50mm for wefts) and setting their count densities (8-12 warps/25mm, 10-14 wefts/25mm). These parameter optimizations balance air permeability for dehydration while preventing fiber removal and maintaining vacuum effect.
2Strength
If lateral rigidity of the fabric is increased, then fabric folding is prevented, but sheet supportability may be compromised
Solution Approach 1:
The patent employs composite material principles by combining multiple yarn types including polyester yarns, polypropylene yarns, and elastic yarns in specific layers. This composite structure achieves both high lateral rigidity to prevent folding and adequate sheet supportability for reliable unwoven fabric formation.
Solution Approach 2:
The patent uses a multi-layer fabric structure with different yarn arrangements in each layer (surface layer, intermediate layer, back layer). This dimensional approach allows optimization of lateral rigidity in the plane while maintaining sheet supportability through the thickness direction.
3Reliability
If surface density is increased to improve sheet supportability, then fabric stability is improved, but air permeability is reduced
Solution Approach 1:
The patent applies local quality by creating different yarn density distributions in different layers and regions of the fabric. The surface and back layers have higher yarn density for sheet supportability, while the intermediate layer has optimized spacing to maintain air permeability for dehydration.
4Ease of manufacture
If the fabric structure is simplified to reduce manufacturing complexity, then production efficiency is improved, but sticking of fiber and curling cannot be prevented
Solution Approach 1:
The patent segments the fabric into multiple functional layers with specific yarn assignments. The binding warp yarns are separated from the main structure and given specific functions (preventing fiber sticking), while carbon fiber yarns are integrated to prevent curling. This segmentation allows each component to address specific problems without complicating the overall manufacturing process.
Data Source
AI summary
The object of the present invention is to provide a two-layer fabric for manufacturing a unwoven fabric which can reduce the sticking of the fiber generated upon the manufacturing of the unwoven fabric, while add the excellent lateral rigidity, the excellent diagonal rigidity, and the excellent sheet supportability to the two-layer fabric for manufacturing the unwoven fabric.In the two-layer fabric for manufacturing the unwoven fabric comprising a right surface side layer consisting of wefts of the right surface side and warps of the right surface side, and a back surface side layer consisting of wefts of the back surface side and warps of the back surface side, the two-layer fabric for manufacturing the unwoven fabric further comprises a first pair of wefts in which a binding warp on the right surface side serving as a binding yarn and a binding warp on the back surface side serving as a binding yarn are arranged in a substantially vertical direction, a second pair of warps in which a warp on the right surface side and a warp on the back surface side are arranged in a vertical direction to be overlapped with each other, and a third pair of warps in which two warps on the right surface side are arranged adjacent to each other.