Warp Knit Textile Panel for Composite Surface Flatness
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Solution Overview
Problem
Knitted textile panels with open stitches used in composite materials suffer from irregular and non-flat surfaces due to visible mesh columns, leading to an unsightly appearance and increased polymer material usage, which is a hindrance for ornamental applications like protective covers and advertising media.
Innovation Solution
A knitted textile panel design featuring alternating and opposing stitches in the warp and weft directions, with weft threads inserted at specific intervals, improves flatness and regularity while maintaining mechanical resistance, allowing for a reduced polymer layer application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional warp-knitted textile panels with single mesh yarn are used, then mechanical resistance is maintained, but surface flatness and regularity deteriorate due to visible mesh columns
Solution Approach 1:
The patent divides the single mesh yarn structure into multiple yarns (first mesh yarn and second mesh yarn) that work alternately to form stitches. This segmentation allows each yarn to create simpler, flatter stitch columns while collectively maintaining the required mechanical resistance, thereby resolving the contradiction between surface flatness and structural complexity.
Solution Approach 2:
The patent applies different yarns (first mesh yarn and second mesh yarn) with potentially different properties to different rows of stitches alternately. This local differentiation allows optimization of surface flatness in specific areas while maintaining overall mechanical performance, addressing the contradiction between surface quality and structural requirements.
2Quantity of substance
If traditional knitted panels with voluminous stitch columns are used, then mechanical strength is ensured, but polymer material consumption increases due to irregular surfaces requiring thicker coating
Solution Approach 1:
By segmenting the stitch formation into alternating first and second stitches from different yarns, the patent creates flatter, more regular surface columns. This reduces the volume of polymer material needed for coating while maintaining the cumulative mechanical resistance equivalent to traditional single-yarn structures.
Solution Approach 2:
The patent changes the structural parameters of the knitted panel by introducing alternating yarns and stitch patterns, which modifies the surface topology to be flatter and more regular. This parameter change reduces polymer material consumption while preserving mechanical strength through the combined effect of multiple yarns.
3Adaptability or versatility
If mesh columns with regular intervals are formed using two mesh bars working simultaneously, then attachment functionality is achieved, but surface regularity and flatness deteriorate
Solution Approach 1:
The patent implements periodic action by having two mesh bars work alternately rather than simultaneously, creating alternating first and second stitches in a regular pattern. This periodic alternation maintains the functional regularity needed for attachment while producing a flatter, more regular surface compared to simultaneous bar operation.
Solution Approach 2:
Instead of having both mesh bars work simultaneously on each row (which creates voluminous projections), the patent inverts the approach by having them work alternately on alternating rows. This inversion creates a flatter surface while preserving the regular interval pattern necessary for attachment functionality.
Data Source
Figure 1A~2B
Figure 3A~5B
Figure 6A~7B
AI summary
The invention relates to a composite material comprising a warp-knitted textile panel having columns of stitches corresponding to the warp direction and rows of stitches corresponding to the weft direction, and first and second opposing faces, said first face being coated with a layer consisting of at least one polymer material. Advantageously, each of said columns of stitches comprises first formed stitches, one row of stitches in two, with a first thread, and second formed stitches, one row of stitches in two, with a second thread, the first and the second stitches being alternated one row of stitches in two and being in opposition. Furthermore, in the weft direction, the first thread and the second thread each form stitches, alternately, one row of stitches in two.