Warp-Knitted Fabric Loop Density Optimization
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Solution Overview
Problem
Existing warp-knitted fabrics with Velcro loops face challenges in achieving a stable and functional hook and loop system at lower basis weights, as lower weights compromise the Velcro function, and there is a need for a cost-effective solution that balances material savings with functionality.
Innovation Solution
Optimizing stitch density and length in the warp-knitted fabric to achieve a basis weight of 5 to 15 g/m², using a mesh density of 2500-7500 meshes/dm² and thin yarns of 10-40 dtex, along with the optional use of foil strips to enhance stability and reduce material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the basis weight of the warp-knitted fabric is reduced to save material costs, then material expenditure and costs decrease, but the stability and functionality of the Velcro loops are compromised
Solution Approach 1:
The patent applies parameter changes by precisely controlling the mesh density (2500-7500 meshes/dm²) and yarn fineness (10-40 dtex) to achieve the optimal basis weight range (5-15 g/m²). This resolves the contradiction by demonstrating that through careful parameter optimization, one can reduce material consumption while maintaining the structural integrity and functional performance of the Velcro loops, contrary to the conventional belief that lower weight necessarily compromises functionality.
2Reliability
If the mesh density is increased to improve loop stability, then Velcro functionality is maintained, but material consumption and basis weight increase
Solution Approach 1:
The patent resolves this contradiction by establishing the optimal mesh density range of 2500-7500 meshes/dm², which provides sufficient loop stability for Velcro functionality while controlling material consumption. Additionally, the use of thinner yarns (10-40 dtex) compensates for the increased mesh density, allowing the fabric to maintain structural integrity with reduced material input.
Solution Approach 2:
The patent employs composite construction by combining multiple thin yarns (total dtex 30-70) woven in a specific pattern to create loops with adequate stability. This composite approach allows the fabric to achieve the required mechanical properties for Velcro function while keeping the overall basis weight low (5-15 g/m²), thus resolving the contradiction between loop stability and material consumption.
Data Source
AI summary
The present invention relates to a fabric sheet made of plastic. A sheet of this type is known from our EP 1 811 070 B1. It should be evident that, when such a sheet is used as the loop component in a hook-and-loop fastener, the strength of the fastener is affected especially after multiple openings and closures, and therefore, a greater surface weight and coarser yarn strands are considered necessary, which requires large amounts of material and is cost-intensive during production. The present invention therefore aims to overcome said shortcoming and, if possible, produce the fabric sheet cost-effectively while obtaining an acceptable hook-and-loop fastener function. Said aim is achieved in an unexpected manner according to the invention by a loop density ranging from 2500 to 7500 loops/dm2, a loop length ranging from 0.5 to 2.0 mm, and a surface weight of 5 to 15 g/m2, in particular 9 to 13 g/m2.