Woven Fabric Composition for Moisture Regain and Dimensional Stability
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Solution Overview
Problem
Sheeting fabrics face challenges with dimensional stability, wrinkle-resistance, moisture regain, thermal conductivity, smoothness, and comfort, particularly when composed of cotton and polyester fibers, which affect their performance and user experience.
Innovation Solution
A woven fabric is developed with a composition of blended warp yarns comprising 70-75% cotton and 25-30% regenerated cellulose fibers, interwoven with continuous polyester filaments, optimizing warp crimp and cover factor to enhance moisture regulation, thermal conductivity, and dimensional stability, while maintaining cotton-like comfort and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sheeting fabrics are formed primarily from cotton fibre to provide comfort, then comfort is improved, but dimensional stability and wrinkle-resistance deteriorate
Solution Approach 1:
The patent applies composite materials by blending cotton fibres with regenerated cellulose fibres (lyocell or modal) in specific ratios (60-80% cotton, 20-40% regenerated cellulose). This composite structure combines the comfort properties of cotton with the dimensional stability and wrinkle-resistance of regenerated cellulose, resolving the contradiction between comfort and stability.
2Stability of the object's composition
If sheeting fabrics comprise cotton and polyester fibres to improve wrinkle resistance and dimensional stability, then dimensional stability is improved, but moisture regain and thermal conductivity deteriorate
Solution Approach 1:
The patent replaces polyester with regenerated cellulose fibres to create a cotton-regenerated cellulose composite. Regenerated cellulose has high moisture regain (10-15%) and good thermal conductivity, unlike polyester. This composite maintains dimensional stability while restoring moisture management properties.
Solution Approach 2:
The patent changes the fiber composition parameters by specifying 60-80% cotton and 20-40% regenerated cellulose, which optimizes the balance between dimensional stability and moisture regain. This parameter optimization resolves the contradiction by achieving both stability and moisture absorption capability.
3Reliability
If sheeting fabrics comprise cotton and polyester fibres to improve wrinkle resistance, then wrinkle-resistance is improved, but smoothness, shine and lustre deteriorate
Solution Approach 1:
The patent uses a composite of cotton and regenerated cellulose fibres where regenerated cellulose contributes smoothness, shine and lustre properties. The combination maintains wrinkle-resistance while improving surface appearance, resolving the contradiction between wrinkle-resistance and smoothness.
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 fabric achieves improved comfort, smoothness, and dimensional stability, with balanced moisture regain and thermal conductivity, ensuring durability and easy care properties, even after multiple washes, and retains vibrant colors.
Implementation Method 1
moisture regain of the woven fabric is in the range of 5.5%-8.5%
Implementation Method 2
optimize moisture and thermal conductivity
Data Source
AI summary
A woven fabric having a novel composition of multiple fibres with improved comfort and performance is disclosed. Further, a fabric composition, construction and crimp control process provides enhanced comfort and performance by improving parameters such as thermal conductivity and moisture regulation along with other parameters such as dimensional stability, smoothness, drying properties and tensile strength. The woven fabric includes a plurality of warp yarns and a plurality of weft yarns interwoven with said plurality of warp yarns, where the plurality of warp yarns is a blended spun yarn including cotton fibre and regenerated cellulose fibre. Each of the plurality of weft yarns is a continuous polyester filament of fine count. The woven fabric composition includes more than 50% cotton, 15-25% regenerated cellulose fibre and less than 35% polyester, further wherein moisture regain of the woven fabric is in the range of 5.5%-8.5%.