Woven Fabric with Hollow Structures Using Water-Soluble PVA Cores

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Solution Overview

Problem

The textile industry has faced challenges in producing woven fabrics with hollow structures using polyvinyl alcohol (PVA) cores due to PVA losing its water solubility under high temperature and alkaline conditions, which are common in textile processing, preventing effective removal of PVA cores from woven fabrics.

Innovation Solution

Maintaining the water solubility of PVA cores by neutralizing alkali before drying and using alternative dyeing methods that avoid high temperature and alkaline environments, followed by washing to remove the cores, which allows for the formation of hollow structures that enhance breathability, resilience, and comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If PVA cores are used in woven fabrics to create hollow structures, then air permeability and comfort are improved, but PVA loses water solubility under high temperature and alkaline conditions preventing effective removal

Engineering Contradiction:

Improveremoval of PVA coresVSAvoidwater solubility of PVA

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent modifies the chemical parameters of the processing environment by controlling pH levels and avoiding high temperature alkaline conditions. By maintaining acidic or neutral pH during processing and using acid-based removal methods instead of alkaline methods, the PVA cores remain water-soluble and can be effectively removed to create hollow structures.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of using the conventional alkaline method to remove PVA cores, the patent inverts the approach by using acid-based removal methods. This reversal of the conventional process allows PVA cores to maintain their water solubility and be effectively removed without the harmful effects of high temperature and alkaline conditions.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of manufacture

If high temperature and alkaline conditions are used in textile processing, then dyeing and finishing processes are effective, but PVA cores lose water solubility and cannot be removed

Engineering Contradiction:

Improvedyeing and finishing processesVSAvoidwater solubility of PVA

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent changes the processing parameters by avoiding high temperature and alkaline conditions. Instead, it uses acidic or neutral pH conditions and lower temperatures that preserve PVA water solubility while still enabling effective dyeing and finishing processes through alternative chemical pathways.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces acid-based agents as intermediaries to facilitate the dyeing and finishing processes without requiring high temperature and alkaline conditions. These intermediaries enable effective textile processing while maintaining the water solubility of PVA cores for subsequent removal.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If conventional weaving methods are used, then fabric durability and shape stability are achieved, but hollow structures cannot be created

Engineering Contradiction:

Improvefabric durabilityVSAvoidhollow structure formation

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent segments the yarn structure by incorporating removable PVA cores within the yarns. These cores are later removed to create hollow structures within the woven fabric, while the outer yarn structure maintains the fabric's durability and shape stability through conventional weaving methods.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent performs preliminary action by incorporating PVA cores into the yarns before weaving. The cores serve as temporary structural elements during the weaving process, ensuring fabric durability, and are subsequently removed to create the desired hollow structures in the finished fabric.

Inventive Principle:

Principle #10Preliminary action

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 approach enables the production of woven fabrics with improved air permeability, resilience, and comfort, while maintaining the water solubility of PVA, allowing for the creation of fabrics with hollow structures that do not require additional softeners and provide a less see-through effect.

Implementation Method 1

maintaining the water solubility of PVA cores by neutralizing alkali before drying and using alternative dyeing methods that avoid high temperature and alkaline environments, followed by washing to remove the cores

Methodology Applied

Scientific EffectWater solubility: Solvation

Data Source

PatentUS11326278B2Fabric constructions with hollow structures

Publication Date: 2022.05.10 KOO KAM CHEUNG

AI summary

Techniques for producing an article having hollow structures are described herein. The disclosed techniques include weaving a plurality of yarns to form a woven fabric, wherein the plurality of yarns each comprise a dissolvable core, and the dissolvable core comprises polyvinyl alcohol (PVA) having a water solubility; neutralizing an alkaline before drying the woven fabric to maintain the water solubility of the PVA; and washing the woven fabric or a garment made by the woven fabric to at least partially remove the dissolvable core.