Woven products
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Solution Overview
Problem
Current methods for producing tufted artificial grass carpets often require multiple layers of primary backing fabrics, which can lead to variable tension and dimensional instability due to separate layer stitching or needling processes, and may not fully utilize the properties of single-layer woven fabrics for enhanced strength and tuft anchorage.
Innovation Solution
A method of simultaneously weaving and interweaving two layers of polypropylene primary backing fabric on a single loom, creating a self-interwoven composite fabric that eliminates tension differences and reduces process steps, resulting in a stronger, more stable double-layer woven product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple separate layers of primary backing fabric are used and stitched or needled together, then tuft anchorage and carpet strength are improved, but dimensional stability deteriorates due to variable tension between layers
Solution Approach 1:
The patent combines two separate woven backing layers into a single integrated woven structure by interweaving the warp and weft tapes of both layers simultaneously on a loom. This merging eliminates the interface between separate layers, ensuring uniform tension distribution and preventing dimensional instability while maintaining enhanced strength through the combined structure.
Solution Approach 2:
The invention creates a composite woven fabric by integrating two different woven backing layers (typically a stiffening layer and a fleecy layer) into a single multilayer woven structure. This composite approach allows the layers to work together as a unified system with consistent mechanical properties, achieving both strength and dimensional stability.
2Strength
If multiple separate layers of primary backing fabric are used, then tuft anchorage is improved, but process complexity increases due to separate layer handling and stitching/needling processes
Solution Approach 1:
The patent merges the production of two separate backing layers and their subsequent joining operations into a single weaving process. By interweaving both layers simultaneously on the loom, the invention eliminates the need for separate stitching or needling processes, thereby reducing process complexity while maintaining the tuft anchorage benefits of multilayer construction.
Solution Approach 2:
The invention performs the joining of the two backing layers during the initial weaving process itself, rather than as a subsequent separate operation. The layers are interwoven and mechanically bonded during loom operation, which preliminarily establishes the integrated structure before any post-processing is required, simplifying the overall manufacturing process.
3Ease of manufacture
If single layer woven primary backing is used, then process simplicity is maintained, but tuft anchorage and carpet strength are insufficient for sports surfaces
Solution Approach 1:
The patent creates a composite woven structure by integrating two functional layers within a single woven fabric. The combination of a stiffening layer (providing dimensional stability) and a fleecy layer (providing tuft anchorage) in a single integrated weave achieves the enhanced strength required for sports surfaces while maintaining relative manufacturing simplicity through continuous loom production.
Solution Approach 2:
The invention merges the functions of two separate backing layers into a single integrated woven product that is produced in one continuous process on the loom. This combined structure delivers both the tuft anchorage of a fleecy layer and the dimensional stability of a stiffening layer, meeting sports surface requirements without requiring post-production assembly operations.
4Productivity
If two separate primary backing layers are stitched together after weaving, then production efficiency is maintained, but manufacturing precision deteriorates due to tension differences between layers
Solution Approach 1:
The patent performs the precise alignment and bonding of the two backing layers during the weaving process itself, before any post-processing occurs. The simultaneous interweaving of both layers on the loom ensures precise dimensional consistency is established during production, eliminating the need for subsequent stitching operations that would compromise precision.
Solution Approach 2:
The invention merges the layer bonding operation into the weaving process, achieving both production efficiency and manufacturing precision through a single integrated operation. The continuous weaving process maintains consistent tension and alignment throughout production, delivering dimensionally precise products without requiring separate post-weaving assembly steps.
Data Source
AI summary
Disclosed is a woven product adapted to be used as a primary backing layer for a surface, ground or floor covering comprising artificial or synthetic grass or turf. The woven product comprises at least a first woven layer and a second woven layer, wherein the first and second woven layers are interwoven, the first woven layer comprises a plurality of warp tapes/threads and a plurality of weft tapes/threads, the warp tapes/threads and the weft tapes/threads of the first woven layer being substantially perpendicular to one another. The second woven layer comprises a plurality of warp tapes/threads and a plurality of weft tapes/threads, the warp tapes/threads and the weft tapes/threads of the second woven layer being substantially perpendicular to one another.