Method of manufacturing hybrid additive fabric, the fabric, and tools for manufacturing fabric

Abstract

A method of manufacturing a fabric by laying a parallel surface of yarn then 3D printing second layer of filament to entangle surface fibres of the yarn, and drying the wet fibre on the yarns and the

Description

The present invention relates to a method of manufacturing a fabric, and the fabric made by the method. Fabric made from yarn is currently produced by either a knitting process which involves the interlooping of yarn, or a weaving process which involves the crossing over and under of yarn, or the entanglement of fibre on yarn. These construction methods have a definite look and texture. There is thus a limitation in the end appearance and functionality. The invention seeks to provide an alternative fabric construction especially for spun yarn, filament, thread and fine wires by an additive method. The new process combines 3D printing and yarn or such like e.g., wire or thread to create what can be considered as a hybrid fabric surface. According to the present invention there is provided a method of manufacturing a fabric comprising: a) laying out first lengths of spun yarn, thread or wire in a parallel array, or a desired shape. b) laying out a second layer of 3D filament in an array or a desired shape to entangle with fibres on surface of yarns in the array or stick to thread or wire, and the 3D printer filament. c) The method may further comprise laying out second, third and multiple layers of spun yarn, thread or wire and 3D pen filament to create a multiple layered textile fabric. d) Preferably if spun yarn is used the method further comprises releasing fibres on the surface of yarn by brushing the yarn to raise fibre from the yarn. e) Preferably the brushing of the yam is done with a rotating brush or a board with a flat hooked surface such as Velcro hook f) Preferably the method of connecting the surface fibre of yarn and the 3D filament is by wetting the yarns with the heated 3D filament which becomes liquidized through heat. g) Preferably the wet 3D filament blending with the fibre of the yarn surface provides entangling sufficient to form a fabric structure when dried. Embodiments of the invention will now be described with reference to the accompanying drawing in which: FIG 1.1 Yarn feed pen with yarn holder; FIG 1. 2 View of an existing 3D printing pen used to place filament; FIG 1. 3 View of attachable dispenser feed to place components onto 3D filament. Referring to Figure 1 there is shown tools for manufacturing fabric. As show in Figure 1 first feed tool 1 with spun yarn is provided to lay out spun yarns into a first parallel array. This could be single yarns side by side or double or more layers of single yarns side by side, e.g., of different texture, colour technical functionality. In addition, yarns can be layered in various shapes not limited to side by side. In addition, yarn can be replaced with wire, thread, or bespoke filament. Via a 3D pen a layer of filament 2 is place onto spun yarn or such like. The filament is heated and when dry will entangle and blend with yarn surface to create a fabric. Components 3 can be easily added to filament to further advance the functionality of the fabric. The fabric of the invention has numerous advantages. Smart components such as semiconductors can be added to the yarns, wires, filaments or thread before they are assembled into an array or preferred shape giving endless functionality and creative potential to the fabric. The air retained within the entangled fibres and the 3D filament result in a construction which is formed from a high percentage of air, e.g. the fabric can be constructed to be 40% air. The open structure provides a transparent fabric surface providing a lightweight fabric. Controlling degree of space between fibres allow easy control of ventilation and insulation properties in the fabric. The manufacturing process is additive therefore layer by layer providing smart materials, eco and sustainable structures and components to be layered between the layers of fibre on yarn, filament and wire and 3D printing filament. There is no interlocking or crossing over of the yarns or filament, which provides space for large components such and circuit boards or drug delivery scaffolds to be easily embedded between the layers which is not possible when using the knitting or weave process. The manufacturing process is much quicker than with fabrics which use the knitting or weave process. The process is easy to use and does not need large or complicated machinery to produce large or small fabric surfaces. The process creates textile fabrics in a rapid time frame and can but used in a small environment such as a laboratory, small studio or private dwellings. The process when embedded with semi-conductors for tracking or monitoring can be easily incorporated with adhesive wound dressing and trauma dressing to enhance functionality. The new invention provides a method to create textiles in a simple and cost efficient in comparison to traditional methods. In addition, extremely small areas can be manufactured for rapid prototyping while reducing waste due to the removal for the need for large machinery. The invention may take a form different to that specifically described above. Further modifications will be apparent to those skilled in the art without departing from the scope of the present invention. 05 09 25

Claims

1. A method of manufacturing a fabric comprising:a) laying out first lengths of spun yam in a parallel array or desired shape;5 b) releasing fibres on the surface of each length of the spun yarn by brushing the spun yam;c) placing filament onto the first lengths of yam in the parallel array or desired shape using a 3D printer or 3D printer pen to entangle surface fibres of the yams; andd) drying wet fibre on the yams and the filament.

102. A method according to claim 1, wherein the brushing of the yam is done with a brush or a flat block with hooks to raise fibre from the yam surface.

3. A method according to claim 1, wherein the entangling of the surface fibres of15 the yams is sufficient to form a flexible fabric surface4. A fabric made by the method of any preceding claim.

5. An apparatus for manufacturing a fabric, comprising:15 a) a first feed station to lay out first lengths of spun yam in a parallel array or desired shape;b) a brush to brush the spun yam to release fibres on the surface of each length of the spun yam;c) a feed to release the 3D printer filament either via a 3D printer or a 3D printer pen to entangle surface fibres of yams in the array or desired shape and the filament; and25 d) means for drying wet fibre on the yams and the filament.

6. A method according to claim 1, wherein the filament is placed onto the first lengths of yam using a 3D printer or a 3D pen.30 7. A method according to claim 1, wherein the first lengths of spun yam are laid out in the parallel array using a powered machine or a yam pen tool.

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