Three-Dimensional Surface Weaving With Individually Controlled Warp Threads
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Solution Overview
Problem
Existing weaving machines are limited to producing plain fabrics and lack the capability to automate the production of three-dimensional surface weaving, while three-dimensional knitting fabrics suffer from poor mechanical properties and material limitations.
Innovation Solution
A system comprising a jacquard device, weaving device, and roller matrix, which selectively raises or lowers warp threads, carries weft threads into sheds, and controls warp threads to move forward or backward, enabling automated three-dimensional surface weaving with improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional weaving machines are used to produce plain fabric, then the fabric has good mechanical properties and structural stability, but the machine lacks the capability to produce three-dimensional surface weaving
Solution Approach 1:
The reed is divided into multiple slices (first slice, second slice, third slice) that can move independently. The second slice is movable between the first and third slices to clamp or unclamp warp threads, enabling selective control of individual warp threads to create three-dimensional surface structures while maintaining the overall weaving machine framework
Solution Approach 2:
The second slice of the reed is designed to be movable rather than fixed, allowing it to dynamically clamp or unclamp warp threads during the weaving process. This dynamic adjustment capability enables the machine to produce varied three-dimensional surface patterns while maintaining structural stability
2Extent of automation
If three-dimensional knitting is used to create 3D garments, then the production can be automated, but the material must be soft and elastic with poor mechanical properties under tensile force
Solution Approach 1:
The invention replaces the knitting mechanism with a weaving mechanism that uses interlacing of warp and weft threads instead of knitting loops. This substitution allows automated production of three-dimensional structures while using materials with superior tensile strength and mechanical properties, as weaving fabric inherently provides better strength characteristics than knitted fabric
3Shape
If existing weaving machines weave plain fabric with complex patterns, then the appearance and texture can be varied, but the fabric remains two-dimensional without three-dimensional surface structure
Solution Approach 1:
The movable second slice of the reed enables control of warp threads in the third dimension by selectively clamping or unclamping individual warp threads. This allows the creation of three-dimensional surface structures that protrude from or recess into the fabric surface, adding vertical dimensionality beyond the traditional two-dimensional plain weave
Solution Approach 2:
The reed slices can selectively clamp or unclamp specific warp threads at different positions, creating local variations in fabric height and texture. This localized control enables complex three-dimensional patterns and surface structures while maintaining the overall fabric integrity
Data Source
AI summary
Systems, devices and methods for three-dimensional surface weaving are disclosed herein. The system includes a jacquard device, a weaving device and a roller matrix. The jacquard device configured to selectively raise or lower the warp threads to form a shed for the weft thread to travel; the weaving device configured to carry the weft thread into the shed and weave the weft thread on the warp threads; and the roller matrix with individually controlled rotate apparatus configured to control the warp threads to move forward or backward. The warp threads come from rotate apparatus installed on the roller matrix. The rotate apparatus is controlled individually to forward or reverse rotate, so that the attached warp thread is able to be longer or shorter. As the warp threads can be shortened during weaving process, the three-dimensional surface can be produced.