3D Weave Fabric Floating Threads Heat Treatment
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Solution Overview
Problem
Existing methods for imparting three-dimensional shapes to fabrics, such as sewing and fusion techniques, often result in the loss of stretch function and other performance characteristics.
Innovation Solution
A three-dimensional weave fabric is created using two layers, a face layer and a back layer, woven together via floating threads with predetermined patterns or areas left unwoven, controlled by a computer program, and then heat treated to enhance stretch functionality and create puffed tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If sewing and fusion techniques are used to impart three dimensional shapes to fabrics, then the fabric can achieve desired three dimensional forms, but the stretch function and other performance characteristics are lost
Solution Approach 1:
The patent transitions from traditional two-dimensional fabric construction to three-dimensional structure by creating tubular formations through selective weaving. The fabric incorporates vertical tubes that extend through the fabric layers, adding a third dimension while maintaining the woven structure's inherent stretch properties. This is achieved by forming continuous tubular elements that integrate with the fabric's warp and weft threads, allowing the fabric to achieve three-dimensional shape without compromising its elastic performance characteristics.
Solution Approach 2:
The patent creates a composite woven structure combining multiple fabric layers with integrated tubular elements. The composite construction involves face and back layers connected by floating threads that form three-dimensional tubes, creating a multi-layer composite material that maintains stretch functionality while achieving desired three-dimensional forms. The composite structure allows different regions of the fabric to have different properties, with tubular areas providing volume while connected regions maintain flexibility and stretch.
2Ease of manufacture
If traditional weaving methods are used, then the fabric structure is simple and easy to manufacture, but the fabric lacks three dimensional shape and enhanced stretch function
Solution Approach 1:
The patent segments the fabric construction into distinct functional zones: face layers, back layers, and intermediate tubular sections. The weaving process is divided into different phases where tubes are formed in specific regions while other areas maintain standard woven structures. This segmentation allows the fabric to incorporate complex three-dimensional elements in targeted areas while keeping the overall manufacturing process compatible with conventional weaving techniques. The segmented approach enables selective formation of tubular structures without requiring complete redesign of the entire fabric construction process.
Solution Approach 2:
The patent introduces floating threads as intermediary elements that connect the face and back layers to form three-dimensional tubes. These intermediary threads act as mediators between the two fabric layers, creating vertical tubular structures that add three-dimensional shape. The floating threads are integrated into the weaving process, allowing them to be incorporated seamlessly while maintaining ease of manufacture. The intermediary elements enable the formation of complex three-dimensional structures without requiring post-weaving assembly or additional manufacturing steps.
3Reliability
If heat treatment is applied to shrink floating threads, then the tubes puff and stand up creating enhanced stretch function, but the manufacturing process becomes more complex
Solution Approach 1:
The patent utilizes parameter changes in the thermal processing stage to achieve the desired fabric properties. By controlling temperature, time, and atmospheric conditions during heat treatment, the floating threads are selectively shrunk to create puffed tubes with enhanced stretch function. The heat treatment parameters are optimized to shrink the floating threads sufficiently to create volume while avoiding damage to the base fabric layers. This parameter control allows the manufacturing process to remain relatively simple, using standard heat treatment equipment with adjusted settings rather than requiring complex additional machinery.
Solution Approach 2:
The patent performs preliminary actions during the weaving stage by incorporating floating threads in specific patterns and configurations that are pre-configured to form tubes. The floating threads are positioned and tensioned during weaving in anticipation of the subsequent heat treatment, ensuring that when shrinkage occurs, the tubes form the desired three-dimensional shape. This preliminary configuration simplifies the overall manufacturing process by preparing the fabric structure in advance, so that the heat treatment step simply activates the pre-planned tube formation rather than requiring complex real-time control during processing.
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 method preserves the stretch function and enhances the fabric's performance by creating puffed tubes that can be filled with fibers for added firmness or texture, allowing for customizable patterns and designs.
Implementation Method 1
The heat treating process shrinks the floating threads, causing manipulation of the tube. Specifically, the tube puffs or stands up more than if there was no heat treatment.
Data Source
AI summary
A three dimensional weave fabric material is disclosed for use in producing garments and other items. The three dimensional weave fabric material comprises two layers of material, a face layer and back layer. The face layer and the back layer are then woven together via floating threads to create predetermined patterns or areas where the two layers are not woven together. These areas which are not woven together create tubes. Specifically, the weaving is controlled by a computer program that will weave or not weave the two layers together. Once the weaving is complete, the three dimensional weave fabric material is heat treated. The heat treating process shrinks the floating threads, causing manipulation of the tube. Specifically, the tube puffs or stands up more than if there was no heat treatment. Additionally, the tubes can be filled with fibers or other suitable materials to make the puffed areas more firm.