3D Distance Woven Fabric Weaving Machine Gap Control
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Solution Overview
Problem
Existing weaving machines, such as velvet weaving machines, are limited in producing three-dimensional woven fabrics with gaps greater than 20 centimeters, failing to meet diverse design requirements for fabrics needing larger inter-fabric distances.
Innovation Solution
A method and apparatus for weaving three-dimensional woven fabrics with gaps greater than 20 centimeters, involving a warp let-off mechanism, heald frames, a picking mechanism, a beating-up mechanism, and a yarn raising mechanism to interweave outer and inter-layered fabrics with inter-yarns, allowing for adjustable gap sizes up to 300 centimeters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If velvet weaving machines are used to fabricate three-dimensional distance fabrics, then the gap between outer fabrics can be achieved up to about 20 centimeters, but the machine cannot fabricate distance fabrics with a gap greater than 20 centimeters
Solution Approach 1:
The invention divides the warp yarns into multiple groups using multiple heald frames, allowing different segments of warp yarns to be controlled independently. This segmentation enables the creation of large gaps between fabric layers by controlling specific warp segments to form inter-yarns that extend far beyond the conventional 20 cm limit, thus achieving gaps greater than 20 centimeters while maintaining structural control.
Solution Approach 2:
The invention introduces an additional dimensional control mechanism by using multiple heald frames arranged in sequence, which allows warp yarns to be divided into multiple layers and controlled in different spatial dimensions. This multi-dimensional control enables the formation of inter-yarns with extended lengths and complex three-dimensional configurations, achieving gaps exceeding 20 cm that cannot be produced by conventional single-plane velvet weaving machines.
2Length of stationary object
If conventional weaving machines are used, then the structure is simple and cost-effective, but the maximum gap is limited to about 20 centimeters
Solution Approach 1:
The weaving machine is segmented into multiple functional units with multiple heald frames, each responsible for controlling specific groups of warp yarns. This segmentation allows the machine to achieve extended gaps greater than 20 cm by coordinating multiple frames, while keeping each individual frame relatively simple in structure, thus balancing increased capability with manageable complexity.
Solution Approach 2:
The multiple heald frames are designed with universal functionality, where each frame can independently control different groups of warp yarns for various fabric structures. This multi-functionality allows the same basic frame structure to be reused multiple times in the system, achieving extended gap capabilities without proportionally increasing overall device complexity, as each frame serves multiple purposes in different operational sequences.
Data Source
AI summary
A three-dimensional distance woven fabric including two outer fabrics, at least one inter-layered fabric and a plurality of inter-yarns connected with each one of the outer fabrics and the inter-layered fabric, wherein a gap between the inter-layered fabrics and each one of the outer fabrics of the three-dimensional distance woven fabric is greater than 20 centimeters and is less than 300 centimeters. A weaving machine and a method for weaving the aforesaid three-dimensional distance woven fabric are also provided.