Self-Supporting 3D Cellular Fabric Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lightweight cellular structures, such as metal foams and lattice polymer materials, are not self-supporting, dimensionally stable, and require complex, time-consuming, and costly manufacturing processes, limiting their economical production and automation.
Innovation Solution
A fabric structure with a cellular structure composed of warp and weft threads that form three-dimensional cells, where weft threads run dimensionally stable and enclose an imaginary elongated hollow body, providing self-support and stability, allowing for automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If metal foams or lattice polymer materials are used for lightweight structures, then weight reduction is achieved, but the structures are not self-supporting and require complex, time-consuming manufacturing processes
Solution Approach 1:
The fabric structure is designed to be self-supporting through its own geometric configuration and material properties. The three-dimensional cells formed by warp and weft threads create inherent structural stability without requiring additional support mechanisms or complex assembly processes, allowing the structure to maintain its shape and function independently
Solution Approach 2:
The structure divides the continuous fabric into discrete three-dimensional cells through the interaction of warp and weft threads. Each cell acts as an independent structural unit that contributes to the overall stability and load-bearing capacity, enabling the structure to achieve lightweight properties while maintaining strength
2Stability of the object's composition
If wire helices or three-axis wire structures are used, then structural stability is improved, but the manufacturing process becomes very complex and time-consuming
Solution Approach 1:
The patent extracts the essential stabilizing function from complex wire assembly processes and implements it through a simplified fabric weaving mechanism. The dimensional stability is achieved through the inherent properties of the woven fabric structure itself, eliminating the need for time-consuming multi-axis wire manipulation and complex assembly operations
Solution Approach 2:
The patent replaces complex mechanical wire assembly systems (multi-axis processes, twisting, gluing, soldering, welding) with a simpler fabric weaving mechanism. The interlacing of warp and weft threads naturally creates the three-dimensional cellular structure and provides dimensional stability through the fabric's own mechanical properties
3Ease of manufacture
If conventional fabric structures are used, then manufacturing is simpler, but the structures are not dimensionally stable and layers are displaceable relative to one another
Solution Approach 1:
The patent transitions from conventional two-dimensional fabric structures to three-dimensional cellular structures by utilizing the vertical dimension (z-direction) through raised and lowered threads. This dimensional enhancement creates cells that interlock and prevent layer displacement while maintaining manufacturing simplicity through fabric weaving processes
Data Source
Figure 1a~1c
Figure 1d~2
AI summary
The invention relates to a fabric structure (1) having a cellular construction. The fabric structure comprises • at least one base layer (6) consisting of warp threads (10), • at least one top layer (7) consisting of warp threads (11), and • weft threads (2) placed in between, wherein the fabric structure (1) is formed by a multiplicity of three-dimensional cells (3, 9) and the height (8) of each individual cell (3, 9) is defined by the spacing (8) between two warp threads (10, 11), located one above the other in the height direction z, in adjacent layers (6, 7), the length (12) of the cell (3, 9) is defined by the spacing (12) between two warp threads (10) or (11), adjacent in the weft direction x, in one layer (6, 7), and the width (13, 14) of a cell (3, 9) is defined by the extent (13) of the weft thread course in the warp direction y and/or by the spacing (14) between two weft threads (2) that are opposite in the warp direction y and adjacent to the particular cell (9). According to the invention, each weft thread (2) extends at least regionally in the fabric structure (1) in a dimensionally stable and three-dimensional manner and winds in the weft direction x about an axis (4) that extends in the weft direction x and in each case through a row of cells (3), and in the process encloses about this axis (4) an imaginary, three-dimensional elongate hollow body, extending through the cells (3), having any desired end face (5). The weft threads (2) intersect the warp threads (10, 11) such that the weft threads (2) and warp threads (10, 11) retain one another and the fabric structure (1) is self-supporting.