Cold Cut Textile Webs with Zigzag Binding
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Solution Overview
Problem
Existing methods for producing narrow woven fabric strips, such as hot cutting, result in hard and rough edges, which are uncomfortable in clothing textiles, and are limited to thermoplastic threads, while cold cutting methods fail to prevent fraying and form an unstable edge.
Innovation Solution
A manufacturing process that binds zigzag threads into the fabric to prevent fraying, followed by cold cutting with a knife, forming weft thread tails for a soft edge, and optionally using thermoplastic threads or hot-melt adhesive to secure the edge without melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hot cutting is used to cut woven fabric strips, then the cutting edge is fray-resistant, but the edge becomes hard and rough
Solution Approach 1:
The patent changes the cutting temperature parameter from high (hot cutting) to low (cold cutting), using a cold cutting knife instead of heated wires or knives. This eliminates the melting and fusing of threads that causes rough edges, while the zigzag binding structure provides the necessary fray resistance without thermal processing
Solution Approach 2:
The patent divides the edge securing function from the cutting process itself. Instead of using heat to both cut and secure the edge simultaneously, it separates these functions: cold cutting performs the separation, while the zigzag binding structure performs the edge securing, eliminating the need for thermal processing
2Reliability
If hot cutting is used to cut woven fabric strips, then the cutting edge is fray-resistant, but the process is limited to thermoplastic threads
Solution Approach 1:
The patent changes the cutting temperature parameter to cold conditions, which is compatible with all fabric materials regardless of their thermal properties. This eliminates the restriction to thermoplastic threads and allows the process to be applied to cotton, wool, silk, and other non-thermoplastic materials that cannot withstand high temperatures
Solution Approach 2:
The zigzag binding structure serves as a universal edge-securing mechanism that works with all types of woven fabrics regardless of material composition. The cold cutting method combined with this binding structure creates a universally applicable process for producing fray-resistant edges on any woven fabric strip
3Object-affected harmful factors
If cold cutting is used to cut woven fabric strips, then the edge remains soft, but the cutting edge frays
Solution Approach 1:
The patent applies preliminary action by creating the zigzag binding structure at the edge of the fabric strip before the cold cutting process. This pre-formed binding structure secures the threads in place, preventing them from fraying during or after the cold cutting operation, while maintaining the softness of the edge
Solution Approach 2:
The patent separates the functions of cutting and edge securing into distinct components: the cold cutting knife performs the cutting function while leaving the edge soft, and the zigzag binding structure independently performs the edge securing function to prevent fraying
Data Source
AI summary
In order to produce a plurality of fabric strips (22) from a fabric (20) during the manufacturing process thereof, a method is proposed which utilizes the steps of: inserting weft threads (24) into the open warp thread shed, laying of a plurality of cover threads (30, 34) in a zigzag shape by a plurality of feed needles (32, 36), cutting the fabric (20) in the drawing-off direction into a plurality of woven strips (22), and pulling off the warp threads (60) that are located between the cutting-side laying points of the cover threads and the cutting device. This method can be implemented in a particularly advantageous manner if, in addition to the cover thread (30, 34) introduced in zigzag manner, a further cover thread (70) is introduced at each fabric edge (26) by a further feed needle in such manner that it is connected to the zigzag thread whereby the zigzag thread is prevented from fraying.