Textile Structure with Concealed Back-Surface Functional Threads
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Solution Overview
Problem
Existing textile structures incorporating functional threads, such as electrically conductive threads, are aesthetically unsuitable for applications requiring high quality appearance due to visible stitching points on the front surface, and current weaving processes are complex and costly.
Innovation Solution
A textile structure is designed with functional threads positioned at the back surface, hidden from view by interlacing with weft yarns at stitching points between the median lying plane and the back surface, using anchoring weft yarns covered by basic weft yarns, and pattern weft yarns to conceal interlacing points, while employing a simplified weaving process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If functional threads are incorporated into the base fabric using conventional weaving techniques, then the textile structure gains functional properties (e.g., electrical conductivity), but the stitching points become visible on the front surface, degrading aesthetic quality
Solution Approach 1:
The patent positions functional threads at the back surface of the base fabric rather than integrating them through the thickness, effectively moving the functional element to a different spatial dimension (z-axis) where it does not interfere with the front surface aesthetics. The functional threads extend along the back surface and are secured by anchoring yarns that dip into the shed, keeping all visible elements confined to the back surface dimension.
Solution Approach 2:
The patent separates the functional thread layer from the visible front surface by creating a distinct back surface layer. The functional threads are segmented from the base fabric's front aesthetic layer, allowing independent positioning and securing at the back surface without affecting front surface appearance. This segmentation enables functional and aesthetic requirements to be satisfied in separate spatial zones.
2Reliability
If conventional weaving processes are used to incorporate functional threads, then the functional threads can be integrated into the fabric, but the process becomes complex and costly
Solution Approach 1:
The patent employs a single weft insertion device that performs multiple functions: inserting basic weft yarns to form the base fabric, inserting anchoring weft yarns to secure functional threads, and inserting pattern weft yarns for aesthetic purposes. This multi-functional approach eliminates the need for separate devices for each function, simplifying the overall weaving system while achieving complex integration results.
Solution Approach 2:
The patent combines the insertion of functional threads with the existing base fabric formation process. The functional threads are laid on the base fabric during the same weaving cycle when weft yarns are inserted, merging two previously separate operations (base fabric formation and functional thread incorporation) into a single integrated process, thereby reducing complexity and cost.
Data Source
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AI summary
In a base fabric (2) having a front surface (F) and a back surface (B) at mutually opposite sides with respect to a median lying plane (P), weft yarns (4a, 4b, 4c) interlace with warp yarns (3) at respective interlacing points (IPa, IPb, IPc) at which the weft yarns cross the median lying plane (P) to override at least one of the warp yarns. At least one functional thread (5) extending along a pre-established pattern at the back surface (B) of the base fabric (2), without crossing the median lying plane (P), and is linked with the weft yarns (4a, 4b, 4c) at stitching points (SP) positioned between the median lying plane (P) and the back surface (B) of the base fabric (2), so that the stitching points (SP) are not visible from a front surface (F) opposite to the back surface (B).