Directed Energy Air Paths for High-Speed Weft Yarn Insertion
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Solution Overview
Problem
Existing weaving technologies face limitations in the speed and stability of weft yarn traversal through the warp, primarily due to drag forces and turbulence, which restricts the productivity and width of the fabric produced.
Innovation Solution
The use of directed energy deposition to create low-density guide paths or tubes ahead of the weft yarn, reducing drag and enhancing stability by impulsively heating the air to create regions of lower density that allow the yarn to propagate more efficiently through the warp, thereby synchronizing energy deposition with the motion of the yarn to minimize resistance and maximize speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional air jet weaving is used to propel weft yarn through warp, then the weaving process can be maintained with simple equipment, but the speed and stability of weft yarn traversal are limited due to drag forces and turbulence
Solution Approach 1:
The patent applies preliminary action by depositing energy ahead of the weft yarn to create a low-density guide path before the yarn arrives. This pre-prepared path reduces drag forces and turbulence that would otherwise act on the yarn during traversal, enabling higher speeds and improved stability.
Solution Approach 2:
The patent changes the density parameter of the air medium by depositing energy to heat the air and create a low-density region. This parameter change reduces the drag forces and turbulence affecting the weft yarn, allowing for faster and more stable traversal through the warp.
2Productivity
If energy deposition is used to create low-density guide paths, then the speed and stability of weft yarn traversal increase, but the device complexity increases due to additional energy deposition systems
Solution Approach 1:
The patent applies universality by integrating the energy deposition system into the existing air jet weaving machine architecture. The energy deposition device is coordinated with the existing air jet propulsion system, allowing the same general area of the machine to serve both functions: creating low-density guide paths and propelling the yarn, thereby reducing overall system complexity.
Solution Approach 2:
The patent merges the energy deposition function with the existing air jet weaving system. By coordinating the energy deposition timing with the air jet propulsion cycles and integrating the systems spatially, the patent reduces device complexity while maintaining the productivity benefits of low-density guide paths.
3Speed
If energy is deposited impulsively to create low-density regions, then the drag reduction and yarn propagation efficiency improve, but the energy consumption increases
Solution Approach 1:
The patent applies partial action by depositing energy only in the specific region where the low-density guide path is needed, rather than heating the entire air volume. This targeted energy deposition creates sufficient drag reduction for yarn propagation while minimizing overall energy consumption compared to blanket heating approaches.
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
This approach significantly increases the speed and stability of the weft yarn traversal, enabling faster throughput, longer fabric widths, and improved productivity by reducing drag forces and turbulence, resulting in a substantial increase in fabric area production with reduced wear and fraying.
Implementation Method 1
impulsively heating the air to create regions of lower density
Implementation Method 2
heating of a medium, including density, viscosity, and/or strength, among others, can result in modifications to the flow properties
Implementation Method 3
reducing drag forces and turbulence, which restricts the productivity and width of the fabric produced
Data Source
Figure 1(a)~3
Figure 4~8
Figure 6~7B
AI summary
The present invention relates to methods, apparatuses, and systems for controlling the density of a fluid near a functional object in order to improve one or more relevant performance metrics. In certain embodiments, the present invention relates to forming a low density region near the object utilizing a directed energy deposition device to deposit energy along one or more paths in the fluid. In certain embodiments, the present invention relates to synchronizing energy deposition with one or more parameters impacting the functional performance of the object.