Industrial Two-Layer Fabric Herringbone Weave Elimination
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Solution Overview
Problem
Industrial two-layer fabrics with diagonal weave lines due to warp knuckles often transfer marks to paper, leading to poor surface smoothness and printing characteristics, and existing solutions like satin or broken twill weaves either cause uneven weft arrangements or separation/aggregation issues.
Innovation Solution
An industrial two-layer fabric with a herringbone pattern of warp knuckles formed by binding warps passing over single upper side wefts, where at least two other warp knuckles are arranged in diagonal directions, eliminating diagonal weave lines and preventing weft separation or aggregation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a twill weave pattern is used to create an industrial two-layer fabric, then the fabric has good structural stability and binding characteristics, but diagonal weave lines appear on the surface causing transfer marks on paper
Solution Approach 1:
The patent applies asymmetry by using a satin weave pattern (4-harness satin) instead of a symmetric twill weave. The surface layer has warp yarns passing over multiple weft yarns in an asymmetric sequence (1-2-3-4-1-2-3-4), eliminating the diagonal symmetry that causes visible weave lines and transfer marks while maintaining structural stability through the binding layer.
2Object-generated harmful factors
If a satin weave pattern is used to improve surface smoothness and eliminate diagonal weave lines, then transfer marks are reduced, but knuckles are not sequentially present causing adjacent wefts to aggregate
Solution Approach 1:
The patent uses a composite two-layer structure where the surface layer (satin weave) provides smoothness and the binding layer (twill weave with binding warps) provides structural stability. The binding warps interlace with both upper and lower wefts to maintain sequential knuckle formation and prevent weft aggregation, combining the advantages of both weave patterns.
3Object-generated harmful factors
If a broken twill weave is used to attempt to reduce diagonal marks, then some diagonal lines are reduced, but dogleg twill lines stand out and separation or aggregation of adjacent wefts occurs with time
Solution Approach 1:
The patent segments the fabric into two functional layers: a surface layer optimized for smoothness (satin weave) and a binding layer optimized for stability (twill with binding warps). This segmentation allows each layer to perform its specific function without the compromises required in a single-layer broken twill weave, preventing weft separation while eliminating diagonal marks.
Data Source
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Figure 3
Figure 4(a)~4(f)
AI summary
The present invention is directed to eliminate diagonal weave lines that appear on the surface of a fabric due to warp knuckles. The present invention is also directed to provide an industrial two-layer fabric that prevents transfer marks from forming by suppressing the separation or aggregation of adjacent wefts, which has occurred in conventional pattern structures, and has excellent surface smoothness and running stability. An industrial two-layer fabric includes an upper layer fabric including upper side warps and upper side wefts and a lower layer fabric including lower side warps and lower side wefts, and the upper layer fabric and the lower layer fabric are bound by warps that function as binding yarns. In the industrial two-layer fabric, warp knuckles are formed on a surface side, and each warp knuckle is formed by allowing a warp to pass over a single upper side weft; in a shaft adjacent to the warp knuckle, at least two other warp knuckles are arranged in a diagonal direction in a planar view; and the warp knuckles are sequentially arranged in such a way as to form a herringbone pattern on a surface layer side of the fabric.