Multi-Layer Fabric Joining via Interweave Stretch
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Solution Overview
Problem
Current textile production methods using shuttle looms are limited in creating fabrics with multiple layers and complex weaves, particularly in achieving fabrics with three or more layers with independent longitudinal edges, as existing techniques struggle to efficiently interweave and constrain layers while maintaining tuck-in selvedges.
Innovation Solution
The method involves interweaving multiple layers of fabric using shuttle looms, with specific weft insertion sequences and interweave stretches that can be longitudinal or transverse, allowing for the creation of fabrics with three or more layers that are initially joined but can be separated, featuring tuck-in selvedges, and can be produced using heddle or jacquard looms with various weave patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple layers of fabric are interwoven using traditional shuttle loom methods, then fabric width can be doubled, but the ability to produce fabrics with three or more independent layers is limited
Solution Approach 1:
The fabric structure is segmented into multiple independent layers (at least three layers) that are interwoven along a common stretch but remain separable. Each layer can be independently manipulated while maintaining the overall fabric integrity through the interweave stretch mechanism.
Solution Approach 2:
The patent introduces a new dimension of layer independence by allowing layers to be separated along the longitudinal axis while maintaining transverse connectivity through the interweave stretch. This creates a multi-dimensional fabric structure where layers can be independently positioned or removed.
2Stability of the object's composition
If layers are constrained by interweave stretches to form multi-layer fabric, then layer stability is improved, but the flexibility to separate and reconfigure layers is reduced
Solution Approach 1:
The interweave stretch creates a dynamic constraint system where layers are held stable during normal use but can be deliberately separated when needed. The constraint is not permanent or rigid, allowing for reconfiguration while maintaining operational stability.
Solution Approach 2:
The interweave stretch acts as an intermediary element that connects multiple layers together, providing stability while allowing controlled separation. This intermediary mechanism enables both constraint and flexibility without requiring permanent bonding.
3Manufacturing precision
If tuck-in selvedges are formed on all longitudinal edges, then edge finishing quality is improved, but production complexity increases
Solution Approach 1:
The loom is configured to form tuck-in selvedges on all longitudinal edges simultaneously, making the edge-finishing function universal across the entire fabric width. This multi-functional approach achieves high-quality edge finishing without requiring separate processing steps.
Data Source
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AI summary
Fabric made up of at least two laps (20, 21), each of which is formed by a series (22, 24) of longitudinal threads of yarn (warp) that are interwoven with one or more series (23, 25) of threads of yarn transverse to these (weft), characterized in that said first (20) and second laps (21) are joined along a common interweave stretch (30), respectively, parallel to the threads of warp yarn (22, 24) or parallel to the threads of weft yarn (23, 25) and in which the threads of weft yarn (23, 25) and of warp yarn (22, 24) of the two laps (20, 21) are interwoven; said common interweave stretch (30) extending laterally to the laps (20, 21) in such a way as to form a sort of third lap of width at least sufficient to guarantee the solidity of the join of the laps (20, 21) along said stretch of joining (30).