Weaving Multilayer Products With Fractional Warp To Heddle Column Ratios
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Solution Overview
Problem
In multilayer weaving processes, high warp fiber counts often lead to fiber congestion and poor warp control due to inadequate shed openings, especially when configuring the weaving apparatus with a single heddle column for multiple warp columns, resulting in inefficient weaving.
Innovation Solution
A weaving apparatus with a fractional numerical ratio of warp columns to heddle columns, allowing a portion of warp fibers to be laced through heddles on one or more heddle columns based on this ratio, which enables better warp control and adequate shed space for efficient weaving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single heddle column is used for multiple warp columns, then device complexity is reduced, but fiber congestion and poor warp control occur due to inadequate shed openings
Solution Approach 1:
The invention segments the heddle system into multiple heddle columns, where each heddle column is responsible for controlling a specific subset of warp columns. This segmentation allows each heddle column to manage fewer warp fibers independently, preventing fiber congestion and maintaining adequate shed openings while still reducing overall device complexity compared to having one heddle per warp column.
2Device complexity
If a single heddle column is used for multiple warp columns, then device complexity is reduced, but fiber congestion occurs due to inadequate shed openings
Solution Approach 1:
The invention segments the heddle system into multiple heddle columns, where each heddle column is responsible for controlling a specific subset of warp columns. This segmentation allows each heddle column to manage fewer warp fibers independently, preventing fiber congestion and maintaining adequate shed openings while still reducing overall device complexity compared to having one heddle per warp column.
3Reliability
If multiple heddle columns are used for high warp fiber counts, then warp control and shed openings are improved, but device complexity increases
Solution Approach 1:
The invention segments the heddle system into multiple heddle columns, where each heddle column is responsible for controlling a specific subset of warp columns. This segmentation allows each heddle column to manage fewer warp fibers independently, preventing fiber congestion and maintaining adequate shed openings while still reducing overall device complexity compared to having one heddle per warp column.
4Object-generated harmful factors
If multiple heddle columns are used for high warp fiber counts, then fiber congestion is reduced, but device complexity increases
Solution Approach 1:
The invention segments the heddle system into multiple heddle columns, where each heddle column is responsible for controlling a specific subset of warp columns. This segmentation allows each heddle column to manage fewer warp fibers independently, preventing fiber congestion and maintaining adequate shed openings while still reducing overall device complexity compared to having one heddle per warp column.
Data Source
AI summary
An apparatus for weaving a multilayer product that has one or more warp columns for placing warp fibers and one or more heddle columns for heddles for lacing the warp fibers. The weaving apparatus has a numerical ratio of warp columns and heddle columns that is a fractional number. And a portion of the warp fibers are laceable through heddles on one or more heddle columns based on the fractional number. A method for weaving a multilayer product where adjacent warp fibers are segmented and laced through heddles on the heddle columns based on the fractional number.