Inkjet Thread Printing for Loom Weaving to Reduce Spool Complexity
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Solution Overview
Problem
Current methods for producing woven fabrics with varied colors and patterns are limited by the number of spools required, leading to increased spatial requirements and manufacturing costs, and printing directly on fabrics can result in image degradation due to ink wicking and limited visibility on one side of the fabric.
Innovation Solution
A system that includes a weft thread printer and a loom with a warp thread printer, where both weft and warp threads can be printed with multiple colors, allowing for precise color application and alignment to create complex patterns, and the use of adhesives to secure the design, ensuring durability and visibility from both sides of the fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple spools of different colored threads are used to achieve varied colors and patterns, then color variety is improved, but spatial requirements and device complexity increase
Solution Approach 1:
The patent extracts the coloring function from the thread spools and relocates it to a printing system. Instead of having multiple spools of pre-colored threads, the system uses a single spool of white or neutral thread and applies color through inkjet printing directly onto the thread, thereby eliminating the need for multiple spools while maintaining color variety
Solution Approach 2:
The patent replaces the mechanical system of multiple spools with a printing system that uses digital control to apply colors. The printing system includes a printhead with multiple ink cartridges that can be controlled by a computer to deposit specific colors at specific locations on the thread, substituting mechanical spool management with a more flexible digital printing approach
2Adaptability or versatility
If multiple spools of different colored threads are used to achieve varied colors and patterns, then color variety is improved, but production speed decreases due to frequent thread changes
Solution Approach 1:
The patent applies preliminary action by printing the desired color patterns onto the weft thread before the weaving process begins. The thread is fed through a printing system where ink is deposited in the desired pattern, and then the pre-colored thread is used in the loom without interruption, eliminating the need to stop for thread changes during weaving
Solution Approach 2:
The patent enables continuous weaving operation by preparing the colored thread in advance. The printing process occurs separately and continuously feeds pre-colored thread to the loom, allowing the weaving process to continue without interruption for thread color changes, thereby maintaining continuous productive action
3Adaptability or versatility
If ink is printed directly on the surface of the woven fabric, then color variety is improved, but image quality degrades due to ink wicking along fibers
Solution Approach 1:
The patent performs the coloring action preliminarily by printing onto the thread before weaving, rather than printing on the finished fabric. This preliminary printing on the thread creates a controlled application point that prevents ink from wicking along the fabric fibers after weaving, as the ink is already set on the thread before the fabric structure is formed
Solution Approach 2:
The patent creates a copy of the desired pattern on the thread itself before weaving. The printing system deposits ink onto the thread in the exact pattern desired, creating a permanent copy of the design that is then woven into the fabric, ensuring the pattern remains fixed and does not shift or wick during the weaving process
4Ease of manufacture
If ink is printed only on one side of the fabric, then manufacturing complexity is reduced, but visibility and durability are limited to one side
Solution Approach 1:
The patent segments the coloring process into two separate operations: printing on the weft thread and printing on the warp thread. Each thread type is printed independently before weaving, allowing different patterns and colors to be applied to each direction of the fabric. This segmentation enables the final fabric to display patterns from both sides, as each thread set contributes its own printed design to the woven structure
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
Enables the production of woven fabrics with intricate patterns and colors without the limitations of traditional spool-based systems, maintaining image quality and durability by ensuring the design is embedded within the fabric fibers, enhancing visibility and resistance to wear.
Implementation Method 1
a printhead positioned to apply coatings of a plurality of colors to the weft thread
Implementation Method 2
an encoder that is configured to detect a length of the weft thread as the weft thread moves through the weft thread printer along a travel path
Implementation Method 3
The printhead may be configured to move along the loom and apply the colored inks to the one or more warp threads
Data Source
AI summary
A system for treatment of thread includes a weft thread printer having an intake positioned to receive a weft thread from a source, as well as an encoder that is configured to detect a length of the weft thread as the weft thread moves through the weft thread printer along a travel path. The system also includes a printhead positioned to apply coatings of a plurality of colors to the weft thread and yield a treated weft thread, as well as an outlet positioned to pass the treated weft thread to a loom.