Jacquard One-Piece Textile Manufacturing
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Solution Overview
Problem
Conventional textile manufacturing processes are inefficient and costly due to the need for multiple steps, including registration, fabric relaxation, trimming, and extensive sewing, which require skilled labor and are prone to errors, making it difficult to automate and increasing production time and costs.
Innovation Solution
A method using a jacquard machine to create a one-piece textile with integrated sewing areas, allowing for direct weaving of base fabric and surface patterns, followed by separation of individual textiles through trimming and minimal sewing for aesthetic appeal, significantly reducing the need for manual labor and process steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional textile manufacturing processes are used with multiple steps including registration, fabric relaxation, trimming, and extensive sewing, then the manufacturing precision and quality control are maintained, but the productivity is low and manufacturing costs are high
Solution Approach 1:
The patent merges multiple separate manufacturing steps (registration, fabric relaxation, trimming, and sewing) into a single integrated jacquard weaving process. The sewing areas are directly woven into the fabric structure during the jacquard weaving step, eliminating the need for separate trimming and sewing operations. This consolidation dramatically improves productivity while reducing process complexity.
Solution Approach 2:
The sewing areas are prepared in advance during the jacquard weaving process itself, rather than performing sewing operations after the fabric is manufactured. By pre-integrating the sewing areas into the fabric structure during weaving, the patent eliminates subsequent manual sewing steps and reduces the need for skilled labor in post-processing.
2Manufacturing precision
If extensive sewing processes are used to connect multiple pieces of cloth, then the manufacturing precision and quality are maintained, but the loss of time and production delays occur
Solution Approach 1:
The patent combines the fabric manufacturing and sewing operations into a single jacquard weaving process. The sewing areas are woven directly into the fabric structure, eliminating the need for separate sewing operations that connect multiple pieces of cloth. This integration maintains manufacturing precision while dramatically reducing production time.
Solution Approach 2:
The sewing areas are created during the initial jacquard weaving process rather than being added later through separate sewing operations. This preliminary integration of sewing areas into the fabric structure eliminates time-consuming post-weaving sewing steps and reduces production delays.
3Manufacturing precision
If manual trimming and sewing operations are performed by skilled staff, then the manufacturing precision and quality control are maintained, but the manufacturing cost increases
Solution Approach 1:
The jacquard weaving machine automatically creates the sewing areas as an integral part of the fabric structure during the weaving process itself. The machine performs what would traditionally require skilled manual trimming and sewing operations, eliminating the need for skilled labor and reducing manufacturing costs while maintaining precision.
Solution Approach 2:
The patent merges the functions of trimming and sewing into the single jacquard weaving process. The sewing areas are directly woven into the fabric structure during manufacturing, eliminating the need for separate manual trimming and sewing operations performed by skilled staff, thereby reducing labor costs while maintaining quality.
4Manufacturing precision
If conventional multi-step manufacturing processes are used, then the fabric quality and pattern accuracy are maintained, but the quantity of substance wasted increases
Solution Approach 1:
The patent combines pattern weaving and sewing area creation into a single jacquard weaving process. By integrating these operations, the patent eliminates the need for separate registration and trimming steps that traditionally waste fabric, while maintaining pattern accuracy through direct jacquard weaving control.
Data Source
AI summary
A method of manufacturing a one-piece textile by a jacquard machine includes a preparation step, a jacquard weaving step, a textile separation step, and a textile ironing step. A woven cloth is made of the method and includes a base fabric and multiple textiles connected with the base fabric by at least one sewing area. The woven cloth is a one-piece structure made by a jacquard machine. The textiles are separated by trimming the at least one sewing area from the woven cloth. Each textile is a complete product with a one-piece structure without sewing. The manufacturing method can improve the efficiency of textile production.