Method for pattern-controlled forming of the connection point of an effect thread in tissue
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for inserting effect threads into tissues, such as those used in weaving processes, often result in the needle not precisely targeting the desired chain thread gap, leading to inaccuracies and difficulties in cutting and electrical connections.
Innovation Solution
The implementation of a manufacturing process where the effect thread floats over a certain length of warp threads, allowing it to precisely integrate between two warp threads, ensuring accurate placement and reducing issues with zigzag structures and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the effect thread needle is used to insert effect threads into the tissue, then the effect thread can be integrated into the tissue structure, but the needle does not always precisely target the desired chain thread gap, leading to placement inaccuracies
Solution Approach 1:
The patent introduces a floating shot thread as an intermediary element between the needle and the target chain thread gap. The needle inserts into the floating shot thread rather than directly into the chain thread gap, and the floating shot thread subsequently slides to the correct position. This intermediary approach decouples the insertion action from the final positioning requirement, resolving the contradiction between insertion capability and positioning precision.
Solution Approach 2:
The floating shot thread is pre-positioned to extend across multiple chain threads before the needle insertion occurs. This preliminary arrangement creates a buffer zone that allows the needle to insert at any point along the floating shot thread while still achieving the desired final positioning through the sliding mechanism, thereby improving both precision and reliability.
2Productivity
If the effect thread needle is inserted at higher web speeds, then productivity increases, but vibration of the web material and needle occurs, worsening placement precision
Solution Approach 1:
The floating shot thread serves as a mediator that absorbs the effects of vibration and speed variations. Since the needle only needs to insert into the floating shot thread (not precisely into the final chain thread gap), the system can operate at higher speeds without sacrificing placement accuracy. The sliding mechanism compensates for any positioning deviations caused by vibration.
3Productivity
If the effect thread needle is inserted at higher web speeds, then productivity increases, but the different quality of the warp threads causes variability in needle positioning
Solution Approach 1:
The floating shot thread acts as a buffer that decouples the needle insertion from the final positioning. Variations in warp thread quality affect the needle insertion point along the floating shot thread, but not the final position where the floating shot thread settles. This allows high-speed processing while maintaining placement consistency.
Solution Approach 2:
The system changes the state of the shot thread from fixed to floating, allowing it to slide and adjust its position. This parameter change (from stationary to mobile) enables the system to accommodate variations in warp thread quality while maintaining consistent final positioning, thereby supporting higher processing speeds.
4Reliability
If zigzag structures are incorporated into the tissue to prevent cutting issues, then cutting reliability improves, but the problem of needle imprecise insertion worsens the overflow of chain threads by zigzag stitch
Solution Approach 1:
The floating shot thread serves as an intermediary that allows the zigzag stitch to be formed without requiring precise needle positioning into each chain thread gap. The floating shot thread absorbs the positioning variations, ensuring that the zigzag structure is formed correctly and that chain threads are properly managed during cutting, thereby maintaining both cutting reliability and stitch accuracy.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In the case of a woven fabric (20) with an additional thread (30, 34) laid in a zigzag shape, in order to ensure in specific cases that over the length of the woven fabric the zigzag thread (30, 34) always has its zigzag tip (38) at the same position, the invention proposes introducing the weft thread (24) at specific points in the woven fabric (20) in a floating manner over a plurality of adjacent warp threads (21), and inserting or introducing the feed needle (32, 36) into the woven fabric (20), at least on one side of the cover thread (30, 34) laid in a zigzag shape, at a plurality of laying points or at all laying points at which the weft thread (24) is floating over a plurality of adjacent warp threads (21). The cover thread (30, 34) is positioned at the inside of the zigzag shape.