Multi-layer Fabric Cell Formation via Segmented Stitching
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Solution Overview
Problem
Existing multi-layered fabrics for architectural features, such as window coverings, lack control over the formation and size of cells between intermediate layers due to uniform stitching points, limiting their ability to provide controlled light transmission, shading, and privacy.
Innovation Solution
A multi-layered fabric design featuring a continuous weaving process where intermediate layers are stitched to exterior layers at different points, allowing for the formation of cells between paired intermediate layers, enabling adjustable light transmission and shading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If intermediate layers are stitched to exterior layers at uniform points, then the structure is simple to manufacture, but control over cell formation and size is lost
Solution Approach 1:
The stitching process is segmented into multiple distinct regions: a first region where the first intermediate layer is stitched to the first exterior layer, and a second region where the second intermediate layer is stitched to the second exterior layer. These regions are positioned at different longitudinal locations, allowing independent control of each intermediate layer's attachment points. This segmentation enables precise control over cell formation while maintaining manufacturing feasibility through region-specific stitching operations.
2Manufacturing precision
If intermediate layers are connected at the same points on exterior layers, then the stitching process is simplified, but the ability to form controlled cells between layers is reduced
Solution Approach 1:
Different stitching patterns and attachment points are applied to different intermediate layers based on their specific functional requirements. The first intermediate layer is stitched at a first longitudinal location while the second intermediate layer is stitched at a second longitudinal location. This local differentiation in stitching quality and positioning enables each layer to contribute differently to cell formation, achieving precise cell size control without requiring complex overall stitching patterns.
3Adaptability or versatility
If all layers are woven together continuously, then the fabric structure is uniform and simple, but adjustability of light transmission and shading is limited
Solution Approach 1:
The multi-layer fabric structure is designed to be dynamically adjustable through the selective stitching of intermediate layers at different longitudinal locations. By controlling which intermediate layers are stitched and where they are stitched, the fabric can transition between different configurations that vary light transmission and shading properties. This dynamic capability is achieved within a relatively simple multi-layer woven structure, balancing adaptability with structural simplicity.
Data Source
AI summary
The present disclosure relates to multi-layered fabrics and coverings for architectural features and methods for manufacturing the same. More particularly, the present disclosure relates to a three-dimensional multi-layered fabric having a first or front exterior layer, a plurality of intermediate or interior layers, and a second or back exterior layer, which are separable from one another, and their method of manufacture, and panels and/or coverings for architectural features having or comprised of a multi-layered fabric, and methods of making the same. The plurality of interior layers extends between the exterior layers, and the separation and stitching of the two paired intermediate layers from at least one of the front exterior layer and back exterior layer are at different locations (points), respectively, which facilitates the formation of a cell, and controls the size and shape of the cell that may form between the two paired, intermediate layers.