Multi-Layer Woven Fabric
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Solution Overview
Problem
Existing methods for manufacturing inflatable support articles, such as air mattresses and cushions, are complex, expensive, environmentally unfriendly, and prone to mechanical failure or leakage.
Innovation Solution
A multi-layer woven fabric with a central region and outer regions, featuring a stitching pattern with a first weave section, a crossover section, and a second weave section, which connects two woven layers to form an air impermeable structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bonding, sealing, or welding methods are used to manufacture inflatable support articles, then the structure can be formed, but the manufacturing process becomes complex, expensive, and time-consuming
Solution Approach 1:
The patent merges multiple manufacturing steps into a single weaving process. The connecting yarns are integrated directly into the woven fabric structure during manufacturing, eliminating the need for separate bonding, sealing, or welding operations that would otherwise be required to attach internal connections to the outer layer.
Solution Approach 2:
The fabric is segmented into distinct regions (central region with starting and ending edge areas) with different yarn interweaving patterns in each region. This segmentation allows the same fabric structure to provide both structural integrity and sealed connection points without requiring additional manufacturing steps.
2Ease of manufacture
If bonding, sealing, or welding methods are used, then the inflatable structure can be formed, but environmental impact increases
Solution Approach 1:
The patent replaces chemical bonding methods (adhesives, sealants) and thermal welding processes with a mechanical weaving system. The connecting yarns are mechanically interwoven with the outer layer yarns during fabric construction, eliminating the need for environmentally harmful chemicals and high-energy welding processes.
3Ease of manufacture
If bonding, sealing, or welding methods are used, then the structure can be assembled, but the product is prone to mechanical failure and leakage
Solution Approach 1:
The patent creates a composite woven fabric structure where connecting yarns, outer layer yarns, and filler yarns work together as an integrated system. The interwoven construction distributes mechanical stresses across multiple yarns and regions, preventing the propagation of failures that would occur in bonded or welded joints.
Solution Approach 2:
The woven structure provides inherent redundancy and stress distribution that cushions against mechanical failures before they occur. The interwoven yarns create multiple load paths, so if one yarn fails, the surrounding yarns continue to bear the load and prevent leakage.
4Ease of manufacture
If complex bonding and sealing methods are used, then the inflatable structure can be formed, but production time increases
Solution Approach 1:
The connecting yarns and their attachment points are prepared in advance during the fabric weaving process itself. The fabric is manufactured with pre-positioned connecting yarns already integrated into the structure, eliminating the need for time-consuming post-manufacturing assembly steps like bonding or welding internal connections to the outer layer.
Data Source
AI summary
The invention relates to a multi-layer woven fabric having a central region which contains a first woven layer, a second woven layer, and a plurality of connecting yarns. The plurality of connecting yarns connect the first woven layer and the second woven layer and each connecting yarn has a stitching pattern that contains a first weave section, a crossover section, and a second weave section. Within the first weave section, each connecting yarn is interwoven only with the first warp. Within the crossover section each connecting yarn is not interwoven with any yarns of the multi-layer woven fabric. Within the second weave section, each connecting yarn is interwoven only with the second warp yarns of the second woven layer.