Multilayer Fabric Formation via Winding Yarn Carriers
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Solution Overview
Problem
Traditional methods for forming integrated multilayer fabrics lack flexibility in varying fiber orientation and cross-sectional shape or dimension, are associated with low production rates, low automation, frequent yarn replenishment, and low fiber volume fraction, and often result in interlaced or intertwined yarns that reduce stiffness and strength.
Innovation Solution
An apparatus and method that use winding yarn carriers to form layers at prescribed angles (0° to ±90°) with binder yarns, allowing for variable cross-sectional geometry, fiber orientation, and integration patterns, without yarn interlacing, using a system of winding yarns and binder yarns with holding yarns to lock the binder yarns in place, enabling the production of complex shapes with large dimensions and high automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If weaving or braiding processes are used to form fully interlocked multilayer fabrics, then layer integration is achieved, but yarn crimps occur that reduce stiffness and strength
Solution Approach 1:
The invention extracts the harmful interlacing action from the fabric formation process. Instead of weaving or braiding yarns through each other, the patent uses a stitching process where binder yarns pass through pre-positioned winding yarn layers without causing them to interlace or crimp. This separates the integration function from the crimping effect, achieving layer bonding while preserving yarn straightness and mechanical properties.
2Strength
If traditional three dimensional weaving or braiding is used to construct fabrics with reinforcing fibers, then through-the-thickness reinforcement is achieved, but the dimensions of fabrics that can be produced are limited
Solution Approach 1:
The invention segments the fabric construction process into independent layers that are formed separately and then stitched together. Each winding yarn layer can be formed to large dimensions using conventional winding techniques, and the layers are subsequently integrated using binder yarns. This segmentation allows each layer to be optimized independently and enables the production of very large fabric dimensions that would be impossible with traditional three-dimensional weaving or braiding.
3Strength
If knitting processes are used to form non-crimp fabrics with parallel fibers, then fiber stiffness is preserved, but flexibility in changing yarn orientations at different locations is lost
Solution Approach 1:
The invention introduces dynamics into the fabric construction process by allowing the winding yarn carriers to be positioned at different angles and locations for each layer. Unlike fixed knitting patterns, the winding process can dynamically adjust yarn orientation at different locations and layers, enabling variable fiber orientations throughout the fabric while maintaining fiber straightness and stiffness. This dynamic positioning capability provides both stiffness preservation and orientation flexibility.
4Productivity
If automated fabric formation processes are used, then production rate increases, but flexibility in adjusting fiber orientation and geometry is reduced
Solution Approach 1:
The invention replaces complex mechanical weaving or knitting systems with a more flexible winding and stitching process. The winding yarn carriers can be programmatically controlled to deposit yarns at any desired angle or location, and the binder yarn stitching process can be automated while still allowing for variable patterns. This substitution of mechanical systems with programmable processes enables both high automation and flexibility in fiber orientation and geometry adjustment.
Data Source
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AI summary
A method for fabricating multilayer fabrics having a prescribed integration pattern and an apparatus of implementing same. In one embodiment, the method include the steps of providing a plurality of winding yarn carriers arranged in a multilayer structure along a first direction and configured such that each winding yarn carrier is operably movable with respect to one another along a second direction that is perpendicular to the first direction, forming a plurality of crossover points of the winding yarns by moving at least one winding yarn carrier along the second direction according to the integration pattern, transporting the binder yarns through the plurality of winding yarn layers at predetermined locations along the first direction, and locking the binder yarns in place, pushing the binder yarns toward the fell of the multilayer fabrics, and taking up the formed multilayer fabrics.