Sewing Device with Spaced Needle Plates
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Solution Overview
Problem
Existing methods for sewing multi-layer structures, such as heat-insulating clothing, compress the insulation material at seam areas, leading to local thermal bridges and reduced heat-insulating effectiveness due to compression and tension from sewing threads.
Innovation Solution
A sewing device with an upper needle plate spaced from a lower needle plate, allowing the multi-layer structure to be sewn without significant compression, using a slit in the upper plate for thread passage and a conveyor system to manage thread tension and web speeds, ensuring even seam formation and minimal compression of the insulation material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional machine sewing is used to sew multi-layer structures, then the layers are securely fixed together, but the insulation material is compressed in the seam areas creating thermal bridges and reducing heat-insulating effectiveness
Solution Approach 1:
The invention introduces a third dimension by spacing the needle plates apart vertically. Instead of sewing on a single flat surface, the needle penetrates through the multi-layer structure between two separated plates, allowing the insulation material to maintain its thickness and volumetric structure while still being securely sewn. This dimensional change prevents compression-induced thermal bridges.
2Loss of energy
If the seam length is reduced to minimize compression effects, then heat insulation is improved, but the fixing stability of the multi-layer structure deteriorates
Solution Approach 1:
By creating vertical spacing between needle plates, the invention allows the full seam length to be utilized without compromising insulation. The spaced configuration enables the needle to traverse the complete thickness of the multi-layer structure including uncompressed insulation, providing both maximum fixing stability and maintained thermal insulation throughout the entire seam path.
3Loss of energy
If spacer elements or textile strips are inserted to maintain distance between layers, then insulation effectiveness is improved, but device complexity and manufacturing effort increase
Solution Approach 1:
The invention extracts and eliminates the need for separate spacer elements by integrating the spacing function directly into the needle plate configuration. The vertical separation of the two needle plates inherently maintains the required distance between layers, removing the need for additional spacer components and simplifying the overall device structure while maintaining insulation effectiveness.
4Loss of energy
If adhesive tape is used to seal seams and prevent thermal bridges, then heat insulation is improved, but additional materials and manufacturing steps are required
Solution Approach 1:
The invention extracts and eliminates the need for post-sewing adhesive tape application by preventing thermal bridge formation during the sewing process itself. The spaced needle plate configuration maintains insulation integrity throughout seam creation, removing the requirement for additional sealing materials and subsequent manufacturing steps.
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a device, a method for forming a stitched multilayer structure, and a stitched multilayer structure comprising at least one top layer and at least one compressible intermediate layer. The device comprises a machine sewing unit, a conveying device (7) for at least one of the top and/or intermediate layers, and a lower stitch plate (2) with a stitch hole (5'). An upper stitch plate (3) is provided, spaced apart from the lower stitch plate (5') according to the intended height of the stitched multilayer structure. The upper stitch plate (3) has a slot (4) extending from a stitch hole (5) in the sewing direction to an edge of the upper stitch plate (3). The upper stitch plate (3) is designed to support the top layer.