Textile Grid Manufacturing Using Adhesive Ribbons
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Solution Overview
Problem
Existing textile grid manufacturing processes are limited by the rate of unwinding and laying of weft yarns, leading to production rate constraints and breakage issues, particularly with methods using rotating arms, which fail to efficiently handle multiple weft thread reels and maintain thread alignment.
Innovation Solution
A process utilizing a cylindrical carousel with adhesive ribbons to continuously deposit and guide weft threads, allowing for adjustable pitch and width, and ensuring effective holding and flattening of threads, enabling higher production rates and longer weft lengths by using a system with multiple weft threads from reels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a rotating arm is used to lay weft yarns, then the manufacturing process can be simplified, but the production rate is limited and weft yarn breakage increases due to speed jolts
Solution Approach 1:
The patent divides the weft yarn laying process into multiple independent zones using several reels (first reel, second reel, third reel) positioned at different locations. Each reel handles a specific segment of the weft yarn deposition, allowing continuous operation without the speed limitations of a single rotating arm. This segmentation enables higher production rates while maintaining process simplicity.
2Device complexity
If a rotating arm is used to lay weft yarns, then the device structure is simpler, but weft yarn alignment and holding effectiveness deteriorate
Solution Approach 1:
The patent introduces adhesive ribbons as intermediary elements between the reels and the final grid structure. These ribbons are deposited on the weft yarns as they pass between reels, providing effective holding and alignment. The adhesive ribbons act as mediators that ensure precise positioning without requiring complex mechanical alignment mechanisms, thus maintaining device simplicity while improving manufacturing precision.
3Productivity
If the weft yarn laying speed is increased to improve production rate, then productivity increases, but weft yarn breakage increases due to speed jolts
Solution Approach 1:
The patent applies adhesive ribbons to the weft yarns in advance, before the yarns undergo tension changes during the laying process. This preliminary application of adhesive ensures that the yarns are securely held and protected from speed jolts and breakage before they encounter mechanical stresses. The adhesive preparation in advance allows for higher laying speeds without compromising yarn integrity.
4Productivity
If multiple weft thread reels are used to increase production rate, then productivity increases, but the device complexity increases
Solution Approach 1:
The patent designs the reel system so that multiple reels perform similar functions - each reel deposits weft yarns onto adhesive ribbons in a standardized manner. The reels are arranged in a modular configuration where each unit follows the same operational pattern, allowing the system to handle multiple weft threads simultaneously. This universal approach enables high production rates while keeping device complexity manageable through functional repetition rather than complex coordination.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances production rate and flexibility by allowing for adjustable pitch and width of weft threads, reducing breakage and improving thread alignment, thereby increasing the efficiency and quality of textile grid production.
Implementation Method 1
between two outer strands of two consecutive belts, called generating belts, two ribbons, at least one of which is adhesive, are continuously deposited facing one on the other on the outer and inner faces of the wires
Data Source
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AI summary
The process for manufacturing a textile grid involves winding the yarns substantially parallel to each other on a carousel having a substantially cylindrical shape generated by the outer strands of endless belts (11) parallel to each other and to the axis of the carousel and moving synchronously; sandwiching the yarns deposited on the carousel between two adhesive strips; cutting the sandwich in the middle, generating two selvedges joining strands of weft yarn; the selvedges (22) are progressively moved apart until the weft yarns (28) are substantially parallel to each other and in a horizontal plane; these weft yarns (28) are then placed in contact with the warp yarns; and finally, the warp yarns are fixed at their points of intersection. Corresponding installation.