Three-dimensional string woven air cushion and manufacturing method thereof
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Solution Overview
Problem
Dual-space woven fabric products, used for manufacturing boats, face limitations in versatility due to vertically interlaced interval maintaining yarns, which require post-processing for cutting and result in poor user sleeping stability under load.
Innovation Solution
A three-dimensional string woven air cushion with interval maintaining yarns interlaced in a zigzag manner between lower and upper sheet layers, using a punching needle part, to maintain a predetermined interval and prevent eccentric distortion, allowing for easier cutting and improved cushioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If interval maintaining yarns are vertically interlaced between lower and upper sheet layers, then the structure is simple and manufacturing is easy, but the upper sheet layer distorts in one direction under load causing poor sleeping stability
Solution Approach 1:
The interval maintaining yarns are configured to extend in multiple directions (zigzag pattern) rather than vertically, creating an asymmetric distribution that prevents one-directional distortion and improves sleeping stability while maintaining manufacturing simplicity
2Reliability
If the dual-space woven fabric product is manufactured for boat manufacturing, then it has strong durability and ease of assembly, but it is limited in purposes and requires post-processing for cutting
Solution Approach 1:
The three-dimensional string woven structure with multi-directional interval maintaining yarns creates a versatile product that can be applied to both boat manufacturing and mattress cushions, eliminating the limitation to single-purpose applications while maintaining durability
3Productivity
If vertically interlaced interval maintaining yarns are used, then the manufacturing process is simple, but post-processing is required to cut unnecessary yarns and finish lateral surfaces
Solution Approach 1:
The interval maintaining yarns are pre-configured in a multi-directional zigzag pattern during the weaving process, which eliminates the need for subsequent cutting and finishing operations, thereby improving productivity while maintaining ease of manufacture
Data Source
AI summary
The present invention relates to a three-dimensional string woven air cushion and a method of manufacturing the same, the three-dimensional string woven air cushion including a lower sheet layer made by interlacing a plurality of weft yarns and a plurality of warp yarns and configured to define a predetermined thickness layer and a bottom surface, an upper sheet layer made by interlacing a plurality of weft yarns and a plurality of warp yarns and configured to define a predetermined thickness layer and a top surface, the upper sheet layer being disposed above the lower sheet layer, provided in parallel with the lower sheet layer, and spaced apart from the lower sheet layer at a predetermined distance, and an interval maintaining yarn layer made by interlacing interval maintaining yarns connected to at least one of the weft yarn and the warp yarn of each of the lower and upper sheet layers, the interval maintaining yarns being continuously interlaced and connected in a zigzag manner in a direction from one side to the other side, thereby providing an advantage that greatly improve a user’s sleeping convenience.