Three-Layered Fabric Light Shielding via Segmented Weaving
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Solution Overview
Problem
Existing three-dimensional fabrics with a single-layer intermediate structure fail to provide complete light shielding, making them unsuitable for applications requiring perfect light blocking, such as movie theaters and laboratories.
Innovation Solution
A three-dimensional fabric with a three-layered structure comprising a backing layer, an intermediate layer, and a surface layer, connected by first and second connecting portions woven in an alternating and repeating pattern, allowing for the formation of connecting warp threads that can be cut to achieve a multi-layered intermediate structure for enhanced light shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer intermediate structure is used in three-dimensional fabric, then the fabric structure is simple and easier to manufacture, but the light shielding capability is insufficient
Solution Approach 1:
The intermediate layer is divided into multiple sub-layers (first intermediate layer and second intermediate layer) with different functions. The first intermediate layer provides light shielding with higher density, while the second intermediate layer provides thermal insulation with lower density. This segmentation allows each layer to be optimized for its specific function, achieving complete light shielding while maintaining manufacturing feasibility through systematic structure design.
Solution Approach 2:
The fabric uses composite material structure in the intermediate layer by combining different material densities and properties. The first intermediate layer uses higher density material for light shielding, while the second intermediate layer uses lower density material for thermal insulation. This composite approach enables the fabric to achieve both complete light blocking and thermal insulation functions that a single-material layer cannot provide.
2Strength
If adhesive or pressure-sensitive adhesive is used to attach blade to fabrics in traditional blinds, then the blade can be securely attached, but indoor environmental pollution occurs and adhesion deteriorates over time due to UV light
Solution Approach 1:
The invention extracts and removes the adhesive layer from the blind structure. Instead of using adhesive to attach the blade to the fabric, the three-dimensional fabric structure itself provides the light control function. The intermediate layer with its multi-layered structure can be moved between positions to block or allow light passage, eliminating the need for adhesive bonding that causes pollution and deterioration.
Solution Approach 2:
The three-dimensional fabric structure acts as an intermediary between the light source and the interior space. Rather than using adhesive as a mediator to attach components, the fabric's intermediate layer serves as the active element that mediates light control through its positional changes, providing both structural integrity and functional performance without harmful adhesives.
3Shape
If three-dimensional shape is imparted to fabrics using sewing or fusion techniques, then the fabric can achieve desired three-dimensional effects, but the production process becomes complex and time-consuming
Solution Approach 1:
The invention merges the three-dimensional shape formation with the fabric weaving process itself. The multi-layered intermediate structure is created during the weaving stage using specific thread arrangements and weaving patterns, rather than requiring separate post-processing steps like sewing or fusion. This integration of shape formation into the base manufacturing process eliminates complex additional operations while achieving the desired three-dimensional structure.
Solution Approach 2:
The three-dimensional structure is prepared in advance during the weaving process through preliminary arrangement of threads and layers. The intermediate layer is pre-formed with its multi-layered structure and connection points during fabric production, so that no additional complex operations are needed later to create the three-dimensional shape. This preliminary formation of the structure simplifies the overall production process.
Data Source
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AI summary
A three-dimensional fabric with three-layered structure is provided. The three-dimensional fabric comprises a surface layer, a backing layer, an intermediate layer, a first interconnection portion for connecting the surface layer and the backing layer, and a second interconnection portion for connecting the intermediate layer and the backing layer. The three-dimensional fabric with three-layered structure can be woven on a single loom in a batch operation and undergo transformation between two-dimensional shape and three-dimensional shape. This fabric is applicable as materials for blinds with high light-shielding rate because intermediate portions have a multi-layered structure.