Industrial Two-Layer Fabric Joint Loop Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional joint loop structures are difficult to implement in industrial two-layer fabrics using warp fabric yarn-contact binding yarns, limiting the ability to form an endless or ended form, which is necessary for efficient mounting on machines, and often require specialized machinery and increased space or cost.
Innovation Solution
A joint loop structure is formed using warps at both ends of the industrial two-layer fabric without independent binding yarns, where upper surface side warps extend to the lower surface side and vice versa, creating a pair of warps that form a joint loop by turning back at least one end portion, ensuring the same number and distance of knuckles for a neat mesh surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional joint loop structures are used in industrial two-layer fabrics, then the fabric can be formed in endless form, but it is technically difficult to implement in warp fabric yarn-contact binding yarn structures
Solution Approach 1:
The fabric structure is segmented into upper surface side fabric and lower surface side fabric, with binding yarns specifically positioned to join these segments. This segmentation allows the joint loop structure to be implemented separately in each layer without interfering with the overall two-layer construction, resolving the technical difficulty of applying conventional joint loops to warp fabric yarn-contact binding yarn structures.
Solution Approach 2:
The binding yarns extend from the upper surface side to the lower surface side, creating a three-dimensional structure that connects two-dimensional fabric layers. This dimensional transition enables the joint loop structure to be formed through the thickness of the fabric, allowing endless form creation in a way that is compatible with the warp fabric yarn-contact binding yarn architecture.
2Ease of operation
If cantilever method is used to process heavy or very long industrial fabric, then the fabric can be introduced to the machine, but it becomes difficult to introduce the fabric and requires specialized machinery
Solution Approach 1:
The fabric is pre-formed with joint loops at its ends before being introduced to the machine. This preliminary preparation of the fabric structure eliminates the need for specialized cantilever machinery during operation, as the fabric can be directly mounted using standard machine infrastructure, thereby reducing device complexity while maintaining ease of operation.
Solution Approach 2:
The fabric structure itself provides the means for easy introduction through its joint loop design, which enables self-mounting capabilities. The fabric can be wound around machine rolls and connected without requiring external specialized equipment, allowing the fabric to serve its own introduction function and eliminating complex machine structures.
3Productivity
If fabric is formed in endless form by winding around machine rolls, then efficient mounting is achieved, but the fabric must be processed to have ends first
Solution Approach 1:
The joint loops are formed at the fabric ends during the fabric manufacturing process itself, before the fabric is introduced to the machine. This preliminary formation of connection structures eliminates the need for complex post-manufacturing processing steps, allowing the fabric to be efficiently mounted in endless form directly after production without additional end-formation operations.
Data Source
AI summary
An industrial two-layer fabric of the contact-yarn binding type without independent binding yarns, at both ends. The upper surface side warp serving as the warp fabric yarn-contact binding yarn is not woven into the upper surface side weft at one or more points of a complete structure, and extends toward the lower surface side instead and is woven into the lower surface side weft at the lower surface side, and then, extends toward the upper surface sides to be woven into other upper surface side weft, while, the lower surface side warp is not woven into the lower surface side weft at a point where the upper surface side warp serving as the warp fabric yarn-contact binding yarn is woven into the lower surface side weft at the lower surface side, and extends toward the upper surface side instead to be woven into the upper surface side weft which is not woven into the upper surface side warp, at the upper surface side, and then extends toward the lower surface side to be woven into other lower surface side weft. The industrial two-layer fabric forms a joint loop by at least one end portion of the warp being turned back at both end portions in its longitudinal direction, and at least a longitudinal yarn in a complete structure includes at least one warp which forms a pair arranged to be opposite to the warp which is turned back for forming the joint loop, and, in a longitudinal structure, the number of knuckles of one of the warps forming the pair is the same as that of the other of the warps forming the pair and distances between said adjacent knuckles are substantially the same.