Variable Path Weft Strands in Warp Knit Fabrics
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Solution Overview
Problem
Conventional warp knitting machines restrict weft threads to a fixed path and pattern, limiting the design and layout of warp knit fabrics, especially when forming conductive regions of varying shapes, sizes, and patterns.
Innovation Solution
The use of a computer-controlled weft insertion device that allows weft insertion strands to extend across less than all of the warp strands, with parallel segments of varying widths, enabling the creation of warp knit fabrics with customizable weft patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional weft thread carriers are used to insert weft threads across the entire width of the knitting machine, then the fabric structure is simple and easy to manufacture, but the design flexibility and ability to create varied conductive regions is limited
Solution Approach 1:
The weft insertion system is divided into multiple independent weft insertion devices, each capable of inserting weft threads into specific zones of the fabric. This segmentation allows different portions of the fabric to have different weft patterns, thereby achieving design flexibility without requiring complete redesign of the entire insertion system.
Solution Approach 2:
The weft insertion devices are made movable and repositionable along the fabric width, allowing dynamic adjustment of insertion positions and patterns. This enables the same device to create varied conductive regions with different shapes, sizes, and patterns by changing its position, rather than being fixed to a single insertion pattern.
2Adaptability or versatility
If fixed-pattern weft threads are used spanning the entire width of the fabric, then the manufacturing process is simple and efficient, but the ability to form conductive regions of different shapes, sizes, and patterns is restricted
Solution Approach 1:
The fabric width is divided into multiple zones, each served by a dedicated weft insertion device or device group. This allows simultaneous creation of different conductive region patterns in different zones, maintaining high productivity while achieving pattern variability.
Solution Approach 2:
The system allows changing of insertion parameters (position, pattern, density) for different weft insertion devices or at different positions along the fabric width. This enables creation of conductive regions with varied shapes, sizes, and patterns while maintaining efficient continuous manufacturing through parameter adjustment rather than physical reconfiguration.
3Adaptability or versatility
If a single weft insertion device is used for the entire fabric width, then the device structure is simple, but the ability to create multiple different weft strand patterns simultaneously is lost
Solution Approach 1:
Each weft insertion device is designed as a multi-functional unit capable of creating different weft strand patterns (straight, curved, diagonal, varying density) by adjusting its operational parameters. This universality allows a single device type to perform multiple pattern functions, reducing the need for numerous specialized devices while maintaining pattern diversity.
Solution Approach 2:
The system achieves pattern diversity through programmable parameter changes in each weft insertion device, such as insertion position, angle, spacing, and timing. By varying these parameters, the same physical device can create multiple different patterns, effectively multiplying its functional capacity without increasing the physical number of devices.
Data Source
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AI summary
An item (10) includes a fabric (20) formed from intertwined strands (12) of material. The strands (12) of material may include non-conductive strands and conductive strands. The strands (12) may be intertwined by a warp knitting machine (28) to produce a warp knit fabric (20). The warp knit fabric (20) may include intertwined warp strands (12-1) and weft insertion strands (12-2) that are inserted amongst the warp strands (12-1). The weft insertion strands (12-2) may extend across less than all of the warp strands (12-1). The weft insertion strands (12-2) may include parallel segments (12S) that each extend across a different portion of the warp strands (12-1). The segments (12S) of weft insertion strands (12-2) may have different widths relative to one another and relative to the width of the fabric (20). The weft insertion strands (12-2) may be inserted into the warp knitting machine (28) across the warp strands (12-1) using a weft insertion device (84) that is positioned by a computer-controlled positioner (86).