Variable Width Woven Strap for Automated Loop Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing strap production methods for climbing rings and other applications are labor-intensive and costly due to manual threading and hot blade cutting, which increases production time and costs, while also failing to meet mechanical strength standards efficiently.
Innovation Solution
A woven strap with variable widths achieved through changes in weave, featuring tubular stitching areas at the ends and a wear/overload indicator, allowing for automated production and enhanced mechanical strength, reducing production costs and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If manual threading and hot blade cutting are used to produce climbing rings from tubular fabric, then the mechanical strength requirements can be met, but the production cost and time increase significantly
Solution Approach 1:
The patent replaces the mechanical manual threading operation with a weaving process that automatically creates loops. The loom weaves the tubular fabric with integrated loop structures, eliminating the need for manual threading and hot blade cutting operations, thereby significantly improving production efficiency while maintaining mechanical strength
Solution Approach 2:
The loop structures are created during the weaving process itself, before the fabric is cut and assembled. The tubular fabric is woven with pre-formed loops that are later cut and stitched, eliminating the need for subsequent manual threading operations and reducing production steps
2Ease of manufacture
If manual threading operations are performed to join strap ends, then the loop structure can be formed, but labor intensity and production time increase
Solution Approach 1:
The manual threading operation is replaced by an automated stitching process. The strap ends with tubular structures are positioned and stitched together using automated sewing equipment, eliminating the need for manual dexterity and significantly reducing assembly time
Solution Approach 2:
The tubular structure at the strap ends is designed to facilitate self-alignment during assembly. The tubular geometry guides the ends into proper positioning for stitching, reducing the complexity of the assembly operation and enabling automated or semi-automated production
3Strength
If hot blade cutting is used to cut tubular fabric, then the fabric is sealed, but it must be reopened for threading, increasing production steps
Solution Approach 1:
The cutting operation is performed after the weaving and loop formation processes, not before. The tubular fabric is woven complete, then cut to length, and the tubular ends are stitched together. This sequence eliminates the need to reopen sealed fabric, as the tubular structure is created through stitching rather than threading through pre-cut openings
4Ease of manufacture
If uniform width straps are used, then production is simplified, but comfort at gripping areas is reduced
Solution Approach 1:
The strap is designed with variable width: a narrower main body for strength and a wider tubular section at the ends for comfort during gripping and stitching. This local variation in dimensions provides both comfort at the gripping area and structural efficiency in the main body, while the weaving process accommodates the width variation through standard loom operations
Data Source
AI summary
A woven strap comprises at least two continuous parts having different widths, wherein the change in width results from a modification of the respective weave of said parts. The strap can thus be used to create a loop or a ring in order to attach or bear a load. The two ends of the strap are joined to each other by stitching. Only the stitching areas of each of the two ends are tubular. The rest of the ring is flat and the stitching areas are placed on top of each other. The loop or ring can include an integrated wear and tear and/or overload indicator.