Weaving Machine for 3D Fabrics with Large Gaps
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Solution Overview
Problem
Existing weaving machines are unable to fabricate three-dimensional woven fabrics with gaps greater than 20 centimeters, which limits their versatility in meeting various design requirements.
Innovation Solution
A weaving machine equipped with a warp let-off mechanism, heald frames, picking mechanism, beating-up mechanism, yarn raising mechanism, and take-up mechanism, allowing for the interweaving of warps and wefts to create fabrics with adjustable gaps exceeding 20 centimeters by controlling the length and direction of inter-yarns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If velvet weaving machines are used to fabricate three-dimensional distance fabrics, then the gap between outer fabrics can be increased to about 20 centimeters, but the machine cannot fabricate fabrics with gaps greater than 20 centimeters
Solution Approach 1:
The invention divides the warp yarns into two distinct groups: inter-yarns that extend across the gap between outer fabrics and outer-yarns that form the outer fabrics themselves. This segmentation allows independent control of gap size and fabric structure, enabling gaps greater than 20 centimeters while maintaining fabric integrity through the inter-yarns that span the enlarged gap space.
Solution Approach 2:
The invention introduces a third dimensional aspect by having inter-yarns extend vertically across the gap space between outer fabrics, rather than only in the horizontal plane. This vertical extension through the gap dimension enables the fabrication of three-dimensional fabrics with adjustable gap sizes exceeding 20 centimeters, adding versatility to meet different design requirements.
2Adaptability or versatility
If the gap between outer fabrics is increased beyond 20 centimeters, then design flexibility is improved, but conventional weaving machines lose the capability to fabricate such fabrics
Solution Approach 1:
The invention employs a dynamic yarn raising mechanism that can selectively raise and lower inter-yarns during the weaving process to create and maintain large gaps between outer fabrics. This dynamic control allows the machine to precisely manage gap sizes greater than 20 centimeters while maintaining manufacturing precision through controlled yarn positioning and tension management.
Solution Approach 2:
The inter-yarns serve as intermediary elements that connect outer fabrics across large gap distances. These intermediary yarns maintain the structural relationship between outer fabrics even when separated by more than 20 centimeters, enabling design flexibility while preserving fabrication capability through the mediating role of inter-yarns that span the enlarged gap space.
Data Source
Figure 1
Figure 1'
Figure 2A~2B
AI summary
A weaving machine for weaving a three-dimensional distance woven fabric including two outer fabrics and inter-yarns connected with the outer fabrics is provided. The weaving machine includes a warp let-off mechanism, heald frames, a picking mechanism, a beating-up mechanism, a yarn raising mechanism, and a take-up mechanism. The warp let-off mechanism includes at least two warp beams for providing and transferring warps. A plurality of vertically arranged heald wires are supported by each of the heald frames, wherein each of the heald wires has a heald eye for the warps passing through. The warps are driven and divided into two warp layers by the heald frames such that a shed is formed between the two warp layers. The picking mechanism transfers wefts to pass through the shed. The yarn raising mechanism is suitable for passing through the shed and raising parts of the warps functioning as the inter-yarns.