Webbing Edge Weaving Method for Soft Skin-Contact Edges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for weaving webbing edges in underwear, swimwear, and sportswear result in sharp, uncomfortable edges due to excessive exposure of weft yarns, which compromises wearability as they scratch the skin.
Innovation Solution
A weaving method that alternately moves warp yarns upward and downward to form upper and lower layers, with weft yarns interweaving between them to create misaligned lock sites, reducing weft exposure and forming shaggy, fluffy, and soft round corners by employing a sequence of fore-and-back trips with specific warp yarn interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the common and simple edge process is used where the weft bypasses the warp at the edge position, then the webbing can be manufactured with a simple process, but the weft yarn is sufficiently exposed to the warp at the edge position making the edges solid and sharp which scratch the skin and cause discomfort
Solution Approach 1:
The patent divides the edge closing process into multiple sequential fore-and-back trips (first, second, third, and fourth trips) with different warp yarn movement patterns. Each trip creates a specific tissue form (three-sinking-one-floating or three-floating-one-sinking) that progressively builds up the edge structure, transforming the single-step simple process into a multi-step segmented process that achieves both manufacturability and comfort.
Solution Approach 2:
The patent introduces the dimension of warp yarn layer positioning by making three of the four warp yarns move in one direction while one moves in the opposite direction during each fore-and-back trip. This creates upper and lower layers of warp yarns with misaligned lock sites, transforming the edge structure from a single-layer sharp edge to a multi-layer fluffy edge that reduces skin irritation.
2Device complexity
If the weft yarn is required to bypass the warp at the edge position at each switch-back stroke, then the edge closing is achieved with a simple process, but the weft yarn exposure makes the edges sharp and uncomfortable
Solution Approach 1:
The patent employs dynamic control of warp yarn movements where different warp yarns (A, B, C, D) are selectively moved upward or downward during each fore-and-back trip. This dynamic positioning creates varying tissue forms (three-sinking-one-floating or three-floating-one-sinking) that progressively build up the edge structure, transforming the static simple bypass process into a dynamic multi-pattern process that achieves both process manageability and comfort.
Solution Approach 2:
The patent uses periodic fore-and-back trips with repeating patterns of warp yarn movements. Each trip follows a specific pattern (e.g., Warp A, B, D move downward while Warp C moves upward) that creates a consistent tissue form, and this periodic action is repeated four times to complete the edge closing, transforming the single bypass action into a periodic multi-trip process that ensures both manufacturability and comfort.
3Stability of the object's composition
If the edges are made solid and sharp for structural integrity, then the webbing maintains its shape, but the exposed weft yarn scratches the skin and reduces wearing comfort
Solution Approach 1:
The patent creates a composite edge structure by interweaving multiple warp yarns (A, B, C, D) with the weft yarn in specific patterns. The resulting tissue form combines sinking and floating sections that create a复合 structure with both structural integrity and softened edges, transforming the single-material sharp edge into a composite multi-layer edge that maintains shape while reducing skin irritation.
Solution Approach 2:
The patent transforms the sharp linear edge into a curved fluffy edge by creating misaligned lock sites between upper and lower warp yarn layers. The periodic fore-and-back trips build up layers of interwoven yarns that form rounded contours instead of sharp edges, transforming the geometric form from linear and sharp to curved and fluffy, thereby maintaining structural integrity while eliminating skin scratching.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The embodiment of the present application discloses a weaving method for braid edge overlock, to weave two side edges of the braid, herein a single side edge of the braid includes a plurality of warp yarns and at least one weft yarn; the warp yarns alternately move upward and downward, thereby forming upper and lower layers; the weft yarn shuttles left and right between the upper and lower layers of the warp yarns, thereby forming the braid edges by interweaving with the warp yarns; either of the left and right edges of the braid includes at least four warp yarns, referred to as Warp A, B, C, D from left to right; the right edge of the braid is provided with a right side yarn. The weaving processes include: first fore-and-back trip, second fore-and-back trip, third fore-and-back trip and fourth fore-and-back trip. The tissue form of the braid edge in the present application includes sinking lock sites and floating lock sites, and the structure of two side edges of the braid enables the sinking and floating of the upper and lower layers misalign properly, forming misaligned positions of warp yarns so as to make the weft yarn weave pair locks, which makes the structures of the left and right edges of the braid form shaggy, fluffy and soft round corners, so as to not scratch when contacting with the skins, and wear more comfortably