Method for pattern-controlled forming of the connection point of an effect thread in tissue
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Solution Overview
Problem
The existing methods for introducing effect threads into fabrics using guide needles often result in imprecise piercing, leading to inconsistent connection points due to vibrations and varying warp thread quality, especially at higher weaving speeds, causing issues with fraying and electrical connections.
Innovation Solution
The method involves floating the weft thread over multiple warp threads, allowing the effect needle to pierce within this floating length, ensuring precise positioning of the effect thread connection point, which automatically adjusts to the desired position during subsequent piercing processes, and utilizing zigzag or meandering patterns for precise electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If guide needles are used to introduce effect threads into the fabric, then the effect threads can be incorporated into the woven material, but the piercing precision is insufficient due to vibrations and varying warp thread quality, causing inconsistent connection points
Solution Approach 1:
The weft thread is pre-positioned to float over multiple warp threads (at least 6 warp threads or 1mm length) before the effect thread needle pierces. This preliminary floating arrangement creates a tolerance zone that compensates for positioning variations during piercing, ensuring the effect thread connection point remains within the floating length regardless of piercing inaccuracies
Solution Approach 2:
The invention changes the spatial parameter of the weft thread by extending it to float over multiple warp threads. This parameter change (from a tight weave to a floating structure) creates a buffer zone that absorbs positioning variations, transforming the rigid precision requirement into a more tolerant system where the connection point can vary within the floating length
2Object-affected harmful factors
If zigzag structures are incorporated to prevent fraying, then edge protection is improved, but inconsistent piercing causes warp threads to be pierced irregularly, making continuous thread removal difficult and causing tearing
Solution Approach 1:
The weft thread is pre-positioned to float over multiple warp threads in the zigzag structure. This preliminary floating arrangement ensures that when the fabric is cut and warp threads need to be removed, the floating weft thread provides a consistent reference point, allowing uniform thread removal without catching or tearing at irregular piercing points
3Adaptability or versatility
If conductor threads are used to create electrical connections, then conductive functionality is achieved, but imprecise piercing results in inconsistent electrical connection points, compromising wiring reliability
Solution Approach 1:
The weft thread is pre-positioned to float over multiple warp threads at locations where electrical connections are needed. This preliminary floating arrangement ensures that conductor threads will make consistent electrical contact with conductive warp threads within the floating length, providing reliable wiring for textile circuits, sensors, and heating elements
Solution Approach 2:
The floating weft thread acts as an intermediary element between the effect thread/conductor thread and the warp threads. It provides a stable, predefined zone that mediates the connection, ensuring consistent electrical contact points even when the exact piercing location varies within the floating length
Data Source
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AI summary
To ensure that, in certain cases, the zigzag thread (30, 34) of a fabric (20) with a zigzag-shaped additional thread (30, 34) always assumes the same position along the length of the fabric, it is proposed to insert the weft thread (24) at specific points in the fabric (20) by floating it over several adjacent warp threads (21), and to insert or pierce the feed needle (32, 36) at least on one side of the zigzag-shaped inserting thread (30, 34) at several or all insertion points into the fabric (20) where the weft thread (24) floats over several adjacent warp threads (21). The inserting thread (30, 34) is positioned on the inside of the zigzag shape.