Woven Structure with Continuous Binding Thread Variation
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Solution Overview
Problem
Existing woven structures, such as aircraft lift bags and complex-shaped articles, suffer from manufacturing defects leading to non-uniform stress distribution and structural weakness at assembly zones, resulting in air leaks, premature wear, and increased production time and cost.
Innovation Solution
A woven structure comprising two interconnected walls with a continuous variation in binding thread length, integrated into the fundamental weave of each wall, providing enhanced mechanical resistance and allowing for complex shapes like conical or cylindrical forms, and the use of different materials for varying mechanical strength zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If separate textile pieces are assembled by sewing or gluing to form complex shapes, then the article can achieve complex geometries, but structural weakness appears at assembly zones leading to premature wear and filling material loss
Solution Approach 1:
The patent merges multiple separate textile pieces into a single integrated woven structure by incorporating binding threads directly into the weaving process. The binding threads connect multiple walls during weaving, eliminating the need for post-weaving assembly operations like sewing or gluing, thereby removing weak assembly zones while maintaining complex geometries
2Shape
If separate textile pieces are assembled by sewing or gluing, then complex shapes can be formed, but assembly time increases and skilled operators are required
Solution Approach 1:
The binding threads are preliminary integrated into the weaving process itself, connecting multiple walls during the fundamental weaving operation. This preliminary action eliminates the need for subsequent assembly steps, significantly reducing assembly time and removing the requirement for skilled assembly operators
3Strength
If binding threads are used to connect woven walls, then structural strength is improved, but manufacturing defects at break points cause air losses and non-uniform stress distribution
Solution Approach 1:
The binding threads are merged with the fundamental weave structure, becoming an integral part of the woven fabric rather than separate connectors. This integration eliminates discrete break points and manufacturing defects associated with separate binding operations, ensuring uniform stress distribution and preventing air leaks while maintaining structural strength
4Strength
If a single-piece woven structure is produced, then mechanical resistance to stress is increased and assembly defects are eliminated, but the weaving process must accommodate continuous variation in binding thread length
Solution Approach 1:
The weaving process dynamically adjusts the length of binding thread segments (lies) between consecutive intersections with weft threads. This dynamic variation in binding thread length allows the single-piece structure to accommodate complex geometries and stress distributions while maintaining uniform stress distribution and eliminating assembly defects
Data Source
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AI summary
The invention relates to a woven structure including at least two woven walls (11, 12) connected together by at least one unattached linking thread (13). According to the invention, the length variation between two consecutive sinkers of said at least one linking thread (13), each of said sinkers corresponding to a riser per weft yarn of a different wall (11, 12), is continuous on at least a portion of said structure in the direction of the warp and/or in the direction of the weft. The invention can be used in the aeronautic, maritime, furniture an automotive fields.