Woven Fabric Flat Thread Orientation via Intermittent Heald Passage
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Solution Overview
Problem
Conventional woven fabrics with flat threads suffer from appearance and functional impairments due to curvature and deformation issues, particularly when flat threads are used instead of thick monofilaments, leading to protrusions and reduced functionality.
Innovation Solution
A method for manufacturing woven fabrics that includes fiber warp threads, fiber weft threads, and flat threads wider than warp threads, where flat threads pass through healds intermittently, oriented along the heald moving direction, and interwoven with warp threads to form woven fabric placement sections, ensuring the flat threads are fixed and hidden within the fabric structure without impairing appearance or function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flat threads are used instead of thick monofilaments, then flexibility and deformability are improved, but the flat threads curve into protruding shapes and functional integrity deteriorates
Solution Approach 1:
The flat threads are segmented by passing them through healds intermittently with respect to multiple fiber warp threads, creating discrete placement sections rather than continuous spans. This segmentation prevents the threads from curving into protruding shapes while maintaining flexibility within each segment.
Solution Approach 2:
Different regions of the flat thread are given different properties: sections passing through healds are constrained to maintain straight orientation, while sections between healds retain flexibility. The hole shape in healds (long in heald moving direction) provides localized orientation control without affecting overall thread flexibility.
2Shape
If flat threads are placed on woven fabric placement section, then appearance is improved, but the center portion of woven fabric is shorter than lateral sides causing curvature
Solution Approach 1:
The flat threads are selectively placed only on woven fabric placement sections rather than uniformly across the entire fabric. This local placement ensures that threads appear on flat, stable regions while avoiding curved center portions, maintaining both appearance and dimensional stability.
Solution Approach 2:
The healds with elongated holes are prepared in advance to orient flat threads along the heald moving direction before weaving occurs. This preliminary orientation prevents curvature development during the weaving process, ensuring threads remain straight on placement sections.
3Reliability
If flat threads pass through healds continuously, then functional integrity is improved, but the flat threads take large proportion of heald breadth causing crowding and rubbing
Solution Approach 1:
Instead of having flat threads pass through all healds continuously, the invention uses partial action by intermittently passing threads through selected healds. This reduces the proportion of heald breadth occupied by flat threads, preventing crowding and rubbing while maintaining functional integrity through strategic placement.
Solution Approach 2:
The continuous path of flat threads through healds is segmented into intermittent passages across multiple fiber warp threads. This segmentation distributes flat threads across more healds with fewer threads per heald, reducing crowding and rubbing while preserving overall thread functionality.
Data Source
AI summary
To provide a method for manufacturing a woven fabric for which neither the appearance nor a function provided by flat threads of the woven fabric are impaired, and to provide the woven fabric.The woven fabric further includes flat threads 3 each wider than a fiber warp thread 10, and the flat threads 3 are caused to pass through healds 102 intermittently with respect to a plurality of the fiber warp threads 10. A hole 102a of each heald is long in a heald moving direction. By causing the flat thread 3 to pass through the hole, the longitudinal direction in transverse plane of the flat thread 3 is oriented along a heald moving direction M. By interweaving fiber weft threads with the fiber warp threads 10, a plurality of woven fabric placement sections is formed so as to be arranged in a weft direction W, each woven fabric placement section being formed as a woven fabric structure and having the flat thread corresponding thereto placed on the woven fabric structure. A flat face HF of the flat thread 3 is disposed on the fiber warp threads 10 in the woven fabric placement section so as to face the fiber warp threads 10. A part of the fiber weft threads is caused to pass over the flat thread 3, to fix the flat thread 3 on the woven fabric placement section. The woven fabric covering section may be formed as a plain weave.