Method for pattern-directed formation of the connection point of an effect thread in the woven fabric
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Solution Overview
Problem
The existing methods for introducing effect threads into woven fabrics often result in imprecise stitching, where the effect thread needle is not consistently stitched into the desired warp thread gap, leading to issues like fraying and electrical connectivity problems.
Innovation Solution
The method involves floating weft threads over multiple warp threads, allowing the effect thread needle to be stitched within this region, ensuring precise binding points and preventing fraying, while enabling precise electrical connections by guiding the weft threads to specific contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the effect thread needle is stitched into the warp thread gap using conventional methods, then the effect thread can be introduced into the woven fabric, but the stitching position is imprecise and may deviate to adjacent warp thread gaps
Solution Approach 1:
The patent introduces a floating weft thread as an intermediary element between the effect thread needle and the warp threads. This floating weft thread acts as a mediator that guides the effect thread needle to the correct position, ensuring precise and consistent stitching while eliminating direct positioning challenges between the needle and warp threads
Solution Approach 2:
The floating weft thread is pre-positioned to float over multiple warp threads before the effect thread needle stitching operation. This preliminary arrangement creates a defined path and positioning reference that ensures the needle stitches precisely into the desired warp thread gap, preventing deviation to adjacent gaps
2Ease of manufacture
If the woven fabric is cut into individual strips after weaving, then the fabric can be processed further, but fraying occurs at the cut edges
Solution Approach 1:
The patent applies zigzag stitching patterns instead of straight lines at the edges of woven fabric strips. This curved/zigzag geometry prevents fraying by creating a interlocking pattern that resists thread separation at cut edges, while still allowing the fabric to be cut into individual strips for further processing
3Adaptability or versatility
If additional warp threads are introduced to extend in a long floating manner, then the fabric structure can be modified, but the effect thread needle positioning problem remains unsolved
Solution Approach 1:
The patent uses a floating weft thread as an intermediary positioning element that works independently of additional floating warp threads. This mediator ensures precise effect thread needle positioning regardless of the warp thread configuration, solving the stitching precision problem while maintaining fabric structure flexibility
Data Source
AI summary
For a woven fabric (20) with an additional thread (30, 34) laid out in a zigzag shape, in order to ensure in certain cases that the zigzag thread (30, 34) has its zigzag tip (38) always at the same position over the length of the woven fabric, it is proposed that the weft thread (24) is introduced at certain points in the woven fabric (20) in a floating manner over a plurality of adjacent warp threads (21) and that the feed needle (32, 36) is introduced or inserted into the woven fabric (20) at least at one side of the zigzag laid cover thread (30, 34) at several laying points or at all laying points where the weft thread (24) is floating over several adjacent warp threads (21). The cover thread (30, 34) is positioned at the inside of the zigzag shape.