CA2279408C - Network-like woven 3d fabric material - Google Patents
Network-like woven 3d fabric material Download PDFInfo
- Publication number
- CA2279408C CA2279408C CA002279408A CA2279408A CA2279408C CA 2279408 C CA2279408 C CA 2279408C CA 002279408 A CA002279408 A CA 002279408A CA 2279408 A CA2279408 A CA 2279408A CA 2279408 C CA2279408 C CA 2279408C
- Authority
- CA
- Canada
- Prior art keywords
- fabric
- warp
- yarns
- woven
- material according
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Landscapes
- Woven Fabrics (AREA)
- Looms (AREA)
Abstract
A network-like woven 3D fabric material (9) comprises select multilayer warp yarns (8) occurring substantially linearly, the remainder multilayer warp yarns (7) occurring in the helical configuration and two orthogonal sets of weft (12c and 12r) and such a network-like fabric construction (9) made possible through a dual-directional shedding operation of the weaving process. Such a fabric may additionally incorporate non-interlacing multi-directionally orientated yarns (n1-n8) across the fabric cross section to improve the fabric's mechanical performance. The produced 3D fabric material, which may be cut into any desired shape without the risk of splitting, may be used wholly or in parts in technical applications.
Description
TECHNICAL FIELD
This invention relates to a woven 3D fabric and its method of production. In particular. the woven 3D
fabric comprises select multilayer warp yams occurring substantially linearly.
the remainder multilayer warp yams occurring in a helical configuration and two orthogonal sets of weft and such a network-like fabric construction made possible through a dual-directional shedding operation of the weaving process. Such a fabric. which may additionally incorporate non-interlacing multi-directionally orientated yams across the fabric cross-section for improving its mechanical performance. is considered useful in technical applications like the manufacture of composite materials, filters. insulating materials. separator-cum-holder for certain materials, electrical/electronic parts, protection material, etc.
BACKGROUND
In the conventional weaving process the foremost operation of shedding is limited in its design to form a shed in only the fabric-width direction. The employed warp, which is either in a single or a multiple layer. is separated into two parts in a 'crossed' manner, in the direction of the fabric-thiclrness through the employment of the heald wires which are reciprocated through their frames by means such as cams or dobb~~ or jacquard to form a shed in the fabric-width direction. Each of these heald wires are reciprocated either singly or jointly or in suitable groups in only the fabric-thiclrness direction to form a shed in the fabric-width direction. A weft inserted into this formed shed enables interconnection between the separated two layers of the warp. The so interconnected warp and weft results in an interlaced structure which is called the woven fabric. A fabric when produced using a single layer warp results in a sheet-like «roven material and is referred to as a woven 2D
fabric as its constituent yams are supposed to be disposed in one plane. Similarly, when a fabric is produced using a multiple layer warp.
the obtained fabric which is characteristically different in construction from the woven 2D fabric. is referred to as a woven 3D fabric because its constituting yams are supposed to be disposed in a three mutually perpendicular plane relationship. However, in the production of both these types of woven 2D
and 3D fabrics the conventional weaving process, due to its inherent working design, can only bring about interlacement of two orthogonal sets of yam: the warp and the weft. It cannot brine about interlacement of three orthogonal sets of yams: a multiple layer warp and t«~o orthogonal sets of weft.
ThlS 15 an inherent limitation of the existing weaving process. The present invention provides a dual=
directional shedding method to form sheds in the columnwise and the row-wise directions of a multilayer warp to enable interlacement of the multilaver warp and two orthogonal sets of weft in such a way that select yams of the multilayer warp occur substantially linearly and the remainder yarns.
which interlace with the t<vo orthogonal sets of weft, occur in a helical eonfirmuation and the obtained fabric has a network-like structure.
Certain technical fabric applications require complex or unusual shapes besides 'other specific characteristics for performance such as a high degree of fabric integration and proper orientation of the constituent yarns. For example. at present it is not possible to obtain a suitable fabric block from which preforms (reinforcement fabric for composite material application) of any desired shape may be cut obtained. This is because the present fabric manufacturing processes of weaving, knitting, braiding and certain nonwoven methods which are employed to produce preforms cannot deliver a suitable highly integrated fabric block from which preforms of any desired shape may be cut obtained. With a view to obtain certain regular cross-sectional shaped preforms, suitable fabric manufacturing methods working on the principles of weaving, knitting, braiding and certain nonwoven techniques have been developed. Such an approach of producing preforms having certain cross-sectional shapes is referred to as near-net shaping. However, through these various techniques preforms of only certain cross-sectional profiles can be produced and preforms of any desired shape cannot be manufactured. The obtaining of preforms of any desired shape can be made practically possible if only a highly integrated fabric block can be made available so that the required shape can be cut from it without the risk of its splitting up.
Also, fabrics for other applications like filters of unusual shapes can be similarly cut obtained from a suitable fabric block. For analogy, this strategy of obtaining any desired shape of three-dimensional fabric item may be seen as the cutting of different shapes of fabric items from a suitable sheet of 2D fabric, for example, during the manufacture of a garment. Therefore, as can be inferred now, to cut obtain three-dimensional fabric items of any desired shape it is essential to first produce a highly integrated fabric in the form of a block. The present invention provides a novel woven 3D fabric and the method to produce such a fabric block which can be cut without the risk of splitting up and which may additionally incorporate non-interlacing yarns in a multi-directional orientation to impart mechanical performance to the fabric, so as to be useful in technical applications.
SUMMARY
In accordance with a broad aspect, the invention provides a block of network-like integrated 3D
fabric which additionally incorporates yarns suitably orientated to impart proper mechanical strength to the fabric so that suitable fabric items of any desired shape can be cut without the risk of its splitting up. Because certain fabric items of any desired shape may be obtained easily this way, such an approach can be advantageous in technical applications such as the manufacture of preforms, i.e. reinforcement fabric for composites application, filters, etc.
In accordance with another broad aspect, the invention provides a dual-directional shedding method to enable interlacement of three orthogonal sets of yarn: a set of multilayer warp and two orthogonal sets of weft. Such an interlacement of the three orthogonal sets of yarn is necessary to provided a high degree of integrity to the fabric to render the fabric resistant to splitting up in the fabric-width as well as in the fabric-thickness directions. This way the objective of producing a network-like interlaced 3D fabric, which may additionally incorporate non-interlacing multi-directionally orientated yarns, is made possible.
The integrity of the fabric is made possible through the formation of multiple row-wise columnwise sheds in the employed multiple layer warp. Two orthogonal sets of weft when inserted in the formed row-wise and columnwise sheds produce a network-like interlaced 3D
fabric. Because the foremost operation of the weaving process happens to be the shedding operation, all other subsequent complementing operations of the weaving process, for example picking, beating-up etc., will follow suit accordingly. As the dual-directional shedding method enables interlacement of two orthogonal sets of weft and a multilayer warp by way of forming sheds in the columnwise and row-wise directions of the multilayer warp to produce a highly integrated network-like fabric structure having a high mechanical performance, it will be described in detail. The subsequent complementing weaving operations like picking, beating-up, taking-up, letting off etc. will not be described as these are not the objectives of this invention.
With a view to keep the description simple and to the point, the simplest mode of carrying out the dual-directional shedding operation will be exemplified and will only pertain to the production of the woven plain weave 3D fabric according to this invention. The method of producing numerous other weave patterns through this invention will be apparent to those skilled in the art and therefore it will be only briefly mentioned as these various weave patterns can be produced on similar lines without deviating from the spirit of this invention.
In accordance with another broad aspect, the invention provides a device for producing woven fabric material with a weaving method incorporating the operation of shedding in two mutually perpendicular directions to form row-wise and column-wise sheds in a multilayer warp disposed according to a cross-sectional profile of the fabric to be produced. The device comprises shedding means which include one or more shafts capable of being reciprocated linearly along its longitudinal axis and also angularly about its longitudinal axis. Each of the shafts bear a set of means along the shaft's length direction such that the length direction of each of these means is orientated perpendicular to the length direction of the shaft. The set of means are intended to support warp strings threaded through its entry port and exit port in accordance with the cross-sectional profile of the fabric to be produced.
This invention relates to a woven 3D fabric and its method of production. In particular. the woven 3D
fabric comprises select multilayer warp yams occurring substantially linearly.
the remainder multilayer warp yams occurring in a helical configuration and two orthogonal sets of weft and such a network-like fabric construction made possible through a dual-directional shedding operation of the weaving process. Such a fabric. which may additionally incorporate non-interlacing multi-directionally orientated yams across the fabric cross-section for improving its mechanical performance. is considered useful in technical applications like the manufacture of composite materials, filters. insulating materials. separator-cum-holder for certain materials, electrical/electronic parts, protection material, etc.
BACKGROUND
In the conventional weaving process the foremost operation of shedding is limited in its design to form a shed in only the fabric-width direction. The employed warp, which is either in a single or a multiple layer. is separated into two parts in a 'crossed' manner, in the direction of the fabric-thiclrness through the employment of the heald wires which are reciprocated through their frames by means such as cams or dobb~~ or jacquard to form a shed in the fabric-width direction. Each of these heald wires are reciprocated either singly or jointly or in suitable groups in only the fabric-thiclrness direction to form a shed in the fabric-width direction. A weft inserted into this formed shed enables interconnection between the separated two layers of the warp. The so interconnected warp and weft results in an interlaced structure which is called the woven fabric. A fabric when produced using a single layer warp results in a sheet-like «roven material and is referred to as a woven 2D
fabric as its constituent yams are supposed to be disposed in one plane. Similarly, when a fabric is produced using a multiple layer warp.
the obtained fabric which is characteristically different in construction from the woven 2D fabric. is referred to as a woven 3D fabric because its constituting yams are supposed to be disposed in a three mutually perpendicular plane relationship. However, in the production of both these types of woven 2D
and 3D fabrics the conventional weaving process, due to its inherent working design, can only bring about interlacement of two orthogonal sets of yam: the warp and the weft. It cannot brine about interlacement of three orthogonal sets of yams: a multiple layer warp and t«~o orthogonal sets of weft.
ThlS 15 an inherent limitation of the existing weaving process. The present invention provides a dual=
directional shedding method to form sheds in the columnwise and the row-wise directions of a multilayer warp to enable interlacement of the multilaver warp and two orthogonal sets of weft in such a way that select yams of the multilayer warp occur substantially linearly and the remainder yarns.
which interlace with the t<vo orthogonal sets of weft, occur in a helical eonfirmuation and the obtained fabric has a network-like structure.
Certain technical fabric applications require complex or unusual shapes besides 'other specific characteristics for performance such as a high degree of fabric integration and proper orientation of the constituent yarns. For example. at present it is not possible to obtain a suitable fabric block from which preforms (reinforcement fabric for composite material application) of any desired shape may be cut obtained. This is because the present fabric manufacturing processes of weaving, knitting, braiding and certain nonwoven methods which are employed to produce preforms cannot deliver a suitable highly integrated fabric block from which preforms of any desired shape may be cut obtained. With a view to obtain certain regular cross-sectional shaped preforms, suitable fabric manufacturing methods working on the principles of weaving, knitting, braiding and certain nonwoven techniques have been developed. Such an approach of producing preforms having certain cross-sectional shapes is referred to as near-net shaping. However, through these various techniques preforms of only certain cross-sectional profiles can be produced and preforms of any desired shape cannot be manufactured. The obtaining of preforms of any desired shape can be made practically possible if only a highly integrated fabric block can be made available so that the required shape can be cut from it without the risk of its splitting up.
Also, fabrics for other applications like filters of unusual shapes can be similarly cut obtained from a suitable fabric block. For analogy, this strategy of obtaining any desired shape of three-dimensional fabric item may be seen as the cutting of different shapes of fabric items from a suitable sheet of 2D fabric, for example, during the manufacture of a garment. Therefore, as can be inferred now, to cut obtain three-dimensional fabric items of any desired shape it is essential to first produce a highly integrated fabric in the form of a block. The present invention provides a novel woven 3D fabric and the method to produce such a fabric block which can be cut without the risk of splitting up and which may additionally incorporate non-interlacing yarns in a multi-directional orientation to impart mechanical performance to the fabric, so as to be useful in technical applications.
SUMMARY
In accordance with a broad aspect, the invention provides a block of network-like integrated 3D
fabric which additionally incorporates yarns suitably orientated to impart proper mechanical strength to the fabric so that suitable fabric items of any desired shape can be cut without the risk of its splitting up. Because certain fabric items of any desired shape may be obtained easily this way, such an approach can be advantageous in technical applications such as the manufacture of preforms, i.e. reinforcement fabric for composites application, filters, etc.
In accordance with another broad aspect, the invention provides a dual-directional shedding method to enable interlacement of three orthogonal sets of yarn: a set of multilayer warp and two orthogonal sets of weft. Such an interlacement of the three orthogonal sets of yarn is necessary to provided a high degree of integrity to the fabric to render the fabric resistant to splitting up in the fabric-width as well as in the fabric-thickness directions. This way the objective of producing a network-like interlaced 3D fabric, which may additionally incorporate non-interlacing multi-directionally orientated yarns, is made possible.
The integrity of the fabric is made possible through the formation of multiple row-wise columnwise sheds in the employed multiple layer warp. Two orthogonal sets of weft when inserted in the formed row-wise and columnwise sheds produce a network-like interlaced 3D
fabric. Because the foremost operation of the weaving process happens to be the shedding operation, all other subsequent complementing operations of the weaving process, for example picking, beating-up etc., will follow suit accordingly. As the dual-directional shedding method enables interlacement of two orthogonal sets of weft and a multilayer warp by way of forming sheds in the columnwise and row-wise directions of the multilayer warp to produce a highly integrated network-like fabric structure having a high mechanical performance, it will be described in detail. The subsequent complementing weaving operations like picking, beating-up, taking-up, letting off etc. will not be described as these are not the objectives of this invention.
With a view to keep the description simple and to the point, the simplest mode of carrying out the dual-directional shedding operation will be exemplified and will only pertain to the production of the woven plain weave 3D fabric according to this invention. The method of producing numerous other weave patterns through this invention will be apparent to those skilled in the art and therefore it will be only briefly mentioned as these various weave patterns can be produced on similar lines without deviating from the spirit of this invention.
In accordance with another broad aspect, the invention provides a device for producing woven fabric material with a weaving method incorporating the operation of shedding in two mutually perpendicular directions to form row-wise and column-wise sheds in a multilayer warp disposed according to a cross-sectional profile of the fabric to be produced. The device comprises shedding means which include one or more shafts capable of being reciprocated linearly along its longitudinal axis and also angularly about its longitudinal axis. Each of the shafts bear a set of means along the shaft's length direction such that the length direction of each of these means is orientated perpendicular to the length direction of the shaft. The set of means are intended to support warp strings threaded through its entry port and exit port in accordance with the cross-sectional profile of the fabric to be produced.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in reference to the following illustrations.
Fig. 1 shows the general arrangement of the shedding shafts for carrying out dual-directional shedding .
Fig. 2 shows the disposal arrangement of the active and the passive warp yarns comprising the multilayer warp.
Fig. 3 shows the location of the shedding shafts in relation to the passive yarns of the multilayer warp indicated in Fig. 2.
Fig. 4a shows the top view of the level position of the shedding shafts and the multilayer warp prior to columnwise shed formation.
Fig. 4b shows the top view of the shedding shafts displacing the active warp yarns drawn through its eyes towards the right side of the passive warp yarns and the formation of the multiple right side columnwise sheds with the passive warp yarns.
Fig. 4c shows the top view of the shedding shafts displacing the active warp yarns drawn through its eyes towards the left side of the passive warp yarns and the formation of the multiple left side columnwise sheds with the passive warps yarns.
Fig. Sa shows the side view of the level position of the shedding shafts and the multilayer warp prior to row-wise shed formation.
Fig. Sb shows the side view of the shedding shafts displacing the active warp yarns drawn through its eyes in the upward direction to form the multiple upper row-wise sheds with the passive warp yarns.
Fig. Sc shows the side view of the shedding shafts displacing the active warp yarns drawn through its eyes in the downward direction to form the multiple lower row-wise sheds with the passive warp yarns.
Fig. 6a is a three-dimensional representation of the typical yarn paths of the active warp yarns at the edges and the surfaces of the plain weave construction of the woven 3D
fabric.
Fig. 6b is a three-dimensional representation of the typical yarn paths of the active warp yarns in the interiors of the plain weave construction of the woven 3D fabric.
3a Fig. 7 is a two-dimensional representation of the front view of the fabric construction shown in Fig. 6.
Fig. 8a is a two-dimensional representation of the top view of the fabric construction shown in Fig. 6a.
Fig. 8b is a two-dimensional representation of the side view of the fabric construction shown in Fig. 6a.
Fig. 9a is a two-dimensional representation of the top view of the fabric construction shown in Fig. 6b.
Fig. 9b is a two-dimensional representation of the side view of the fabric construction shown in Fig. 6b.
3b Fig. IOa is a two-dimensional representation of the axial view of a modified fabric construction showing the path of the active wasp yarns obtainable according to a specific shedding order.
Fig. lOb is a two-dimensional representation of the axial view of a modified fabric construction showing the path of the active warp yarns obtainable according to a specific shedding order.
Fig. lOc is a two-dimensional representation of the axial view of a modified fabric construction showing the path of the active warp yams obtainable according to combined specific shedding orders indicated in Figs. l0a and I Ob.
Fig. 11 is the firont view of the fabric construction incorporating additional non-interlacing yams in the fabric-width, -thiclmess and the two diagonal directions.
Fig. 12a is a two dimensional representation of the finnt view of a useful fabric construction producible in which the exterior part is only interlaced to fimrxion as a woven covering for the non-interlacing yarns which occur internally withoutinterlacement.
Fig. 12b is a two dimensional representation of the front view of a useful fabric construction producible in which specifically disposed yams of the multilayer warp are interlaced to form a sandwich or a core type of fabric construction.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The method of producing the woven 3D fabric using two orthogonal sets of weft and a muttilaver warp will now be described in reference to the above stated drawings. The working principle of the dual-directional shedding method will be described first and then the particular way of constructing usefirl fabrics according to this invention will be described.
The method to be described now follows a completely new plan for erecting shedding compared with the conventional shedding methods. In Fig. 1 is shown the essential features of the novel dual-directional shedding arrangement ( 1 ) for effecting shed fomration in the fabric-width and -thickness directions. Each of the cylindrical heald shafts (2) carry a set of fixed flat healds {3) as indicated. Each heald has two openings: the front one is the heald-eye (4) and the n"ar one is a heald-guide (5). Such an assembly comprising the cylindrical heald shaft (2) and the flat healds (3) is suitably supported in supports (s), as indicated in Fig. 1, in a manner that each of these assemblies can be reciprocated in two directions: (i) along and (ii) about the shaft axis: that is linearly and angularty respectively.
The disposal arrangement of the employed multilaver~ed warp (6) is indicated in Fig. 2. Such a disposal is required to achieve a uniform integration at the fabric's surfaces (excluding end surfaces) and for the balanced distribution of the yarns in the fabric. The peculiarity of this arrangement is that it comprises active (7) and passive (8) warp yarns such that each passive warp end (8) is 'surrounded' by active warp ends (7) for achieving uniform fabric integration. Such a multilayer wrp disposal arrangement (6) may be described as comprising alternate rows or columns of active (7) and passive (8) warp ends.
Thus. the alive-warp yarn rows will be designated by 'a', 'c', 'e'. etc. and the passive-warp yarn rows by 'b', 'd', 'f etc. as indicated in Fig. 2. The occurring aitemate columns of the active (7) and passive (8) warp yams will be designated by 'A', 'C', 'E' etc. and 'B', 'D'. 'F' etc.
respectively as indicated in Fig 2. Each of the active warp ends (7) of a given row (or column) is drawn through the corresponding flat heald's (3) guide (~) and the eye (4). The passive warp yams (8) of a given row (or column) are drawn through the open space occurring between corresponding two adjacent heald shafts (2). Thus.
the multilayer warp yarns (6) and the heald shafts (2) will occur as indicated in Fig. 3.
The above described disposal arrangement of the multilaver warp (6) and the shedding shafts (2) shown in Fig. 3 defines the level position of the system. From this level position, each of the active warp ends (7) passing through a corresponding heald eye (4) can be displaced in the fabric-width and -thiclmess directions by moving the heald shaft (2) along its axis and turning it about its axis respectively. In relation to the passive wasp ends (8), which do not pass through the heald eyes (4), and hence are stationary, the displaceable active warp ends (7) readily form multiple columnwise (10) and row-wise ( 11 ) sheds upon their displacement in the required direction from the level position as shown in Figs. 4 and 5. The Linear and the angular displacements of the heald shafts (2) from its level position to form the row-wise ( 11 ) and the columnwise ( 10) sheds can correspond to the distance between two adjacent active (7) (or passive (8)) warp yams in the given direction of movement and may be referred to as the shedding displacement pitch. In the formation of these multiple sheds ( 10) and ( I 1 ), the displacement of the active warp ends (7) of a given row or column may thus be referred to as a unit shedding displacement pitch. However in real practice this displacement can be increased up to a maximum of 1.5 times the shedding displacement pitch to form a correspondingly greater shed for practical advantage in weft insertion.
In its simplest mode, all the shafts (2} are moved simultaneously, either linearly or. arrgularly, and in the same direction to form corresponding directional movement's multiple sheds as shown in Figs. 4 and 5 respectively. Hy picking a weft ( 12) in each of these fob sheds ( 10) and ( 11 ), interlacement within the individual columns and the rows of the multilayer warp (6) with the corresponding v~~efts (12c and 12r) is achieved. Such an alternate row-wise and columnwise shedding and corresponding picking thus leads to the production of the plain weave woven 3D fabric of this method. The typical yarn paths at the edges and the surfaces of the fabric (9), and in the interiors of fabric (9) are respectively indicated in Figs. 6a and 6b. The simplest working of this dual-directional shedding system ( 1 ) is outlined below in reference to Figs. 4 and 5.
1n Fig. 4 is illustrated the formation of the columnwise sh~s ( 10). Fig. 4(a) indicates the level position of the system. In Figs. 4 (b) and (c) are shown the directions of the linear movement of a heald shaft (2) along its axis. The former and the latter figures respectively show the displacement of the active warp ends (7), from their level positions, in the fabric-width direction to form the right side and the leR side coltunnwise sheds (10) with the stationary passive warp yams (8). Fig. 5 shows the formation of the row-wise sheds (11). Fig. 5(a) indicates the level position of the system. In Figs. 5 (b) and (c) are illustrated the directions of the angular movement of a heald shaft (2) about its axis. The former and the latter figures respectively show the displacement of the active warp ends (7), from their level positions.
in the fabric-thiclrness direction to form the upper and lower row-wise sheds (I l) with the stationary passive warp yarns (8).
As can be inferred from the Figs. 4 (b) and (c) and 5 (b) and (c), the optimum displacement of the shafts can be up to 1.~ times the shedding displacement pitch in practice to obtain relatively larger WO 98!39507 PCTISE97/00355 sheds for convenience in weft insertion. The shafts may be displaced up to the extent that an active warp yarn (?) does not cross two passive warp yarns (8).
It is to be noted that in reference to the stationary passive warp yarns (8), the right and the left side colummvse sheds, and the upper and the lower row-wise sheds are not formed simultaneously but in a specific order. The shedding shafts (2) revert to their level position every time subsequent to a particular shed formation and picking operation. For example, in the construction of the plain weave woven 3D fabric (9) obtainable tluough this method, and indicated in Fig. 6, the order of shedding and picking indicated below is followed, starting from the level position of the system. The movements of the shedding shafts described below are viewed from the rear of the shedding means in the direction of the fabric-fell.
1 ) Upward angular movement of the shedding shafts (2); fom~ation of the row-wise upper sheds ( 11);
followed by pick insertion in the formed sheds (i.e. in the fabric-width direction) 2) Reverting shedding shafts (2) to the !eve! position of the system 3) Righttvard linear movement of the shafts (2); formation of the columnwise right side sheds { 10);
followed by pick insertion in the formed sheds (i.e. in the fabric-thickness direction) 4) Reverting shafts (2) to the level position of the system 5) Dowward angular movement of the shafts {2); formation of the row-wise lower sheds (11);
followed by pick insertion in the formed sheds {i.e. in the fabric-width direction) 6) Reverting shafts (2) to the level position of the system 7) Leftward linear movement of the shafts (2); formation of the columnwise left side sheds(10);
followed by pick insertion in~the formed sheds (i.e. in the fabric-thickness direction) 8) Reverting shafts (2) to the level position of the system ' The above indicated shedding order, together with the necessary complementing operations of the weaving process like picking, beating-up, taking-up etc. at appropriate moments constitute one complete «rorking cycle of the process. Fig. 7 shows the front view of the plain weave woven 3D fabric construction (9) obtainable through the above stated shedding order. It is to be noted that the two sets of weft ( 12c and 12r), which may be inserted in their respective sheds by employing means like shuttles. rapiers etc. and may be picked in as either a single yarn or hairpin-like folded yam, uniquely interlace with the active warp yams (?) and get connected to the passive warp yarns (8). Because of their interlacement with the active warp yarns (?) the two sets of weft ( 12c and 12r) will occur in an undulating manner and not straight as indicated in Figs. 6 and ?. These two sets of weft (12c and 12r) are shown straight for only easy representation. However, the incidence of its crimp can be reduced, for example, by feeding the active warp yarns (?) under suitable tension and at a suitable rate.1n Figs. 8a and 8b are shown the top and the side views respectively of the fabric (9) to indicate the typical paths of the active warp yarns (?) at the fabric's edges and surfaces. The series of letters A-B-C-D, P-Q-R-S
etc. respectively indicate the individual active warp yam (?) paths at the edges and surfaces of the fabric construction shown in Figs. 6a and 7. 1n Figs. 9a and 9b are shown the top and the side views respectively of the fabric (9) to indicate the typical path of the active warp yam (?) in the interior of the fabric construction shown in Fig. 6b. The series of numbers 111-112-113-114 indicates the individual active warp yarn (?) path in the interior of the fabric construction shown in Figs. 6b and 7.
An important feature of the fabric construction (9) to be noted in Figs. 6, 7, 8 and 9 is the occurrence of the active warp yams in a 'helical' configuration. Though not following a circular path, the active warp yarns occur in a 'triangular helix' at the fabric's edges and surfaces (indicated by different series of letters, A-B-C-D, P-Q-R S etc. in Fig. 7) and in a 'square helix' in the interiors (indicated by differcnt series of numbers, 101-102-103-104, 131-132-133-134 etc. in Fig. 7). Further, both these helices are not fom~ed about any of the passive warp yams. Also, the fabric has a network-like construction.
There may be introduced minor alterations in the above fiarrrework of operations. For example, the above indicated order of shedding operations may be altered to produce a modified network-like fabric construction (9m) shown in Fig. 10. In reference to the shedding order indicated above. if the order given below is carried out, then modified network-like fabric constructions (9m) may be obtained and will correspond with those indicated in Fig. 10 in which the general path of the active warp yam in the interior of the fabric is only shown and corresponds as follows:
a) Shedding order: 1, 2, 5, 6, 3, 4, 7, 8 and repeat b) Shedding order: 1, 2, 5, 6, 7, 8, 3, 4 and repeat c) Shedding order: 1, 2, 5, 6, 3, 4, 7, 8, 1, 2, 5, 6. 7, 8, 3, 4 and repeat.
These obtained modified network-like fabric constructions (9m) shown in Fig.
10 will differ from the one indicated in Figs. 6, 7, 8 and 9 in which the typical paths of the active warp yarns (7) in accordance with the initially mentioned shedding order are indicatcd. The difference in the fabric construction (9m) due to the change of the shedding order will be that the wefts of a given set will occur successively and not aitemately as shown in the figures, and also the active warp yarns (7) will additionally occur in the fabric-width and -thiclrness directions in addition to the diagonal directions as represented in Fig. 10.
This is because the wefts ( 12c and 12r) will be picked successively in the 'forward and backward' directions of the respective side (row-wise or columnwise direction).
Nevertheless, the active warp yams (7) in all these constructions (9) and (9m) may be considered to occur in a helical configuration for the purpose of easy understanding.
Fmm the foregoing description of the dual-directional shedding method, the following points will be apparent to those skilled in the art.
a) All the columnwise (or the row-wise) sheds can be formed simultaneously for increased production efficiency and not successively one columnwise (or row-wise) warp layer after the other.
b) Multiple wefts of a set may be picked simultaneously employing means like shuttles, rapiers etc. and each of the wefts may be inserted as either a single yarn or a hairpin-like folded yarn.
c) The active warp yarns (7) may be made to occur in the fabric-length direction either in ahelical configuration or additnnally in the fabric-width and - thickness directions by corrtrollinghe shedding order.
d) The helical progression of all the active warp yams (7) provides unique network-like fabric integration throughout the fabric by interlacing with the two sets of weft and interconnecting these t<vo sets of weft to the passive warp yams.
e) The helical progression of the active warp yams (7) provides unique discrete placement of the active warp yams (7) in either the 'diagonal' directions or additionally in the fabric-width and -thiclmess directions.
f) The optimum shedding displacement pitch of the shedding shaft (2) in the fabric-thicirness and the -width dituctions is 1.~ since a greater displacement will cause interference with the pick insertion and unnecessary concentration of the active warp yams (7) at the fabric's surfaces and thus lead to uneven fabric surface and unbalanced fabric construction.
g) Dii~erent v~ave patterns can be created by displacing independently and selectively in the fabric width and thicaaiess directions the required shafts {2) which bear the healds (3) which are suitably h) It is possible to carry out shedding involving only the active warp ends (7) by displacing independently pairs of the shafts (2) in opposite directions, and the healds (3) of which are suitably threaded.
i) Tubular fabrics of either square or rectangle cxoss-section and solid profiled fabrics like L, T, C etc.
can be directly produced by disposing the multilayer warp in accordance with the cross-sectional profile to be produced and suitably effecting the shedding and the picking operations in a suitable discrete manner. for example by employing more than one set of picking means in each of the two directions.
It will now be apparent to those skilled in the art that the mechanical performance of the fabric can be improved. if required, by the inclusion of non-interlacing 'stuffer' yams in the fabric-width. -thickness and the two diagonal directions across the fabric cross-section. An example of one such construction is outlined below.
In reference to the shedding and picking order mentioned earlier, the insertion of non-interlacing yarns (nl-n8) may be included in the fabric according to the steps indicated below and illustrated in Fig. l l .
1 ) Upward angular movement of the shedding shafts: formation of the row-wise upper sheds: followed by pick insertion (12r) in the formed sheds 2) Reverting shedding shafts to the level position of the system 3) Insertion of the set of non-interlacing yarn (nl) between given two rows of the passive wasp yarns (8) 4) Insertion of the set of diagonal non-interlacing yarn (n2) between given two diagonally occurring layers of the passive warp yarns (8) 5) Right<vard linear movement of the shafts; formation of the right side columnwise sheds: followed by pick insertion ( 12c) in the formed sheds 6) Reverting shafts to the level position of the system 7) Insertion of the set of non-interlacing yam (n3) between given two columns of the passive warp yarns (8) 8) Insertion of the set of diagonal non-interlacing yam (n4) between given two diagonally occxuxing layers of the passive warp yarns (8) 9) Downward angular movement of the shafts: fom~ation of the lower row-wise sheds: follov~ed by pick insertion ( 12r) in the formed sheds 10) Reverting shafts to the level position of the system 11 ) Inserrion of the set of non-interfacing yarn (n5) between given two rows of the passive warp yarns(8) 12) Insertion of the set of diagonal non-interlacing yam (n6) between given two diagonally occurring layers of the passive warp yarns (8) 13) Leftward linear movement of the shafts: formation of the left sidecolumnwise sheds: followed by pick insertion ( 12c) in the formed sheds 14) Reverting shafts to the level position of the system 15) Insertion of the set of non-interlacing yam (n7) between given two columns of the passive warp yarns (8) 16) Insertion of the set of diagonal non-interlacing yarn (n8) between given two diagonally occurring layers of the passive warp yarns (8) Further, this method is not limited to the producxion of a block of either fabric construction (9) or (9m) or (9n) having either a square or a rectangle cross-section. By disposing the multilayer warp in accordance with the desired shape of cross-section. including tubular types with square or rectangle cross-section, and following suitable discrete sequence of operations described above, network-like fabric constructions either (9) or (9m) or (9n) of the cotTesponding cross-sectional profile can also be produced. It may be mentioned here that depending on the complexity of the cross-sectional profile being produced, more than one set of weft inserting means for each of the two directions can be employed. Such different sets of the weft insetting means of a given direction (i.e. row-wise or colummvise) tray be operated either simultaneously or discretely to achieve the required weft insertion for the profile under production. This method of fabric production is therefore not limited to the production of a fabric of a particular cross-sectional profile. Further, because of the unique network-like interlacement, there is no need to carry out any separate binding operation at the exterior surfaces of the fabric to achieve the fabric integrity. This elimination of the binding process is apparently advantageous in simplifying and quickening the fabric production. Further.
this method of producing network-like interlaced 3D fabric blocks and other cross-sectional profiles eliminates to the need to develop methods for producing certain cross-sectional shapes as from the produced block of the network-like fabric obtainablc through this method, any desired shape of preform, filter etc. material can be easily cut obtained without the risk of its splitting up.
Further, it is possible to produce another useful fabric material by carrying out shedding involving only the warp yams occurring at the exteriors of the disposed multilayer warp (6) by suitably displacing the shafts (2), the healds (3) of which have been correspondingly threaded as described earlier. In reference to Fig. 12a, the top and the bottom woven surfaces can be produced by moving angularly the top and the bottom shafts (2), and hence displacing the healds (3), to displace the active warp yarns (7) to form .
row wise sheds with the passive warp yarns (8) and inserting the wefts ( 12r) into these exterior top and bottom row-wise sheds. Similarly, the left and the right side woven surfaces can be produced by moving linearly the shafts {2), and hence displacing the heaids (3), to displace the active warp yams (7) to form columnwise sheds with the passive warp yarns (8) and inserting wefts (12c) into these exterior left and right columnwise sheds. Thus such operations will produce an interlaced exterior surface which will function as a woven covering for the interrtally occurring non-interlacing multilayer yams (6n) of the fabric material (9e) as shown in Fig. 12a.
Further, it is also possible to produce a core or a sandwich type of fabric material (9s) shown in Fig:
12b by interlacing the suitably disposed multiiayer warp yarns. Here again. by displacing independently the heald shafts (2), the healds (3) of which have been correspondingly threaded, the row-wise and the columm~~ise sheds can be respectively formed by moving these shafts (2) angularly and linearly as described earlier. Inserting wefts ( 12r) and ( 12c) into the formed row-wise and columnwise sheds respectively, the interlaced fabric structure (9s), generally referred to as sandwich or core type fabric structure, shown in Fig. 12b is obtained.
Further, it is also possible to produce multiple woven 2D fabric sheets employing the described shedding means. Such multiple sheets can be produced by disposing the multilayer warp as described before and moving the shafts (2) either angularly or linearly to form correspondingly either the row-wise or the columnwise sheds and inserting correspondingly either wefts (12r) or (12c) into the formed sheds of the given direction. Thus, by forming row-wise sheds and effecting corresponding picking, the multiple sheets of woven 2D fabric will be produced in the horizontal form.
Similarly; by forming columnwise sheds and~effecting corresponding picking, the multiple sheets of woven 2D fabric will be produced in the vertical form in reference to the arrangement shown in Fig. 3.
Needless to mention, in all the above described methods of fabric production.
the other complementing operations of the weaving process like the beating-up, taking-up etc. will be canied out at the appropriate moments of the weaving cycle to produce a satisfactory fabric of the required specification.
It will be now apparent to those skilled in the art that it is possible to alter or modify the various details of this invention without departing from the spirit of the invention.
Therefore. the foregoing description is for the purpose of illustrating the basic idea of this invention and it does not limit the claims which are fisted below.
SUBSTITUTE SHEET (RULE 26)
The invention is described in reference to the following illustrations.
Fig. 1 shows the general arrangement of the shedding shafts for carrying out dual-directional shedding .
Fig. 2 shows the disposal arrangement of the active and the passive warp yarns comprising the multilayer warp.
Fig. 3 shows the location of the shedding shafts in relation to the passive yarns of the multilayer warp indicated in Fig. 2.
Fig. 4a shows the top view of the level position of the shedding shafts and the multilayer warp prior to columnwise shed formation.
Fig. 4b shows the top view of the shedding shafts displacing the active warp yarns drawn through its eyes towards the right side of the passive warp yarns and the formation of the multiple right side columnwise sheds with the passive warp yarns.
Fig. 4c shows the top view of the shedding shafts displacing the active warp yarns drawn through its eyes towards the left side of the passive warp yarns and the formation of the multiple left side columnwise sheds with the passive warps yarns.
Fig. Sa shows the side view of the level position of the shedding shafts and the multilayer warp prior to row-wise shed formation.
Fig. Sb shows the side view of the shedding shafts displacing the active warp yarns drawn through its eyes in the upward direction to form the multiple upper row-wise sheds with the passive warp yarns.
Fig. Sc shows the side view of the shedding shafts displacing the active warp yarns drawn through its eyes in the downward direction to form the multiple lower row-wise sheds with the passive warp yarns.
Fig. 6a is a three-dimensional representation of the typical yarn paths of the active warp yarns at the edges and the surfaces of the plain weave construction of the woven 3D
fabric.
Fig. 6b is a three-dimensional representation of the typical yarn paths of the active warp yarns in the interiors of the plain weave construction of the woven 3D fabric.
3a Fig. 7 is a two-dimensional representation of the front view of the fabric construction shown in Fig. 6.
Fig. 8a is a two-dimensional representation of the top view of the fabric construction shown in Fig. 6a.
Fig. 8b is a two-dimensional representation of the side view of the fabric construction shown in Fig. 6a.
Fig. 9a is a two-dimensional representation of the top view of the fabric construction shown in Fig. 6b.
Fig. 9b is a two-dimensional representation of the side view of the fabric construction shown in Fig. 6b.
3b Fig. IOa is a two-dimensional representation of the axial view of a modified fabric construction showing the path of the active wasp yarns obtainable according to a specific shedding order.
Fig. lOb is a two-dimensional representation of the axial view of a modified fabric construction showing the path of the active warp yarns obtainable according to a specific shedding order.
Fig. lOc is a two-dimensional representation of the axial view of a modified fabric construction showing the path of the active warp yams obtainable according to combined specific shedding orders indicated in Figs. l0a and I Ob.
Fig. 11 is the firont view of the fabric construction incorporating additional non-interlacing yams in the fabric-width, -thiclmess and the two diagonal directions.
Fig. 12a is a two dimensional representation of the finnt view of a useful fabric construction producible in which the exterior part is only interlaced to fimrxion as a woven covering for the non-interlacing yarns which occur internally withoutinterlacement.
Fig. 12b is a two dimensional representation of the front view of a useful fabric construction producible in which specifically disposed yams of the multilayer warp are interlaced to form a sandwich or a core type of fabric construction.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The method of producing the woven 3D fabric using two orthogonal sets of weft and a muttilaver warp will now be described in reference to the above stated drawings. The working principle of the dual-directional shedding method will be described first and then the particular way of constructing usefirl fabrics according to this invention will be described.
The method to be described now follows a completely new plan for erecting shedding compared with the conventional shedding methods. In Fig. 1 is shown the essential features of the novel dual-directional shedding arrangement ( 1 ) for effecting shed fomration in the fabric-width and -thickness directions. Each of the cylindrical heald shafts (2) carry a set of fixed flat healds {3) as indicated. Each heald has two openings: the front one is the heald-eye (4) and the n"ar one is a heald-guide (5). Such an assembly comprising the cylindrical heald shaft (2) and the flat healds (3) is suitably supported in supports (s), as indicated in Fig. 1, in a manner that each of these assemblies can be reciprocated in two directions: (i) along and (ii) about the shaft axis: that is linearly and angularty respectively.
The disposal arrangement of the employed multilaver~ed warp (6) is indicated in Fig. 2. Such a disposal is required to achieve a uniform integration at the fabric's surfaces (excluding end surfaces) and for the balanced distribution of the yarns in the fabric. The peculiarity of this arrangement is that it comprises active (7) and passive (8) warp yarns such that each passive warp end (8) is 'surrounded' by active warp ends (7) for achieving uniform fabric integration. Such a multilayer wrp disposal arrangement (6) may be described as comprising alternate rows or columns of active (7) and passive (8) warp ends.
Thus. the alive-warp yarn rows will be designated by 'a', 'c', 'e'. etc. and the passive-warp yarn rows by 'b', 'd', 'f etc. as indicated in Fig. 2. The occurring aitemate columns of the active (7) and passive (8) warp yams will be designated by 'A', 'C', 'E' etc. and 'B', 'D'. 'F' etc.
respectively as indicated in Fig 2. Each of the active warp ends (7) of a given row (or column) is drawn through the corresponding flat heald's (3) guide (~) and the eye (4). The passive warp yams (8) of a given row (or column) are drawn through the open space occurring between corresponding two adjacent heald shafts (2). Thus.
the multilayer warp yarns (6) and the heald shafts (2) will occur as indicated in Fig. 3.
The above described disposal arrangement of the multilaver warp (6) and the shedding shafts (2) shown in Fig. 3 defines the level position of the system. From this level position, each of the active warp ends (7) passing through a corresponding heald eye (4) can be displaced in the fabric-width and -thiclmess directions by moving the heald shaft (2) along its axis and turning it about its axis respectively. In relation to the passive wasp ends (8), which do not pass through the heald eyes (4), and hence are stationary, the displaceable active warp ends (7) readily form multiple columnwise (10) and row-wise ( 11 ) sheds upon their displacement in the required direction from the level position as shown in Figs. 4 and 5. The Linear and the angular displacements of the heald shafts (2) from its level position to form the row-wise ( 11 ) and the columnwise ( 10) sheds can correspond to the distance between two adjacent active (7) (or passive (8)) warp yams in the given direction of movement and may be referred to as the shedding displacement pitch. In the formation of these multiple sheds ( 10) and ( I 1 ), the displacement of the active warp ends (7) of a given row or column may thus be referred to as a unit shedding displacement pitch. However in real practice this displacement can be increased up to a maximum of 1.5 times the shedding displacement pitch to form a correspondingly greater shed for practical advantage in weft insertion.
In its simplest mode, all the shafts (2} are moved simultaneously, either linearly or. arrgularly, and in the same direction to form corresponding directional movement's multiple sheds as shown in Figs. 4 and 5 respectively. Hy picking a weft ( 12) in each of these fob sheds ( 10) and ( 11 ), interlacement within the individual columns and the rows of the multilayer warp (6) with the corresponding v~~efts (12c and 12r) is achieved. Such an alternate row-wise and columnwise shedding and corresponding picking thus leads to the production of the plain weave woven 3D fabric of this method. The typical yarn paths at the edges and the surfaces of the fabric (9), and in the interiors of fabric (9) are respectively indicated in Figs. 6a and 6b. The simplest working of this dual-directional shedding system ( 1 ) is outlined below in reference to Figs. 4 and 5.
1n Fig. 4 is illustrated the formation of the columnwise sh~s ( 10). Fig. 4(a) indicates the level position of the system. In Figs. 4 (b) and (c) are shown the directions of the linear movement of a heald shaft (2) along its axis. The former and the latter figures respectively show the displacement of the active warp ends (7), from their level positions, in the fabric-width direction to form the right side and the leR side coltunnwise sheds (10) with the stationary passive warp yams (8). Fig. 5 shows the formation of the row-wise sheds (11). Fig. 5(a) indicates the level position of the system. In Figs. 5 (b) and (c) are illustrated the directions of the angular movement of a heald shaft (2) about its axis. The former and the latter figures respectively show the displacement of the active warp ends (7), from their level positions.
in the fabric-thiclrness direction to form the upper and lower row-wise sheds (I l) with the stationary passive warp yarns (8).
As can be inferred from the Figs. 4 (b) and (c) and 5 (b) and (c), the optimum displacement of the shafts can be up to 1.~ times the shedding displacement pitch in practice to obtain relatively larger WO 98!39507 PCTISE97/00355 sheds for convenience in weft insertion. The shafts may be displaced up to the extent that an active warp yarn (?) does not cross two passive warp yarns (8).
It is to be noted that in reference to the stationary passive warp yarns (8), the right and the left side colummvse sheds, and the upper and the lower row-wise sheds are not formed simultaneously but in a specific order. The shedding shafts (2) revert to their level position every time subsequent to a particular shed formation and picking operation. For example, in the construction of the plain weave woven 3D fabric (9) obtainable tluough this method, and indicated in Fig. 6, the order of shedding and picking indicated below is followed, starting from the level position of the system. The movements of the shedding shafts described below are viewed from the rear of the shedding means in the direction of the fabric-fell.
1 ) Upward angular movement of the shedding shafts (2); fom~ation of the row-wise upper sheds ( 11);
followed by pick insertion in the formed sheds (i.e. in the fabric-width direction) 2) Reverting shedding shafts (2) to the !eve! position of the system 3) Righttvard linear movement of the shafts (2); formation of the columnwise right side sheds { 10);
followed by pick insertion in the formed sheds (i.e. in the fabric-thickness direction) 4) Reverting shafts (2) to the level position of the system 5) Dowward angular movement of the shafts {2); formation of the row-wise lower sheds (11);
followed by pick insertion in the formed sheds {i.e. in the fabric-width direction) 6) Reverting shafts (2) to the level position of the system 7) Leftward linear movement of the shafts (2); formation of the columnwise left side sheds(10);
followed by pick insertion in~the formed sheds (i.e. in the fabric-thickness direction) 8) Reverting shafts (2) to the level position of the system ' The above indicated shedding order, together with the necessary complementing operations of the weaving process like picking, beating-up, taking-up etc. at appropriate moments constitute one complete «rorking cycle of the process. Fig. 7 shows the front view of the plain weave woven 3D fabric construction (9) obtainable through the above stated shedding order. It is to be noted that the two sets of weft ( 12c and 12r), which may be inserted in their respective sheds by employing means like shuttles. rapiers etc. and may be picked in as either a single yarn or hairpin-like folded yam, uniquely interlace with the active warp yams (?) and get connected to the passive warp yarns (8). Because of their interlacement with the active warp yarns (?) the two sets of weft ( 12c and 12r) will occur in an undulating manner and not straight as indicated in Figs. 6 and ?. These two sets of weft (12c and 12r) are shown straight for only easy representation. However, the incidence of its crimp can be reduced, for example, by feeding the active warp yarns (?) under suitable tension and at a suitable rate.1n Figs. 8a and 8b are shown the top and the side views respectively of the fabric (9) to indicate the typical paths of the active warp yarns (?) at the fabric's edges and surfaces. The series of letters A-B-C-D, P-Q-R-S
etc. respectively indicate the individual active warp yam (?) paths at the edges and surfaces of the fabric construction shown in Figs. 6a and 7. 1n Figs. 9a and 9b are shown the top and the side views respectively of the fabric (9) to indicate the typical path of the active warp yam (?) in the interior of the fabric construction shown in Fig. 6b. The series of numbers 111-112-113-114 indicates the individual active warp yarn (?) path in the interior of the fabric construction shown in Figs. 6b and 7.
An important feature of the fabric construction (9) to be noted in Figs. 6, 7, 8 and 9 is the occurrence of the active warp yams in a 'helical' configuration. Though not following a circular path, the active warp yarns occur in a 'triangular helix' at the fabric's edges and surfaces (indicated by different series of letters, A-B-C-D, P-Q-R S etc. in Fig. 7) and in a 'square helix' in the interiors (indicated by differcnt series of numbers, 101-102-103-104, 131-132-133-134 etc. in Fig. 7). Further, both these helices are not fom~ed about any of the passive warp yams. Also, the fabric has a network-like construction.
There may be introduced minor alterations in the above fiarrrework of operations. For example, the above indicated order of shedding operations may be altered to produce a modified network-like fabric construction (9m) shown in Fig. 10. In reference to the shedding order indicated above. if the order given below is carried out, then modified network-like fabric constructions (9m) may be obtained and will correspond with those indicated in Fig. 10 in which the general path of the active warp yam in the interior of the fabric is only shown and corresponds as follows:
a) Shedding order: 1, 2, 5, 6, 3, 4, 7, 8 and repeat b) Shedding order: 1, 2, 5, 6, 7, 8, 3, 4 and repeat c) Shedding order: 1, 2, 5, 6, 3, 4, 7, 8, 1, 2, 5, 6. 7, 8, 3, 4 and repeat.
These obtained modified network-like fabric constructions (9m) shown in Fig.
10 will differ from the one indicated in Figs. 6, 7, 8 and 9 in which the typical paths of the active warp yarns (7) in accordance with the initially mentioned shedding order are indicatcd. The difference in the fabric construction (9m) due to the change of the shedding order will be that the wefts of a given set will occur successively and not aitemately as shown in the figures, and also the active warp yarns (7) will additionally occur in the fabric-width and -thiclrness directions in addition to the diagonal directions as represented in Fig. 10.
This is because the wefts ( 12c and 12r) will be picked successively in the 'forward and backward' directions of the respective side (row-wise or columnwise direction).
Nevertheless, the active warp yams (7) in all these constructions (9) and (9m) may be considered to occur in a helical configuration for the purpose of easy understanding.
Fmm the foregoing description of the dual-directional shedding method, the following points will be apparent to those skilled in the art.
a) All the columnwise (or the row-wise) sheds can be formed simultaneously for increased production efficiency and not successively one columnwise (or row-wise) warp layer after the other.
b) Multiple wefts of a set may be picked simultaneously employing means like shuttles, rapiers etc. and each of the wefts may be inserted as either a single yarn or a hairpin-like folded yarn.
c) The active warp yarns (7) may be made to occur in the fabric-length direction either in ahelical configuration or additnnally in the fabric-width and - thickness directions by corrtrollinghe shedding order.
d) The helical progression of all the active warp yams (7) provides unique network-like fabric integration throughout the fabric by interlacing with the two sets of weft and interconnecting these t<vo sets of weft to the passive warp yams.
e) The helical progression of the active warp yams (7) provides unique discrete placement of the active warp yams (7) in either the 'diagonal' directions or additionally in the fabric-width and -thiclmess directions.
f) The optimum shedding displacement pitch of the shedding shaft (2) in the fabric-thicirness and the -width dituctions is 1.~ since a greater displacement will cause interference with the pick insertion and unnecessary concentration of the active warp yams (7) at the fabric's surfaces and thus lead to uneven fabric surface and unbalanced fabric construction.
g) Dii~erent v~ave patterns can be created by displacing independently and selectively in the fabric width and thicaaiess directions the required shafts {2) which bear the healds (3) which are suitably h) It is possible to carry out shedding involving only the active warp ends (7) by displacing independently pairs of the shafts (2) in opposite directions, and the healds (3) of which are suitably threaded.
i) Tubular fabrics of either square or rectangle cxoss-section and solid profiled fabrics like L, T, C etc.
can be directly produced by disposing the multilayer warp in accordance with the cross-sectional profile to be produced and suitably effecting the shedding and the picking operations in a suitable discrete manner. for example by employing more than one set of picking means in each of the two directions.
It will now be apparent to those skilled in the art that the mechanical performance of the fabric can be improved. if required, by the inclusion of non-interlacing 'stuffer' yams in the fabric-width. -thickness and the two diagonal directions across the fabric cross-section. An example of one such construction is outlined below.
In reference to the shedding and picking order mentioned earlier, the insertion of non-interlacing yarns (nl-n8) may be included in the fabric according to the steps indicated below and illustrated in Fig. l l .
1 ) Upward angular movement of the shedding shafts: formation of the row-wise upper sheds: followed by pick insertion (12r) in the formed sheds 2) Reverting shedding shafts to the level position of the system 3) Insertion of the set of non-interlacing yarn (nl) between given two rows of the passive wasp yarns (8) 4) Insertion of the set of diagonal non-interlacing yarn (n2) between given two diagonally occurring layers of the passive warp yarns (8) 5) Right<vard linear movement of the shafts; formation of the right side columnwise sheds: followed by pick insertion ( 12c) in the formed sheds 6) Reverting shafts to the level position of the system 7) Insertion of the set of non-interlacing yam (n3) between given two columns of the passive warp yarns (8) 8) Insertion of the set of diagonal non-interlacing yam (n4) between given two diagonally occxuxing layers of the passive warp yarns (8) 9) Downward angular movement of the shafts: fom~ation of the lower row-wise sheds: follov~ed by pick insertion ( 12r) in the formed sheds 10) Reverting shafts to the level position of the system 11 ) Inserrion of the set of non-interfacing yarn (n5) between given two rows of the passive warp yarns(8) 12) Insertion of the set of diagonal non-interlacing yam (n6) between given two diagonally occurring layers of the passive warp yarns (8) 13) Leftward linear movement of the shafts: formation of the left sidecolumnwise sheds: followed by pick insertion ( 12c) in the formed sheds 14) Reverting shafts to the level position of the system 15) Insertion of the set of non-interlacing yam (n7) between given two columns of the passive warp yarns (8) 16) Insertion of the set of diagonal non-interlacing yarn (n8) between given two diagonally occurring layers of the passive warp yarns (8) Further, this method is not limited to the producxion of a block of either fabric construction (9) or (9m) or (9n) having either a square or a rectangle cross-section. By disposing the multilayer warp in accordance with the desired shape of cross-section. including tubular types with square or rectangle cross-section, and following suitable discrete sequence of operations described above, network-like fabric constructions either (9) or (9m) or (9n) of the cotTesponding cross-sectional profile can also be produced. It may be mentioned here that depending on the complexity of the cross-sectional profile being produced, more than one set of weft inserting means for each of the two directions can be employed. Such different sets of the weft insetting means of a given direction (i.e. row-wise or colummvise) tray be operated either simultaneously or discretely to achieve the required weft insertion for the profile under production. This method of fabric production is therefore not limited to the production of a fabric of a particular cross-sectional profile. Further, because of the unique network-like interlacement, there is no need to carry out any separate binding operation at the exterior surfaces of the fabric to achieve the fabric integrity. This elimination of the binding process is apparently advantageous in simplifying and quickening the fabric production. Further.
this method of producing network-like interlaced 3D fabric blocks and other cross-sectional profiles eliminates to the need to develop methods for producing certain cross-sectional shapes as from the produced block of the network-like fabric obtainablc through this method, any desired shape of preform, filter etc. material can be easily cut obtained without the risk of its splitting up.
Further, it is possible to produce another useful fabric material by carrying out shedding involving only the warp yams occurring at the exteriors of the disposed multilayer warp (6) by suitably displacing the shafts (2), the healds (3) of which have been correspondingly threaded as described earlier. In reference to Fig. 12a, the top and the bottom woven surfaces can be produced by moving angularly the top and the bottom shafts (2), and hence displacing the healds (3), to displace the active warp yarns (7) to form .
row wise sheds with the passive warp yarns (8) and inserting the wefts ( 12r) into these exterior top and bottom row-wise sheds. Similarly, the left and the right side woven surfaces can be produced by moving linearly the shafts {2), and hence displacing the heaids (3), to displace the active warp yams (7) to form columnwise sheds with the passive warp yarns (8) and inserting wefts (12c) into these exterior left and right columnwise sheds. Thus such operations will produce an interlaced exterior surface which will function as a woven covering for the interrtally occurring non-interlacing multilayer yams (6n) of the fabric material (9e) as shown in Fig. 12a.
Further, it is also possible to produce a core or a sandwich type of fabric material (9s) shown in Fig:
12b by interlacing the suitably disposed multiiayer warp yarns. Here again. by displacing independently the heald shafts (2), the healds (3) of which have been correspondingly threaded, the row-wise and the columm~~ise sheds can be respectively formed by moving these shafts (2) angularly and linearly as described earlier. Inserting wefts ( 12r) and ( 12c) into the formed row-wise and columnwise sheds respectively, the interlaced fabric structure (9s), generally referred to as sandwich or core type fabric structure, shown in Fig. 12b is obtained.
Further, it is also possible to produce multiple woven 2D fabric sheets employing the described shedding means. Such multiple sheets can be produced by disposing the multilayer warp as described before and moving the shafts (2) either angularly or linearly to form correspondingly either the row-wise or the columnwise sheds and inserting correspondingly either wefts (12r) or (12c) into the formed sheds of the given direction. Thus, by forming row-wise sheds and effecting corresponding picking, the multiple sheets of woven 2D fabric will be produced in the horizontal form.
Similarly; by forming columnwise sheds and~effecting corresponding picking, the multiple sheets of woven 2D fabric will be produced in the vertical form in reference to the arrangement shown in Fig. 3.
Needless to mention, in all the above described methods of fabric production.
the other complementing operations of the weaving process like the beating-up, taking-up etc. will be canied out at the appropriate moments of the weaving cycle to produce a satisfactory fabric of the required specification.
It will be now apparent to those skilled in the art that it is possible to alter or modify the various details of this invention without departing from the spirit of the invention.
Therefore. the foregoing description is for the purpose of illustrating the basic idea of this invention and it does not limit the claims which are fisted below.
SUBSTITUTE SHEET (RULE 26)
Claims (31)
1. A network-like woven 3D fabric material characterised by the constitution of multilayer warp comprising yarns which occur in accordance with the cross-sectional profile of the fabric and two orthogonal sets of weft yarns such that first yarns of the multilayer warp occur substantially linearly, and second yarns of the multilayer warp occur in a helix-like configuration such that the second yarns occur in an interlacing manner with the two orthogonal sets of weft yarns and link the two sets of weft yarns to the first warp yarns in a manner that the second warp yarns do not occur in the helix-like configuration about any of the first warp yarns comprising the fabric material.
2. A woven fabric material, comprising:
at least one second yarn of a multilayer warp occur in a helix configuration by interlacing with two orthogonal sets of weft yarns in at least one portion of the fabric; and at least one first warp yarn arranged to directly interlace with at least one of said two orthogonal sets of weft yarns.
at least one second yarn of a multilayer warp occur in a helix configuration by interlacing with two orthogonal sets of weft yarns in at least one portion of the fabric; and at least one first warp yarn arranged to directly interlace with at least one of said two orthogonal sets of weft yarns.
3. The woven fabric material according to claim 1, wherein the helically configured second warp yarns occur in discrete disposal in the directions defined by at least one of a width and a thickness of the fabric in addition to the diagonal directions of the axial cross-section of the fabric.
4. The woven fabric material according to claim 1, wherein at least a portion of the fabric has one of the two orthogonal sets of weft yarns occurring successively in a direction defined by a length of the fabric.
5. The woven fabric material according to claim 1, wherein certain portions of the fabric are one of hollow containing no warp yarns and filled up with non-interlacing multilayer yarns.
6. The woven fabric material according to claim 5, wherein said certain portions of the fabric contain non-interlacing weft yarns of at least one of the two orthogonal weft yarn sets.
7. The woven material according to claim 1, wherein the first warp yarns that interlace with the two orthogonal sets of weft yarns occur in columns and rows configuration.
8. The woven fabric material according to claim 1, further comprising additionally non-interlacing yarns incorporated in the directions defined by one of a width and a thickness of the fabric and in at least one diagonal direction of the axial cross-section of the fabric.
9. A woven material according to claim 1, wherein the fabric is curved/bent in at least one part.
10. The woven fabric material according to claim 1, further comprising at least one fibrous material chosen from carbon fibers, synthetic fibers including elasto-resistive polymeric fibers, natural fibers including fibers from the sea, inorganic fibers, glass fiber and metallic fibers.
11. The woven fabric material according to claim 10, wherein the woven fabric material comprises at least one of the following fiber types: meltable, hollow/tubular, optical and cut-resistant.
12.The woven fabric material according to claim 1, wherein the woven fabric material comprises a combination of fibrous and non-fibrous material.
13.The woven fabric material according to claim 1, wherein at least one of the yarn materials is impregnated with a chemical formulation.
14.The woven fabric material according to claim 2, wherein the helically configured second warp yarns occur in discrete disposal in the directions defined by one of a width and a thickness of the fabric in addition to the diagonal directions of the axial cross-section of the fabric.
15.The woven fabric material according to claim 2, wherein at least a portion of the fabric has one of the two orthogonal sets of weft yarns occurring successively in a direction defined by a length of the fabric.
16.The woven fabric material according to claim 2, wherein certain portions of the fabric are one of hollow containing no warp yarns and filled up with non-interlacing multilayer yarns.
17.The woven fabric material according to claim 16, wherein said certain portions of the fabric contain non-interlacing weft yarns of at least one of the two orthogonal weft yarn sets.
18.The woven material according to claim 2, wherein the first warp yarns that interlace with the two orthogonal sets of weft yarns occur in columns and rows configuration.
19.The woven fabric material according to claim 2, further comprising additionally non-interlacing yarns incorporated in the directions defined by one of a width and a thickness of the fabric and at least one diagonal direction of the axial cross-section of the fabric.
20.A woven material according to claim 2, wherein the fabric is curved/bent in at least one part.
21. The woven fabric material according to claim 2, further comprising at least one fibrous material chosen from carbon fibers, synthetic fibers including elasto-resistive polymeric fibers, natural fibers including fibers from the sea, inorganic fibers, glass fiber and metallic fibers.
22.The woven fabric material according to claim 21, wherein the woven fabric material comprises at least one of the following fiber types: meltable, hollow/tubular, optical and cut-resistant.
23.The woven fabric material according to claim 2, wherein the woven fabric material comprises a combination of fibrous and non-fibrous material.
24.The woven fabric material according to claim 2, wherein at least one of the yarn materials is impregnated with a chemical formulation.
25.A device for producing woven fabric material with a weaving method incorporating the operation of shedding in two mutually perpendicular directions to form row-wise and column-wise sheds in a multilayer warp disposed according to a cross-sectional profile of the fabric to be produced, said device comprising shedding means, said shedding means including:
a) at least one shaft capable of being reciprocated linearly along its longitudinal axis and also angularly about its longitudinal axis, b) each of the shafts bearing a set of means along the shaft's length direction such that the length direction of each of these means is orientated perpendicular to the length direction of said shaft, c) said means intended for supporting warp strings threaded through its entry port and exit port in accordance with the cross-sectional profile of the fabric to be produced.
a) at least one shaft capable of being reciprocated linearly along its longitudinal axis and also angularly about its longitudinal axis, b) each of the shafts bearing a set of means along the shaft's length direction such that the length direction of each of these means is orientated perpendicular to the length direction of said shaft, c) said means intended for supporting warp strings threaded through its entry port and exit port in accordance with the cross-sectional profile of the fabric to be produced.
26. A device according to claim 25 wherein the shedding means is dual directional, said dual-directional shedding means comprises at least one set of shedding shaft assemblies arranged in one of the following manners:
a) with the longitudinal axis of the shafts occurring in at least one parallel plane, b) with the longitudinal axis of the shafts occurring in a perpendicular orientation to the axis of disposed strings of the multilayer warp, c) in a manner to provide space between given two shafts to draw strings of warp through, d) in a manner that each of the warp strings drawn through the space between given two shafts, occurs surrounded by the warp strings which are threaded through said means.
a) with the longitudinal axis of the shafts occurring in at least one parallel plane, b) with the longitudinal axis of the shafts occurring in a perpendicular orientation to the axis of disposed strings of the multilayer warp, c) in a manner to provide space between given two shafts to draw strings of warp through, d) in a manner that each of the warp strings drawn through the space between given two shafts, occurs surrounded by the warp strings which are threaded through said means.
27. A device according to claim 26, wherein the dual-directional shedding shaft assemblies are capable of being reciprocated at least one of linearly and angularly in one of the following manners:
a) collectively as a whole set;
b) in select groups;
c) individually; and d) a combination of b) and c).
a) collectively as a whole set;
b) in select groups;
c) individually; and d) a combination of b) and c).
28. A device according to any one of claims 26 and 27 wherein the dual-directional shedding shaft assemblies are capable of being reciprocated at least one of linearly and angularly in the following manners:
a) in the same direction at the same time;
b) in the opposite directions at the same time;
c) in a discrete manner.
a) in the same direction at the same time;
b) in the opposite directions at the same time;
c) in a discrete manner.
29. A device according to any one of claims 26 through 28 wherein the dual-directional shedding means are capable of being employed to produce a material in which warp yarns of the multiple layer warp are involved for interlacement with wefts and such an outer interlaced assembly serves to function as a woven covering for elements which occur internally.
30. A device according to any one of claims 26 through 28 wherein the dual-directional shedding means includes means for producing a material in which suitably disposed warp yarns of the multiple layer warp are involved for interlacement with wefts to result in one of a sandwich and a core structure.
31. A device according to any one of the claims 25 through 28 capable of being employed to produce multiple woven 2D fabric sheets simultaneously.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/SE1997/000355 WO1998039507A1 (en) | 1997-03-03 | 1997-03-03 | Network-like woven 3d fabric material |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2279408A1 CA2279408A1 (en) | 1998-09-11 |
| CA2279408C true CA2279408C (en) | 2006-08-15 |
Family
ID=20405644
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002279408A Expired - Fee Related CA2279408C (en) | 1997-03-03 | 1997-03-03 | Network-like woven 3d fabric material |
Country Status (4)
| Country | Link |
|---|---|
| AT (1) | ATE232565T1 (en) |
| CA (1) | CA2279408C (en) |
| DE (1) | DE69719093T2 (en) |
| HK (1) | HK1025137A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108701753A (en) * | 2015-12-25 | 2018-10-23 | 三井化学株式会社 | Piezoelectricity base material, piezoelectricity woven fabric, piezoelectricity knitted fabric, piezo-electric device, force snesor, actuator and Biont information acquisition device |
-
1997
- 1997-03-03 AT AT97919800T patent/ATE232565T1/en not_active IP Right Cessation
- 1997-03-03 DE DE69719093T patent/DE69719093T2/en not_active Expired - Lifetime
- 1997-03-03 CA CA002279408A patent/CA2279408C/en not_active Expired - Fee Related
-
2000
- 2000-07-19 HK HK00104404A patent/HK1025137A1/en not_active IP Right Cessation
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108701753A (en) * | 2015-12-25 | 2018-10-23 | 三井化学株式会社 | Piezoelectricity base material, piezoelectricity woven fabric, piezoelectricity knitted fabric, piezo-electric device, force snesor, actuator and Biont information acquisition device |
| CN108701753B (en) * | 2015-12-25 | 2023-06-27 | 三井化学株式会社 | Piezoelectric substrate, piezoelectric woven fabric, piezoelectric knitted fabric, and piezoelectric device |
Also Published As
| Publication number | Publication date |
|---|---|
| DE69719093D1 (en) | 2003-03-20 |
| ATE232565T1 (en) | 2003-02-15 |
| CA2279408A1 (en) | 1998-09-11 |
| DE69719093T2 (en) | 2003-11-20 |
| HK1025137A1 (en) | 2000-11-03 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| EP1015677B1 (en) | Network-like woven 3d fabric material | |
| CA2279848C (en) | Woven 3d fabric material | |
| US6315007B1 (en) | High speed three-dimensional weaving method and machine | |
| US6431222B1 (en) | Network-like woven 3D fabric material | |
| Unal | 3D woven fabrics | |
| EP2038459B1 (en) | 3d fabric and preparing thereof | |
| US7836917B1 (en) | Weaving connectors for three dimensional textile products | |
| US4922969A (en) | Multi-layer woven fabric having varying material composition through its thickness | |
| Chiu et al. | Weaving method of 3D woven preforms for advanced composite materials | |
| CN101529003B (en) | Three-dimensional surface weave | |
| US5127444A (en) | Method and apparatus for leno weaving a three dimensional fabric | |
| EP1398403B1 (en) | Method for weaving a pile fabric | |
| CA2279408C (en) | Network-like woven 3d fabric material | |
| KR102197616B1 (en) | 3D profiled beam preforms in which the thickness direction fibers are continuously reinforced and a method for manufacturing the same | |
| CN1079123C (en) | Woven 3D fabric material | |
| KR20000075914A (en) | Network-like woven 3d fabric material | |
| Sennewald et al. | Woven semi-finished products and weaving techniques | |
| CN115161852B (en) | Preparation method of three-dimensional woven spacer fabric for reinforcing weft yarn binding | |
| JPH02191742A (en) | Three-dimensional cloth and production thereof | |
| US5400832A (en) | Method for manufacture of extra-broad woven fabrics | |
| CN117188015A (en) | Integral forming knitting method for multiple 2.5D layer-connected fabrics with interval intersecting three-dimensional fabrics | |
| JPH02191743A (en) | Production of three-dimensional cloth | |
| WO2015044956A1 (en) | Rotating disk shedding system for producing a woven 3d multilayer orthogonal interlaced fabric and its corresponding method | |
| JPH0411044A (en) | Three-dimensional woven fabric and weaving of the same woven fabric | |
| Kolte et al. | 3D FABRIC |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |