DE69736005T2 - FAST METHOD FOR PRODUCING A SUBSTANCE - Google Patents

Description

AREA OF INVENTION

The Invention teaches a method and apparatus for fast Forms a flat or shaped textile and that by molded fabric, which consists of yarn groups that narrow a surface cover.

STATE OF TECHNOLOGY

Textiles Tissue becomes common by weaving or knitting or the like of strands or threads of yarn formed to the strands together. Method of weaving and knitting, in which strands above and under adjacent strands guided be, are slow and allow not big Diversity in fabricating fabric shapes. In a loom to Weaving fabrics adds the weft yarns one at a time. These Lead procedure typically to flat or cylindrical fabrics. It There is a need for a method that, in addition to producing flat or cylindrical textile products, more diversity in manufacturing of textile products with, for example, three-dimensional random forms allows the manufacture of a clothing article, such as of a shirt would without pieces of tissue cut and sew them together to have to. Tailoring tissue wastes in irregularly shaped patterns a lot of fabric, add to that Cropping and sewing over the immediate steps of the textile article. The same There is a problem with creating flexible designed shapes, such as For example, automobile airbags, sailboat sails, industrial filter bags or similar. In these cases brings the need for seams for making three-dimensional shapes problems with the structural Strength and / or permeability, So that the Seams carefully made Need to become.

It There is a need for a way to quickly form a flexible one Fabric of yarn strands; There is a need for a way to quickly create a three-dimensional, flexible textile article, without a flat textile product to cut and sew.

It is also a problem in making complex shapes for composite structures, with a curable Resin impregnated can be. It is sometimes desired The strings before adding the resin or during resin addition in one set down three-dimensional shape. Current resources for this include complex ones Molds with retractable proppants a, to the threads to hold in place before the resin cures. There is a need in a simpler way for preforming these textile forms without Seams. Such seams would affect the strength of the composite structure.

A series of patents by Oswald ( US 4600456 . US 4830781 and US 4838966 ) deposits a pattern of partially vulcanized rubber-coated strips or cords to form a loop of a preformed reinforcing belt for a vehicle tire. The strips or cords are adhered to each other wherever they touch each other to form a relatively rigid structure. The cords are laid in a "repeating zigzag pattern, with successive lengths of the strips being offset from each other. The cord lengths are interleaved with cord lengths arranged at an opposite angle ... This nesting relationship results in a woven structure. "The tack of the partially vulcanized rubber apparently holds the cords in place on a forming surface and together until the belt with others Assembled elements of the tire and molded under heat and pressure to form a finished tire.

The method practiced by Oswald et al. Uses a cord or a few cords which are crossed back and forth across the belt numerous times to complete a circumference. It is believed that this results in a multi-layered structure in which the cords in any given layer are thin but do not completely cover the belt surface. Only after repeated zigzagging over the belt surface, the surface is covered thinly with cord. Due to the repeated zigzagging of only a few cords, it is assumed that there are cords laid down in any position in two different directions that do not cross each other. Cords that cross each other would be in different positions. These structural features of the reinforcing belts are symptomatic of a process that only deposits a few cords at a time and must make repeated passes over the belt surface to provide coverage of the surface. There is a need for a simple non-weaving process that can produce textile structures by simultaneously laying down many yarns over a fabric area to quickly thin-coat them and stack a plurality of such thin yarn covers to cover the area tightly.

US 4325999 discloses methods for making biased fabrics in which a plurality or pluralities of yarns are alternately reciprocated between an opposing pair of movable conveyors provided with means for securing the yarns thereto. The means for attaching the yarns to the conveyors may include elongate, upstanding members such as pins, or in the alternative may comprise annular members which have the pins mounted thereon and which may be moved in different groups, or slotted guides adapted for Transfer coupled with a moving Garnlegeeinheit and can be attached to the conveyor to attach the yarns to the same.

SUMMARY THE INVENTION

The invention relates to a textile product and a method for producing the product. Included in the invention are the following embodiments:
A woven fabric structure comprising:
a plurality of first yarn subgroups having a plurality of yarns oriented in a first angular direction free from crossings, the first yarn subgroups forming a stack having a plurality of second yarn subgroups having a plurality of yarns oriented in a second angular direction devoid of crossings,
the yarn in each subgroup being followed by substantially parallel webs spaced in a repeating pattern with each other so as to thinly cover a common predetermined fabric area, the yarn subgroups being stacked alternately with a first subgroup adjacent a second subgroup the yarns in the first subgroup cross the yarns in the second subgroup,
wherein the yarns in any subset of the plurality of first subgroups are offset from the yarns in all other subgroups of the first plurality of subgroups,
wherein the yarns in any subset of the plurality of second subgroups are offset from the yarns in all other subgroups of the second plurality of subgroups,
wherein stacking all of the plurality of first subgroups forms a first group of yarns containing yarns which tightly cover the predetermined fabric area, and stacking all of the plurality of second subgroups forms a second group of yarns containing yarns sealing the predetermined fabric area cover, and
wherein the yarns in the top subgroup in the stack are joined to the yarns in the bottom subgroup in the stack to thereby contain the other subgroups in the stack in a woven fabric structure.

Preferably there are separate unconnected areas of the links, and the inherent flexibility of the yarns in the structure is maintained in the unconnected areas.

Preferably the connections exist between the top subgroup of the Structure and the lowest subgroup of the structure either directly or by the yarns in other subgroups such that a compound between crossing points of yarn groups at 0.3% to 80% of yarn Male occurs in which the yarns intersect.

Preferably the yarns are handled in a subgroup of a group, to become the yarns in a subgroup of another group and to cross them by it.

Preferably becomes a foil or a nonwoven web between two adjacent ones Subgroups arranged within the structure.

Also claimed herein is a method of making a woven fabric structure comprising:
Laying down a first yarn subgroup having a plurality of yarns oriented free of crossovers in a first angular direction, the yarns in the first subgroup following substantially parallel webs spaced in a repeating pattern with respect to each other to form a common one thinly cover specified fabric area,
Stacking a second yarn subgroup adjacent to the first yarn subgroup, the second yarn subgroup having a plurality of yarns oriented in a second angular direction free of crossings, wherein the yarns in the second subgroup follow substantially parallel webs spaced in a repeating pattern with each other so as to thinly cover a common predetermined fabric area,
Continuing the alternating stacking of a plurality of first yarn subgroups and a plurality of second yarn subgroups, comprising the following substeps:
Offsetting the plurality of yarns in any subset of the plurality of first subgroups from the yarns in all other subgroups of the first plurality of subgroups and depositing all of the yarns in one of the first plurality of subgroups prior to depositing the yarns in another subgroup,
Offsetting the plurality of yarns in any subgroup of the plurality of second subgroups from the yarns in all other subgroups of the second plurality of subgroups and depositing all the yarns in one of the second plurality of subgroups before laying down the yarns in another subgroup,
Halting stacking when all of the plurality of first subgroups form a first yarn group containing yarns that tightly cover the predetermined fabric area and when stacking all of the plurality of second subgroups form a second yarn group including yarns containing the previous yarn groups tightly cover specified fabric area, and
Joining the yarns in the top subgroup in the stack with the yarns in the bottom subgroup in the stack to thereby contain the other subgroups in the stack and form a woven fabric structure.

The The method may further comprise: pressing the stacked subset each group, so they nested into a solidified structure, with the Yarns in a group over bend the yarns in the adjacent groups.

Preferably comprises the bonding step involves bonding the subgroups to each other with gap arranged areas and providing the bonded Areas of separate unbonded areas, with the inherent flexibility of the yarns is maintained in the unbonded areas.

The Connecting the outermost ones Subgroups may also include strands from the innermost subgroups connect to. The connecting means may consist of yarn loops, adhesive stains, Bonded joints (such as those made by squeezing the outermost Groups and apply ultrasonic energy to the depressed yarns made), brackets and clamps are made.

Preferably, the woven fabric structure is a three-dimensional molded product, with the yarns in the sub-groups not necessarily being generally parallel but regularly spaced to follow the contours of the mold. The three-dimensional shaped woven fabric structure includes:
a stack of a first plurality of subgroups, a second plurality of subgroups, and a third plurality of subgroups, each subgroup having yarns spaced apart to define a thin coverage of a fabric area, the yarns are generally parallel, and the yarns follow a curved path in space,
wherein the stacked subgroups are arranged in a predetermined grouping with respect to a common axis and a common reference plane perpendicular to the axis,
wherein the first subgroups are disposed at a first angle in relation to the reference plane and positioned at a first rotational angle about the axis, the second subgroups are disposed at a second angle in relation to the reference plane and positioned at a second rotational angle about the axis third subgroups disposed at a third angle in relation to the reference plane and positioned at a third rotational angle about the axis, wherein the yarns in any one of the first, second and third subgroups, the yarns in another of the first, the second and the crossing third subgroups to thereby form a group of yarns for each of the respective subgroups, the group covering a fabric area densely for any respective subgroup,
wherein the top subgroup in the stack is connected to the bottom subgroup in the stack to thereby form a three dimensional, shaped, woven fabric structure.

• (a) eine Endlos-Fördereinrichtung mit einer fahrbaren Auflagefläche zum Tragen der gerade geformten Textilerzeugnisstruktur, wobei die Fläche gegenüberliegende Kanten parallel zur Bewegungsrichtung und Halter längs jeder Kante hat, um das Garn zeitweilig zu halten, um einer seitlichen Bewegung des Garns zu widerstehen, wobei die Fördereinrichtung einen regelbaren Motor zum Vortrieb der fahrbaren Auflage hat,
• (b) eine Vielzahl von Führungsstangen, geeignet für eine Bewegung über die Fläche von Kante zu Kante, wobei jede Stange eine Vielzahl von Führungen zum wiederholten Führen von Garnen von den Haltern längs der einen Kante zu den Haltern längs der gegenüberliegenden Kante und zurück zu der einen Kante enthält, wobei die Führungsstangen ein regelbares Stellglied zum Vortrieb der Stangen hin und her über die Auflagefläche haben,
• (c) eine Vielzahl von Bondeinrichtungen, die über der Auflagefläche zwischen den Auflageflächenkanten und über die letzte Führungsstange hinaus in der Bewegungsrichtung der Fläche angeordnet sind, wobei die Bondeinrichtungen geeignet sind, ein Garn an ein anderes Garn zu bonden, wo sie sich kreuzen,
• (d) ein Steuergerät zum Koordinieren des regelbaren Motors und der Stellglieder, um ununterbrochen eine Textilerzeugnisstruktur auf der Auflagefläche der Fördereinrichtung herzustellen.

A fabric-making apparatus suitable for producing a fabric structure of a plurality of yarns comprises:

• (a) an endless conveyor having a moveable support surface for supporting the fabric structure being formed, the surface having opposite edges parallel to the direction of movement and holders along each edge to temporarily hold the yarn to permit lateral movement of the yarn resist, wherein the conveyor has a controllable motor for propulsion of the mobile support,
• (b) a plurality of guide rods adapted for movement across the surface from edge to edge, each rod having a plurality of guides for repeatedly guiding yarns from the holders along the one edge to the holders along the opposite edge and back to the one includes an edge, wherein the guide rods have a controllable actuator for propelling the rods back and forth over the support surface,
• (c) a plurality of bonding devices disposed over the bearing surface between the bearing surface edges and beyond the last guide rod in the direction of movement of the surface, wherein the bonding devices are adapted to bond a yarn to another yarn where they intersect,
• (d) a controller for coordinating the controllable motor and the actuators to continuously produce a fabric structure on the support surface of the conveyor.

• (a) ein mechanisches Führungsbetätigungsmittel,
• (b) eine Garnführung, die einen Rahmen umfaßt, der eine hohle Welle umfaßt, durch die Garn hindurchgehen kann,
• (c) einen Schieber, der an der Garnführung befestigt ist und ebenfalls an dem Führungsbetätigungsmittel befestigt ist,
• (d) einen an der hohlen Welle angebrachten Block, der eine Vielzahl von flexiblen Federn trägt, die sich an einem gemeinsamen Punkt überschneiden,
• (e) an dem Überschneidungspunkt der Federn befindet sich eine hohle Spitze mit einem halbkugelförmigen Ende, durch welches das Garn hindurchgehen kann, wobei die Federn eine Bewegung der Spitze in einer Axial- oder Winkelrichtung ermöglichen, wobei die Drehung der Welle ermöglicht, daß die Spitze über eine beliebige Fläche rollt, die sie berührt, während sie sich ebenfalls frei in Axial- und in Winkelrichtung biegen kann, um so ein Garn genau auf der Fläche anzuordnen, während das Garn durch ein Loch in der hohlen Welle und ein Loch in der hohlen Spitze hindurchgeht.

Another yarn dispensing apparatus suitable for accurately laying yarn on a composite curvature when using a mechanical actuator comprises the following elements:

• (a) a mechanical guide actuator,
• (b) a yarn guide comprising a frame comprising a hollow shaft through which yarn can pass,
• (c) a slider attached to the yarn guide and also attached to the guide actuating means,
• (d) a block attached to the hollow shaft carrying a plurality of flexible springs which overlap at a common point,
• (e) at the point of intersection of the springs there is a hollow point with a hemispherical end through which the yarn can pass, the springs allowing movement of the point in an axial or angular direction, rotation of the shaft enabling the point it rolls over any surface that touches it, while also freely bending in the axial and angular directions so as to place a yarn exactly on the surface while the yarn passes through a hole in the hollow shaft and a hole in the hollow Lace goes through.

SHORT DESCRIPTION THE PICTURES

1A to E show plan views of yarn lay progression to produce a basic flexible two-group (bidirectional or biaxial) fabric from a plurality of multi-yarn subgroups.

2A to E show plan views and side views of the yarn subgroups of base cells of the fabric.

3A to C show plan and elevational views of variations of the yarn arrangement in a cell.

4A to D show plan views of additional biaxial fabric structures.

5A to B show two different top views of a three-layer (three-directional or triaxial) fabric.

6 shows an apparatus for continuously producing a two-dimensional biaxial garment fabric, wherein the yarns are oriented at an acute angle to the machine direction, and a fabric thus produced.

7 is an enlarged view of a portion of the fabric of 6 ,

8A to B show another apparatus for continuously producing a two-dimensional biaxial garment fabric similar to that of FIG 7 ,

9 is an enlarged view of a portion of a through the device of 8th fabric produced.

10A to B show a table apparatus for producing a single batch of a two-dimensional or three-dimensional fabric structure and a sample of a piece of a three-dimensional biaxial fabric structure.

11A shows a spike device for making a single batch of a two-dimensional or three-dimensional fabric structure.

11B shows a mandrel device for making a tubular batch of fabric structure.

11C shows a flattened view of one on the device of 11B fabricated tubular fabric structure.

11D shows a special device for a Niederlegearm.

12 Figure 11 shows another mandrel apparatus for making a single batch of a three-dimensional fabric structure.

13 Figure 11 shows another apparatus for continuously producing a two-dimensional biaxial fabric structure with the yarns oriented at 0 degrees and 90 degrees to the machine direction.

14 shows a schematic view of a fabric cell.

15 shows a generalized yarn dispensing system for a molded mandrel.

16A to 16D show the general orientation of a single subgroup of a single group on the form of 15 ,

17A to 17D show the alignment of a single subgroup of three groups to the shape of 15 ,

18A to 18E show the alignment of successive subgroups of each group that are laid down to take the form of 15 to densely cover and form the molded fabric.

19A to 19E show a system for making a shirt fabric.

20 shows a particular device for laying down yarn on thorns with compound curvatures.

DETAILED DESCRIPTION

1A to E show a simplified basic structure and method for producing a bi-directional or biaxial garment fabric 22 ( 1E ) of the invention on a flat surface 23 , in 1A become two yarns 30 and 32 in a first direction, such as a ninety degree direction 34 , laid down. The yarns 30 and 32 are with a cell gap or gap 33 which may be about 3 to 20 yarn diameters (preferably 4 to 16 and most preferably 4 to 8); Here it is shown that four diameters ensure 4 positions for yarns to be laid with clearance or offset to the other yarns in that direction. In 1B become two yarns 36 and 38 in a second direction, such as a zero-degree direction 40 , and laid down on top of the first yarns. The yarns 36 and 38 are also with a cell spacing or gap 42 removed, which is the same size as the cell spacing for these yarns having the same width 33 , For yarns with different widths or for special effects, the cell spacings 33 and 42 be different. In 1C become two yarns 44 and 46 with the gap 33 and in the direction 34 arranged and become adjacent to the yarns 30 respectively. 32 and on top of the yarns 36 and 38 placed. After that, two yarns 48 and 50 with the gap 42 and in the direction 40 arranged and become adjacent to the yarns 36 respectively. 38 and on top of the yarns 44 and 46 placed. In 1D become two yarns 52 and 54 with the gap 33 and in the direction 34 arranged and become adjacent to the yarns 44 respectively. 46 and on top of the yarns 48 and 50 placed. After that, two yarns 56 and 58 with the gap 42 and in the direction 40 arranged and become adjacent to the yarns 48 respectively. 50 and on top of the yarns 52 and 54 placed. In 1E become two yarns 60 and 62 with the gap 33 and in the direction 34 arranged and become adjacent to the yarns 52 respectively. 54 and on top of the yarns 56 and 58 placed. After that, two yarns 64 and 66 with the gap 42 and in the direction 40 arranged and become adjacent to the yarns 56 respectively. 58 and on top of the yarns 60 and 62 placed.

This accomplishes yarn laying, and a basic flat textile structure 22 has been created from a variety of yarns, which are now held in place only by friction and gravity. It remains to fix the yarns in place. This is done in the easiest way by attaching the top yarns 64 and 66 at the bottom yarns 30 and 32 where they are at points 68 . 70 . 72 and 74 cross, done. This now holds all the yarns together in the structure so that they can not be removed in the way they were assembled.

In the 1E Structure shown is also in 2A shown slightly expanded and the ends of the yarns extended for the purpose of further discussion. The structure, as in 2A illustrated, has a characteristic structure or cell 61 that would be repeated in a large area of the fabric; it is shown outlined by semi-bold dashed lines. There is a crossing point in each cell of this structure between the topmost yarns and the bottommost yarns, such as the dot 68 in the cell 61 , where the top yarn 66 a bottom yarn 32 crosses.

2 B shows a side elevation 2B-2B of the fabric 22 in 2A in which the yarns are shown as rigid elements. It will be appreciated that since the yarns are flexible, they will bend over and under each other in the structure and collapse to about two times four yarn thicknesses so that it will be difficult to pull unbonded yarns out of the structure. This up and down of a yarn in a structure is referred to as weaving in the field of textile products. The more interweaving, the more stable the fabric, and the yarns tend to stay in place without shifting and opening holes in the fabric. That is, the fabric has good integrity. This is a desirable feature to maintain the covering ability of the fabric over a surface. An illustration of a completely collapsed structure appears in 2C pictured where the individual yarns in each subgroup 1 through 8 are identified. The completely collapsed thickness at 57 is about the thickness of a single yarn of a group in one direction, 34 stacked on top of a single yarn of the other group in the other direction, 40 , This fully consolidated thickness is about two yarn diameters thick, which can be achieved by compressing the yarns with an increased level of bonding. By regulating the bonding to a minimum, as in 2A As shown, the fabric structure can be much bulkier and have a thickness 59 reach from 3 to 4 yarn diameters. This is 1½ to 2 times more voluminous than if the same yarn were used in a woven structure. Alternatively, in the structure of the invention, a less expensive, less bulky yarn with less texture and / or crimp could be used to achieve the same bulky fabric as a woven structure using a more expensive, high bulk yarn. This is a unique advantage of the fabric of the invention.

It is useful to develop some specific definitions by referring to 1E . 2A and 2 B to discuss the general features of the invention:
Yarn - a predominantly one-dimensional, elongated, flexible textile element of substantially continuous length, such as a strand, a fiber, a filament, a wire, a rope, a strip, a ribbon, a rope, a thread, a hose, a string or of the like consisting of one or more sub-elements, which may be of continuous length (such as a continuous multifilament yarn) or of interrupted length (such as a staple yarn).

Cell - A cell is the smallest section of a fabric in which the yarn pattern seems to repeat itself over most of the fabric structure and where, for convenience, the top yarn, such as the yarn 66 along one side of the cell and the next upper yarn, such as the yarn 60 , lies along the other side of the cell (other repeating units of the cell could be selected, if desired). In 2A becomes a complete cell as a cell 61 shown. In some structures, the edges of the fabric may only have sub-cells, or there may be several cells in a fabric with slightly different yarn lay-up patterns that will repeat in the fabric. For some fabrics, there may be very variable or very large cell repeats, and it may not be useful to label a cell; the entire fabric can be referred to as a cell.

Yarn Group - A yarn group includes all yarns in a fabric or cell in a given direction, such as a zero degree direction or a ninety degree direction. In 2A For example, the zero-degree yarn group for all cells is indicated by the Roman numeral I, and the ninety-degree yarn group for all cells is indicated by the Roman numeral II. The yarns in a group form a dense yarn covering over a surface, and the yarns in a group follow substantially parallel tracks, which may include curved tracks or loop paths in which a given yarn may intersect itself. To achieve the densest coverage, the yarns would all be non-overlapping and preferably parallel; this is not necessary for less dense coverage.

Cell Space - The cell space is the length of the side of a cell that determines the space available for a number of non-overlapping, overlap-free yarns in a group. For simple repeating cells, this dimension defines the yarn spacing between thinly spaced yarns in a subset (see below). For group II the cell space is added 33 shown; for group I the cell space is added 42 shown. Within the in 1A . 1B and 2A shown cell space 33 or 42 There are four positions for the yarns in this group that are offset from each other. For the in 2A The cell shown identified using the developed conventions is the cell space 33 between the upper yarns 64 and 66 to see.

Yarn Subgroup - A subgroup is a variety of yarns that make up a thin subdivision of a group. The yarns in a group are stacked in subgroups with yarns of other groups. In 2A . 2 B and 2C the total number of eight subgroups for a complete cell is denoted by 1 to 8, all yarns in a subgroup being given the same number; Subgroups 1, 3, 5, 7 make group I for the cell 61 and subgroups 2, 4, 6, 8 make group II for the cell 61 out. Each subgroup by itself is a thin covering of yarns over the fabric area. For example, the yarns labeled 1 constitute subgroup I, and they are spaced at the cell space 33 arranged. The yarns designated 1 comprise the lowest subgroup of group I and also the cell, and they are stacked against the yarns designated 2 in the lowest subgroup of group II in the cell. The yarns in the different subgroups in Group I are non-overlapping, that is, they are not superposed on each other in the plan view, although in special cases involving yarn loops, a single yarn, as in FIG 2E , can cross themselves and other subgroup yarns.

Yarn Position - The yarn position in a given group refers to the location in a cell where a yarn is positioned in the same group relative to a preselected reference yarn. Within the path of a cell space, there are a finite number of yarn positions available to the yarns in the subgroup of a group that are parallel and offset from one another. In a preferred convention, an X-axis is placed over an uppermost yarn in the cell, and a Y-axis is laid through an origin which is defined by the intersection of the uppermost yarn and a yarn in the next subgroup crossing the uppermost yarn. is defined. By convention, the cell would be defined as the repeating unit of a yarn structure having an edge adjacent to the X axis and the XY origin in the lower left corner of the cell. The yarn position for a subgroup may then be defined as the fraction of the total number of possible yarn positions spaced from the reference yarn, with the reference yarn in the zeroth position. If the webs of the yarns, unlike the examples of 1A to E and 2A In the case of a sine or zigzag path, the X-axis would align with the predominant non-straight path, which may be the symmetry axis of the yarn path. In the cell 61 from 2A becomes the top yarn 66 is selected as the reference yarn in subgroup 8 of group II and coincides with an X axis 71 together. The yarn 60 in the next subgroup 7 of the cell 61 crosses the reference yarn 66 in the subgroup 8th , Where is the reference yarn 66 crosses, it defines an origin 75 through which a Y-axis 77 passes. The subgroup positions of the Group I yarns within the cell 61 are denoted by 0/4, 1/4, 2/4, 3/4, with subgroup 8 represented by the uppermost yarn 66 is in the 0/4 position and the character is determined by the direction of the Y coordinate where the yarn crosses the Y axis. The subgroup positions of the Group II yarns within the cell 61 are denoted by 0/4, 1/4, 2/4, 3/4, with subgroup 7 represented by the next yarn 60 is in position 0/4 and the character is determined by the direction of the X coordinate where the yarn crosses the X axis. With reference to 2A and 2 B the yarns in the cell shown are in subgroup 1 of group II, such as the yarn 32 , in the position 1/4, which is the position +1 of 4 possible positions. With reference to 2A and 2D the yarns in the cell shown are in subgroup 6 of group I, such as the yarn 56 , in position 3/4, which is the position +3 of 4 possible positions.

A matrix can be generated to describe the arrangement of the yarns in a cell of a structure. For example, for the two groups of yarns, 0 and 90, the matrix would be for the in 2A . 2 B and 2C illustrated textile look like this:

In 1E Four yarns are used to clear the gap 33 to fill; yarn 30 . 44 . 52 and 60 , From a practical point of view, the size of each space determines 33 and 40 the length of unattached yarn at the top and bottom surfaces of the fabric structure, such as length 76 in the top zero grade yarn 64 and the length 78 in the lowest ninety degree yarn 30 in 1E , As this gap increases as more subgroups of yarns are added to the structure, the unattached yarn length grows and may present a problem hidden in the finished fabric structure. On the other hand, for some applications, it may be desirable to have such an unattached yarn on the surface of the fabric. In satin weaves made by conventional weaving techniques, there are many long segments of unsecured yarn on the surface of such fabric to create a particular style and feel. However, if it is desired to minimize the length of unfortified yarn on the surface of the fabric, four to eight yarn diameters is the preferred determinant for the interstice 33 and 40 and the number of subgroups. Sixteen to twenty yarn diameters are likely to be a maximum cell space from a practical point of view. If a thicker structure is acceptable or desired, two complete fabric structures can be assembled together and then the outer subgroups joined to increase the number of subgroups without increasing the unattached yarn length at the fabric surface.

Various patterns are available for laying down the yarn subgroups. All the yarns in a subgroup are in place before the subsequent subgroup is put in place, which identifies the yarns in a subgroup. 2A shows the basic module of in 1E shown fabric structure, wherein the sequence of subgroup arrangement in each ninety-degree group, going from left to right, 1-3-5-7 and in each zero-degree group, going from bottom to top in the figure, 2-4 -6-8 is. In 3A is the sequence of subgroup ordering in each ninety degree group, going from left to right, 1-5-7-3, the sequence of subgroup ordering in each zero degree group going from bottom to top in the figure is 2 -6-8-4. 3B is a 3B-3B elevation of 3A and shows the position of the subgroups in the cell 79 in 3A , 3C shows another pattern wherein the ninety-degree yarns as in 2A (1-3-5-7) were shifted and the zero-degree yarns as in 3A (2-6-8-4). As can be seen, various patterns of yarn displacements in each subgroup are possible to change the yarn patterns or features as desired, and the zero degree and ninety degree subgroups can be shifted differently. Another variation is in 4A shown where the yarns are arranged in subsequent subgroups in the middle of the remaining cell space to produce a different looking yarn pattern. In general, the arrangement is in 4A less preferable; instead, it is preferable to arrange the yarns in subsequent subgroups adjacent to a yarn in a preceding subgroup. This results in improved accuracy of yarn placement and restriction of yarn movement in the direction of the adjacent yarn during construction of the structure prior to bonding. 4B shows another pattern.

The steps actually followed by a yarn arranging device for sequentially arranging the subgroups may also be further changed as desired. For example, with reference to 2A and the ninety-degree group, a device by the numerical sequence 1, 3, 5, 7 walk as in parentheses 63 or 65 or 67 or 69 to see; The zero-degree group can be changed similarly. The steps followed will not affect the appearance and structure of the pattern in the middle portion of the fabric structure, but may be used to determine the appearance along the edge of the fabric.

For joining the upper and lower yarns other means are possible than by connecting only the overlapping points. In a preferred embodiment, an ultrasonic horn becomes diagonal in a path 51 , such as by the point 68 and the point 74 ( 1E ), passed over the structure to continuously connect all the yarns in the web to their overlapping neighbors. A parallel track 53 would be through the point 70 run, and another parallel track 55 would be through the point 72 run so that a plurality of ultrasonically bonded webs would be present to hold the structure together. Alternatively, the bondlines could be from point 68 to 70 or 68 to 72 to run. In practice, the tracks would not have to go directly through the points 68 . 70 . 72 and 74 run to effectively capture the yarns in the structure. It is important that the uppermost yarns and the lowermost yarns are connected to other yarns which are finally joined together, so that the upper yarns are finally connected to the lower yarn by a series of joints. This "webbing" method of bonding is advantageous in that exact positioning of the bonds at the upper and lower yarn overlap points is not required, although it is preferable. "Such a gap of webs, as just discussed, results in a low enough bond frequency in order to maintain the inherent flexibility of the yarns in the structure, despite the high frequency of fusion bonds of molten polymer The bond webs form a bonded area in the fabric structure and can be used to control the fabric volume between the bond webs, such as the webs 51 and 55 There is an unbound area 49 where the yarns remain unbonded and unconnected so that the inherent flexibility of the yarn used in the structure is maintained. It will be appreciated that many yarns would be used to make a fabric size of a convenient size and many bonded and unbonded areas would be used.

4C shows a small area of a portion of a fabric having a pattern similar to that in FIG 1E ( 2A also). The in 1E / 2A shown small area textile product section 22 , which is referred to as a single cell / single step pattern (or single cell pattern only), may be four passes from two yarns in each group, such as four passes of two layup yarns 30 and 32 in the ninety-degree direction, alternated with four passes of two lay-up yarns 36 and 38 in the zero-degree direction. In each sublayer, the succeeding yarns close to the previous yarns are spaced apart from a single yarn step. This fabric could be made quickly in this way. An in 4C shown equivalent fabric section 24 was made with eight passes of only one lay-up yarn in each group, such as eight passes of a lay-up yarn 41 in the ninety-degree direction, alternated with eight passes of a lay-up yarn 43 in the zero-degree direction, made. If the at 45a shown numbered sequence for the ninety-degree landing yarn 41 followed and the at 45b shown numbered sequence for the zero degree application yarn 43 is followed, a pattern, very similar to the one in 1E / 2A , generated. The pattern in the as in 1E / 2A The fabric section produced shows four fabric cells with four yarns per cell side, and the pattern in the as in 4C The fabric section produced shows a fabric cell with eight yarns per cell side. Some visual differences can be seen in the fabric when looking at the lower right quadrant of the two fabrics where it can be seen that 2A (as well as 1E ) subgroup 5 passes under subgroup 6 and subgroup 7 passes under subgroup 8; but in the equivalent textile product in 4C subgroup 11 passes over subgroup 10 and subgroup 15 passes over subgroup 14.

This pattern in 4C is referred to as a split cell / single step pattern (or only split cell pattern) because the second yarn deposited in each group of yarns, 41a and 43a , the cell spacing, such as the distance 47 into a cell fraction, such as a half cell, as in the same gap cell spacings 47a and 47b shown. The following yarns in each group, such as the yarns 4lb and 43b , then become close to the previous yarns, such as the yarns 41 respectively. 43 at a distance from a single yarn step in the first gap cell intervals, such as 47a , laid down. Also the following yarns, such as the yarns 41c and 43c , then become close to the previous yarns, such as the yarns 41a respectively. 43a at a distance from a single yarn step in the second gap cell spacings, such as 47b , laid down. In this way, the two or more split-cell fractions are assembled together. When the cell is finished, the intersection of the upper and lower yarns, as at 73 , bonded. Additional bond lines, similar to those at 51 . 53 and 55 in 1E could also be used to, as at 73a . 73b and 73c in 4C shown to bind several of the yarns together. As desired, more or less bond lines can be used. For the single cell / single step pattern and the split cell / single step pattern and for any other similar pattern that produces good yarn interlacing, it may be possible to have less than the suggested one bond per one large fabric pattern having many cells and bonds Cell to use.

4D shows for comparison a textile product 26 , manufactured using the single cell pattern as in 1E / 2A but using eight yarns per cell spacing instead of just four. Only a single application yarn for each group of yarns would be needed for the fabric area shown in this single cell. The at 27a The numbered sequence shown is for the ninety-degree landing yarn 25 followed, alternating with the at 27b shown numbered sequence, which for the zero degree application yarn 28 followed. This single cell pattern covers the same area as the four-cell area of 1E / 2A or the single cell area of 4C However, it has a large number of long unattached yarn lengths, which may be undesirable for some applications. When depositing a large number of yarns per cell (8 or more), it is preferable to use the split cell pattern to minimize the number of long unsupported yarn lengths.

• – eine Vielzahl von ersten Garnuntergruppen mit einer Vielzahl von in einer ersten Winkelrichtung frei von Verkreuzungen ausgerichteten Garnen, wobei die ersten Garnuntergruppen einen Stapel mit einer Vielzahl von zweiten Garnuntergruppen mit einer Vielzahl von in einer zweiten Winkelrichtung frei von Verkreuzungen ausgerichteten Garnen bilden,
• – wobei das Garn in jeder Untergruppe wesentlich parallelen Bahnen folgt, die in einem sich wiederholenden Muster mit Zwischenraum zueinander angeordnet sind, so daß sie eine gemeinsame vorher festgelegte Textilerzeugnisfläche dünn bedecken,
• – wobei die Garnuntergruppen abwechselnd mit einer ersten Untergruppe neben einer zweiten Untergruppe gestapelt sind, wobei die Garne in der ersten Untergruppe die Garne in der zweiten Untergruppe kreuzen,
• – wobei die Garne in einer beliebigen Untergruppe der Vielzahl von ersten Untergruppen gegenüber den Garnen in allen anderen Untergruppen der ersten Vielzahl von Untergruppen versetzt sind,
• – wobei die Garne in einer beliebigen Untergruppe der Vielzahl von zweiten Untergruppen gegenüber den Garnen in allen anderen Untergruppen der zweiten Vielzahl von Untergruppen versetzt sind,
• – wobei das Stapeln aller der Vielzahl von ersten Untergruppen eine erste Garngruppe bildet, die Garne enthält, welche die vorher festgelegte Textilerzeugnisfläche dicht bedecken, und das Stapeln aller der Vielzahl von zweiten Untergruppen eine zweite Garngruppe bildet, die Garne enthält, welche die vorher festgelegte Textilerzeugnisfläche dicht bedecken, und
• – wobei die Garne in der obersten Untergruppe in dem Stapel mit den Garnen in der untersten Untergruppe in dem Stapel verbunden sind, um dadurch die anderen Untergruppen in dem Stapel in einer verwebten Textilerzeugnisstruktur zu enthalten.

It has been shown that the in 1E / 2A and 4C illustrated patterns of yarns provide particularly good interweaving of yarns so that the fabric structures tend to hold their shapes better without yarn shifting and opening holes in the fabric. However, there are some significant differences in the two types of yarn looms. The simple cell of 1E / 2A uses more application yarns per inch of fabric than the splitting cell of 4C and if the practice of providing at least one bond per cell is followed, more bonds would be used per area of the fabric. The use of more apply yarns may require a larger yarn creel and more yarn guides, as will be appreciated as various devices are discussed below. However, this use of more application yarn per inch results in faster fabric development using the single cell pattern. The split cell pattern, on the other hand, ensures the same good interweaving of yarns as the single cell pattern and, in exchange for fabric forming time, provides more flexibility in forming different yarn structures with a given device. Generally speaking, the fabric structure of the invention is a woven fabric structure which comprises:

• A plurality of first yarn subgroups having a plurality of yarns oriented in a first angular direction free of crossings, the first yarn subgroups forming a stack having a plurality of second yarn subgroups having a plurality of yarns oriented in a second angular direction free of crossings,
• The yarn in each subgroup being followed by substantially parallel webs spaced in a repeating pattern with each other so as to thinly cover a common predetermined fabric area,
• Wherein the yarn subgroups are alternately stacked with a first subgroup adjacent to a second subgroup, the yarns in the first subgroup crossing the yarns in the second subgroup,
• Wherein the yarns in any subset of the plurality of first subgroups are offset from the yarns in all other subgroups of the first plurality of subgroups,
• Wherein the yarns in any subset of the plurality of second subgroups are offset from the yarns in all other subgroups of the second plurality of subgroups,
• Wherein stacking all of the plurality of first subgroups forms a first yarn group including yarns which tightly cover the predetermined fabric area, and stacking all of the plurality of second subgroups forms a second yarn group containing yarns containing the predetermined fabric area tightly cover, and
• Wherein the yarns in the top subgroup in the stack are joined to the yarns in the bottom subgroup in the stack to thereby contain the other subgroups in the stack in a woven fabric structure.

• – die Garne in aufeinanderfolgenden der Vielzahl von ersten Untergruppen in dem Stapel sind gegeneinander um die Breite eines Garns in jener Untergruppe des Textilerzeugnisses versetzt, und
• – die Garne in aufeinanderfolgenden der Vielzahl von zweiten Untergruppen in dem Stapel sind gegeneinander um die Breite eines Garns in jener Untergruppe des Textilerzeugnisses versetzt.

In the case of the single-cell, single-step pattern, the woven fabric structure also includes:

• The yarns in successive ones of the plurality of first subgroups in the stack are mutually offset by the width of a yarn in that subgroup of the fabric, and
• The yarns in successive ones of the plurality of second subgroups in the stack are mutually offset by the width of a yarn in that subset of the fabric.

in the Case of the split cell pattern closes the woven fabric structure also the following:

• - the Plurality of first subgroups is arranged in the stack so that she defines a total number of yarn displacement steps, equal to the Number of subgroups containing the plurality of first subgroups make out (the distance of such a Garnschritts corresponds to Yarn diameter of a yarn in the subgroup, as in the fabric appears), and wherein successive of the plurality of first Yarn subgroups in a plurality of equal subintervals the yarn steps are arranged to each other,
• - and successive ones of the plurality of first thread subgroups arranged stepwise in the subintervals, wherein the plurality of yarns in the successive of the plurality of first subgroups offset by a yarn step to each other,
• - the Plurality of second subgroups is arranged in the stack so that she defines a total number of yarn displacement steps, equal to the Number of subgroups containing the plurality of second subgroups and successive ones of the plurality of first ones Yarn subgroups in a plurality of equal subintervals the yarn steps are arranged to each other,
• - and successive ones of the plurality of first thread subgroups arranged stepwise in the subintervals, wherein the plurality of yarns in the successive of the plurality of first subgroups is offset by a yarn step to each other.

The Connecting means for Fabrics of the invention may, as discussed, be ultrasonic bonding if the yarns are of a thermoplastic polymer and the top ones and lower yarns compatible Are polymers that fuse together by fusion. The compound (or binder) agent may also be a hot melt adhesive, a solvent, which softens the yarn polymer and allows the yarns to fuse together, a room temperature curing Adhesive, a solvent-based adhesive or another impregnating one Art, a mechanical fastener, such as a Clamp, a belt or a band or other such means be.

in the Case of a bonded connection does not have all the yarns in the Structure thermoplastic yarns to act as binding yarns. The polymer used to provide the tacky polymer, partially dissolved, melted polymer or the like necessary binding yarns can on a variety of ways about the entire structure be distributed. A twine is a yarn, that while connecting another twine or a non-twine mechanically or sticking. A non-binding yarn is a yarn that during of bonding no other non-binder yarn mechanically or adhesively would engage. In a simple case can some or all of the yarns for the structure may be made of nonbonded fibers by twisting or wrapped with binder fibers are. An example of such a wrapped yarn is a yarn with a non-thermoplastic multifilament core, with a Multifilamenthülle wrapped, which contains some or all thermoplastic filaments. The Shell can consist of continuous filaments or staple fibers. In the case of staple fibers may be the shell a mixture of binder and nonbond fibers, such as thermoplastic nylon staple fibers and non-thermoplastic Aramid or cotton staple fibers, be. Such a yarn structure can be made using a "friction spinning machine DREF 3 ", available from the textile machinery factory Ernst Fehrer AG from Linz, Austria, getting produced. An admixture of 5 to 25 percent by weight Thermoplastic binder fibers in the sheath may work well for this application. As required, can other binder and nonbond fibers are used for the fibers in the yarn become. When bonding using such a sheath-core yarn is to be expected that the Hüllenfilamente affected by the bonding process would but not the core filaments. On the Kernfilamente one could rely on the bonding in the structure after bonding to wear. In some cases may be desirable be to form ties at all yarn intersections to form a stiff, to form a tabular textile product structure. This can be done by heating and squeezing all binder fiber in the structure are accomplished, so that essential all yarns are bonded together.

Another way of distributing binder adhesive material to bond the structure together is to provide twine for one or more top subgroups, for example, the zero degree group of yarns, and for one or more bottom subgroups, for example, the ninety degree group of yarns. These upper and lower yarns may be the sheath-core yarns described above. Another way of dispensing binder material is to use a binder containing yarn for a fraction of each subgroup of, for example, zero and ninety degree yarns, such as every other or every tenth yarn in each subgroup. One structure that has been shown to work well is to make the top and the next subgroups of yarns and the bottom and the next subgroups of yarns with binder fibers. During bonding, the binding threads become the top and the next Partial layer and the lowermost and the next sub-layer adhesively bonded, and other Nichtbindegarne can be brought into mechanical, such as by embedding, wrapping, encapsulation or the like, engaged. This additional engagement of nonbonding fibers results in load paths extending from the top to bottom yarn subgroups, even if the top and bottom subgroups do not directly contact each other.

It has shown that, when a distribution of binder fibers in the structure of the invention is used, a distribution of about 5% to 60% binder fiber of total fiber weight useful is, and preferably works a distribution of about 10% up to 20% of the total fiber weight well, to ensure good fabric integrity; while a good fabric softness is maintained (stiffness and To reduce boarding of the fabric to a minimum). In some cases it may be desirable to have a structure made entirely of (thermoplastic) twine and to fix the bonds so that they at some or all overlaps between the top and bottom subgroups of yarns are predominant in the structure, without the overlaps between them two subgroups carefully to have to position.

If For example, ultrasound is used to make thermoplastic yarns Can supply energy it possible be, this preferential bond by using thick or "thick" yarns for the top and reach the bottom subgroups of yarns. If you between a broad area Ultrasonic funnel and an anvil is squeezed, the overlap the fat yarns absorb more squeeze pressure than the adjacent ones thinner Yarns, so that the Ultrasonic heating preferably at the intersections of the greases Yarns will occur with minimal bonding of the intersections of the thinner yarns.

The bonded fabric structure must have a controlled number of bonds to achieve adequate strength, control the bulk of the fabric, and to maintain the inherent flexibility of the yarns used in the fabric. Too few compounds, and fabric integrity is compromised; Too many compounds and fabric flexibility is compromised and volume is reduced. The number of joints can be a fraction of the total number of yarn crossings in the structure. For good integrity, volume control and good flexibility, the number of connections must be controlled within limits. 14 is a schematic view of a single cell 380 a fabric structure, and the cross marks represent the yarn crossings in the cell. The cell 380 Figure 10 illustrates a biaxial fabric structure with eight yarns per direction for a total of (8 x 8) 64 crossings per cell. The lines 382 . 384 . 386 and 388 represent possible edges for a bond path through the cell. The circle 390 represents a single bond between a yarn at the top of the structure and a yarn at the bottom of the structure, which would be the minimum number of bonded crossings for the cell. Between the lines 384 and 386 would there be a single-crossing-length bonding web, which would be an average number of bonded crossings for a cell; between the lines 384 and 388 would there be a double crossover bond web, which would be a high number of bonded crossings for a cell; and between the lines 382 and 388 For example, there would be a triple crossover bond web, which would be a very high number of bonded crossings for a cell.

Below is a table of variables and values for determining the fraction of bonded crossover to total crossings. "N" represents the number of yarns per direction in a single square cell, in the single cell 380 this number is 8. "Min" is the bond fraction if only one cross of N ² total crosses is bonded; "Med" is the bond fraction if a single crossover bond web is used that bonds N crossings of N ² total crosses; "Hi" is the bond fraction if a double-crossover bond web is used which bonds N + (N-1) crosses of N ² total crosses; "V Hi" is the bond fraction if a triple crossover bond web is used, of N ² total crosses N + (N-1) + (N-1) crossbonding bonds.

BINDING FRACTION TABLE

Overall has been discovered that one Bond fraction within the range of about 0.003 to 0.778 is preferable. A bond fraction within a sphere from about 0.008 to 0.520 is most preferable, or that is, about 1% to 50% of the available Crossbones bonded or otherwise connected. This fraction can be regulated by the number of yarns in a cell and the number of bonds in a cell that can be regulated by the width of the bond web and the number of bond webs within a cell. If there is more than one bond path within a cell there, the bond sheets should be narrow.

Under Referring to the bond fraction table above, which uses the single cell method was prepared as a model, it should be noted that a textile product using 16 yarns per cell attached to the one End of the preferred scale is most preferable when using the split cell / single step method will be produced. This is because, through this process, interweaving is improved and the number of long unattached yarn lengths for a given Number of yarns per cell is reduced. Generally, though ensures more weaving in a fabric of the invention is, the number of bonds per cell is reduced and yet a good one Fabric integrity to be kept. For example, in the table, if the split cell fraction 1/2, the split-yarn product with 16 yarns per cell (in preference) equivalent to the single-cell fabric with 8 yarns per Be a cell.

5A Figure 12 shows another flexible fabric structure in which the yarns are laid down in groups in three directions, at 0 degrees, 60 degrees and 120 degrees, to make a triaxial structure. For purposes of discussion, at 88 a parallelogram-shaped basic cell of structure is shown which is consistently repeated, with sides shown by dashed lines along the zero and sixty-degree directions oriented. Alternatively, the repeating basic cell could also have been selected as one with sides aligned along the zero and one-twenty twenty degree directions. The yarn 81 the upper subgroup defines the position of the X-axis, and the intersection of the yarn 8l with the yarn 83 the next subgroup defines the origin 85 and thereby the Y-axis. The cell space for the zero-degree group is added 89 The cell space for the sixty-degree group is shown at 90 The cell space for the one hundred and twenty-degree group is shown at 91 shown. The yarn 87 The third subgroup crosses the X axis at about 0.5 / 4, which defines the third group shift from the origin. The upper and lower yarn subgroups 12 and 1 are joined where they intersect and overlap at the points 80 and 82 that both fall to the edge of the cell. Other overlap bond points in the structure, when developed into a larger area fabric, would appear at the cross-hatched points, such as 84 and 86 , are located. It should be noted that the yarns of subgroup 2 lie between the yarns of the upper subgroup 12 and the yarns of the lower subgroup 1 and are at least partially included in the bond. 5B shows a bigger piece 95 of a similar triaxial fabric, but made using eight yarns in each cell space, a plurality of cells and a third group displacement from the origin equal to zero so that equilateral triangles are formed by the yarns of the three groups.

Using the positional conventions discussed above, the matrix would be for the structure of 5A the following:

• – eine Vielzahl von dritten Garnuntergruppen mit einer Vielzahl von in einer dritten Winkelrichtung frei von Verkreuzungen ausgerichteten Garnen, wobei die dritten Garnuntergruppen einen Stapel mit den ersten und zweiten Garnuntergruppen bilden, wobei die Garne in der dritten Untergruppe die Garne in der ersten und der zweiten Untergruppe kreuzen,
• – wobei das Stapeln aller der Vielzahl von dritten Untergruppen eine dritte Garngruppe bildet, die Garne enthält, welche die vorher festgelegte Textilerzeugnisfläche dicht bedecken.

Generally speaking, the triaxial structure of the invention is similar to a biaxial structure of the invention, with the addition that the woven fabric structure further comprises

• A plurality of third yarn subgroups having a plurality of yarns oriented in a third angular direction free of crossings, the third yarn subgroups forming a stack with the first and second yarn subgroups, the yarns in the third subgroup comprising the yarns in the first and second subgroups cross,
• - wherein stacking all of the plurality of third subgroups forms a third group of yarns containing yarns which tightly cover the predetermined fabric area.

In 6 discloses an apparatus for continuously forming a biaxial fabric structure with basic cells similar to those of US Pat 1E and 2A , shown. The device consists of an elongated Garnauflagefläche, such as a flat perforated, by a motor 107 powered, belt 91 containing a grouping of pens, such as a pen 93 , along one edge 94 and a parallel grouping of pens, such as a pen 96 , along the opposite edge 98 of the belt 91 has to hold the yarns against the forces of the yarn return safely. Below the belt is one at a vacuum source 99 attached vacuum chamber 97 arranged the yarn in place on the belt 91 to keep. Along the edge 98 becomes a variety of Garnführungsblöcken 100 . 102 . 104 and 106 shown, each on guide means, such as guides 101 and 103 , are mounted and each drive means, such as an actuator 105 for the block 100 , have to get the strap 91 from an edge 98 to an opposite edge 94 to cross. Each yarn guide block has a plurality of yarn guides, such as a guide 173 in the block 100 to form a yarn such as one from a yarn supply roll 113 emerging yarn 111 to guide exactly on the belt. The dashed outlines 100 ' . 102 ' . 104 ' and 106 ' on the edge 94 show the position of the blocks after crossing the strap 91 would take. A variety of ultrasonic funnels, such as a funnel 108 at a position 110 , is above the belt 91 arranged to act on a laid yarn to melt-connect the overlapping yarns at spaced positions in a laid-down fabric. The strap and a rigid pad 109 below it acts as an ultrasonic anvil to couple the energy through the yarn. Once the yarn cools from ultrasonic bonding, the fabric structure may be stripped from the pins or hooks along the edges of the belt, and the belt may be returned while the fabric is being wound in a roll on a core (not shown). The fabric wrap would be controlled to avoid twisting of the fabric along the direction of the belt which is along the fabric diagonal (skew) and along the axis of the bond web.

On the belt is a representation of a laid-down biaxial two-tier fabric 112 shown. The illustration shows the laid yarn pattern when the process begins and the belt in the direction of the arrow 114 moved from right to left, when the blocks together on a coordinated with the belt movement along the Gurtlängsachse way from the edge 98 to the edge 94 move it substantially vertically over the belt and continue this to and fro as indicated by the arrows 116 shown. Shown is what was generated at the beginning and then stopped and the belt retracted to align the starting pattern with the guide blocks. For a correct representation, the block would 100 (and the other blocks) in the image to the right, to a position just beyond the block 106 , to be shown. At the left end 118 of the textile product 112 the upper subgroups are placed alone because at the beginning, none of the other subgroups are in place. At the right end 120 of the textile product 112 All subgroups are in place for a fully formed fabric at position 122 and thereafter the fabric is continuously fully formed as the belt and blocks continue to move as described. The speed of the belt and the speed of the blocks are controlled by a control unit 115 regulated and tuned with the engine 107 and the actuator for each view, such as the actuator 105 , connected is. This ensures that the yarn passing through the guide blocks and lying on the belt forms a straight path at an angle of 45 degrees to the center line and the edge of the belt, so that it, as in 119 , a first yarn group with +45 degrees and, as at 121 , gives a second yarn group with -45 degrees. By altering the controlled movements, other trailing angles and curved trajectories are also possible. The first and second (lower) yarn subgroups are passed through the block 106 laid down, the third and the fourth (middle) yarn subgroup are passed through the block 104 deposited, the fifth and the sixth (middle) yarn subgroup are through the block 102 laid down, and the seventh and eighth (upper) yarn subgroups are passed through the block 100 resigned. A given yarn can switch across the fabric in cells between subgroups as it travels across the fabric. In this example, the belt moves and the blocks only move back and forth over the belt, and the belt moves continuously from right to left. The same pattern can be created if the belt is considered to be fixed and unusually long and the blocks reciprocate diagonally from left to right at 45 degrees along the belt.

• – eine Vielzahl von wesentlich parallelen Garnen in einer Gruppe ist so angeordnet, daß sie eine Fläche dicht bedeckt, wobei die Garne einer Gruppe so angeordnet sind, daß sie die Garne einer anderen Gruppe kreuzen,
• – jede Gruppe besteht aus einer Vielzahl von Untergruppen, wobei jede Untergruppe eine Vielzahl von dünn angeordneten Garnen hat,
• – die Vielzahl von Garnen in einer Untergruppe einer Gruppe ist gegenüber der Vielzahl von Garnen in den anderen Untergruppen der gleichen Gruppe versetzt,
• – die Garne in der obersten Untergruppe und der untersten Untergruppe sind an mit Zwischenraum angeordneten Positionen entweder unmittelbar oder mittelbar durch die Garne in den anderen Untergruppen miteinander verbunden.

The pattern of top and bottom yarns is changing in the fabric, as in the cells 124 . 126 and 128 expresses. 7 shows this section of the fabric 112 magnified to discuss. The yarns are shown arranged in each group with slight spacing for clarity. In 7 is a yarn 130 in the cells 124 and 126 the top yarn of the eighth subgroup, but is in cell 128 the yarn of the seventh subgroup. Similar is a yarn 132 in the cells 124 and 126 the yarn of the sixth subgroup, but is in cell 128 the yarn of the fifth subgroup. Similar changes occur in the remaining subgroups. This deviation from a perfectly regular pattern within a fabric, unlike the pattern in 1E and 2A , does not affect the structural integrity of the fabric and is an example of some acceptable changes in the patterns of the invention. The neighboring cells 134 . 136 and 138 are all identical and are the same as the cells of 1E and 2A , Each yarn has a subgroup assignment and a position assignment in a cell. However, both subgroup assignment and position assignment in a given fabric structure may vary from cell to cell, or they may remain constant and in both cases follow the rules for implementing the invention, which are:

• A plurality of substantially parallel yarns in a group are arranged so as to densely cover one surface, the yarns of one group being arranged to intersect the yarns of another group,
• Each group consists of a plurality of subgroups, each subgroup having a plurality of thinly arranged yarns,
• The plurality of yarns in one subgroup of one group is offset from the plurality of yarns in the other subgroups of the same group,
• The yarns in the uppermost subgroup and the lower subgroup are interconnected at spaced positions either directly or indirectly through the yarns in the other subgroups.

The bond point from top to bottom for the cell 124 is located at 140 , the bond point for the cell 126 is located at 142 , the bond point for the cell 128 is located at 144 , For a subcell 146 at the edge of the fabric, the bond point is included 148 , All of these bonding points would be covered by ultrasound trajectories, with the arrows 150 at the left end of 7 are aligned.

Four yarns in each guide are sufficient to cover the belt for a four-yarn cell space fabric with the width shown and for a 45-degree pattern. In 6 takes the space through a yarn, such as a yarn 152 , which is covered by the strap side 94 over to the belt side 98 and back over the belt 91 enter a stretch along the belt, as at 154 shown. Four yarns, such as yarns 152 . 156 . 158 and 160 in the lead 100 Fill this space for the 1 subgroups 8 and 7. If a wider belt would be used, with the opposite edge 98 join in 162 would be through the yarn 152 that over the belt 91 go back and forth, covered space take a stretch along the belt, as at 164 shown. This would be extra yarns 166 . 168 . 170 and 172 require to fill this space for subgroups 7 and 8. The leadership 100 would have to be extended for this wider fabric to hold 8 yarns instead of just 4, and the block 102 should be along the length of the belt 91 be moved to accommodate the larger block 100 to accomplish. The block 102 and the other blocks 104 and 106 would be extended and moved similarly. The first yarn guide hole 171 in the block 102 becomes with clearance to the last yarn guide hole 173 in the block 100 arranged shown to a track 175 a cell diagonal plus a yarn position diagonal to move the yarns of subgroups 5 and 6 in staggered positions to those through the block 100 deposited yarns of subgroups 7 and 8. This distance is for the subsequent guide blocks along the side of the belt 91 similar. This distance may be smaller or larger by units of a cell diagonal, depending on how much space is required for the guide blocks.

• (a) Bereitstellen einer länglichen Textilerzeugnis-Auflagefläche, die eine Längsachse und einander gegenüberliegende Seitenkanten parallel zu der Achse hat, und Anordnen der Fläche angrenzend an eine Vielzahl von Garnführungsblöcken, die längs der einander gegenüberliegenden Seitenkanten der länglichen Fläche angeordnet sind,
• (b) Bereitstellen einer Vielzahl von Führungen an den Führungsblöcken, wobei jede Führung geeignet ist, ein Garn von einer Garnquelle zu der Auflagefläche zu führen,
• (c) Ineingriffbringen der Garne an einer Kante der Auflagefläche,
• (d) Bereitstellen einer relativen Bewegung zwischen der Auflagefläche und jedem der Vielzahl von Führungsblöcken, so daß die Führungsblöcke Garn von den Führungen in einer ersten, im Verhältnis zur Kante der Fläche diagonalen, Richtung und in einer vorher festgelegten Richtung längs der Auflagefläche auf die Fläche niederlegen,
• (e) Ineingriffbringen der Garne an einer gegenüberliegenden Kante der Auflagefläche,
• (f) Umkehren der relativen Bewegung der Führungsblöcke und der Auflagefläche, so daß die Führungsblöcke Garn von den Führungen in einer zweiten, im Verhältnis zur Kante der Fläche diagonalen, Richtung und in der vorher festgelegten Richtung auf die Fläche niederlegen,
• (g) Anordnen der Führungsblöcke und Führungen und Anordnen der relativen Bewegung so, daß, wenn die Garne von den Blöcken auf der Fläche niedergelegt werden, die diagonalen Positionen jedes Garns zu den anderen Garnen versetzt sind, um dadurch die Auflagefläche in einem Zyklus relativer Bewegung von der einen Kante zur gegenüberliegenden Kante und zurück zu der einen Kante dicht mit den Garnen zu bedecken.

This clearance and the coordinated movement between the blocks and the belt result in the 45 degree diagonal yarn pattern in which the positions of each of the diagonal yarns are adjacent (rather than overlapping) the other yarns, thereby sealing the yarn support surface on the belt to cover with the yarns. If a denser, thicker structure is desired, additional guide blocks may be employed and another dense structure may be built on top of the first to create a ply structure. Generally speaking, the method just described for forming a woven fabric structure includes:

• (a) providing an elongated fabric support surface having a longitudinal axis and opposite side edges parallel to the axis, and disposing the surface adjacent to a plurality of yarn guide blocks disposed along the opposite side edges of the elongated surface,
• (b) providing a plurality of guides on the guide blocks, each guide being adapted to guide a yarn from a yarn source to the support surface,
• (c) engaging the yarns at an edge of the support surface,
• (d) providing relative movement between the support surface and each of the plurality of guide blocks so that the guide blocks receive yarn from the guides in a first diagonal direction relative to the edge of the surface and in a predetermined direction along the support surface on the surface resign,
• (e) engaging the yarns at an opposite edge of the support surface,
• (f) reversing the relative movement of the guide blocks and the support surface so that the guide blocks deposit yarn from the guides on the surface in a second diagonal direction relative to the edge of the surface and in the predetermined direction;
• (g) arranging the guide blocks and guides and arranging the relative movement so that when the yarns are laid down from the blocks on the surface, the diagonal positions of each yarn are offset from the other yarns thereby to move the support surface in a cycle of relative movement from the one edge to the opposite edge and back to the one edge to cover tightly with the yarns.

In the arrangement shown with separate guide blocks, the position of the subgroup yarns in the cell space can be determined by shifting the blocks along the length of the belt 91 to be changed. With a gap between the guide blocks and the way of laying down the yarns to form a fabric, it is possible to add materials between the subgroups of yarns within a fabric structure. For example, a roll could be foil 117 be arranged so that they continuously foil between the blocks 104 and 106 feeds to a guide 119 and on the textile product 112 between through the block 106 (Subgroups 1 and 2) and the block 104 (Subgroups 3 and 4) deposited yarn subgroups. In another case, yarns could 121 and 123 be arranged in the machine direction so that they continuously yarn between the blocks 102 and 104 through guides 125 respectively. 127 and on the textile product 112 between through the block 104 (Subgroups 3 and 4) and the block 102 (Subgroups 5 and 6) deposited yarn subgroups. Such inserts of material between subgroups are a unique ability of the fabric of the invention. In the illustrated case, the addition of the film and yarns in the machine direction may reduce the deflection of the diagonal fabric in the machine direction or may achieve other particular purposes. Other materials such as nonwovens, wires, elastomeric fabrics or yarns, fabrics of natural or synthetic materials, scrims, etc., may be used.

There is another way to use guide blocks to continuously lay down yarn to form a fabric on a belt. The blocks could be in alternating positions along the edge of the belt 91 be arranged and arranged so that they move in opposite directions over the belt when the belt, as in 8A and 8B shown, moved. In 8A are the blocks 100 and 104 along the edge 94 of the belt 91 arranged, and the blocks 102 and 106 are along the edge 98 , When the belt 91 , like 8A to 8B As seen walking from right to left, the blocks cross the belt to the opposite side, thereby laying yarn in a diagonal path on the belt. Repeated actuation of the blocks to and fro as the belt continues to run becomes a pattern such as in the enlarged fabric 174 from 9 to see, generate. This pattern is slightly different from the fabric 112 from 6 and 7 , Looking at the cells 176 . 178 and 180 are the cells 176 and 178 Cells with five subgroups, while the cell 180 is a cell with eight subgroups. In the cell 176 there is a yarn 181 in subgroup 5, yarns 182 and 184 are in the same subgroup, subgroup 4, yarns 186 and 188 both are in subgroup 3, yarns 190 and 192 are both in subgroup 2, and a yarn 194 is in subgroup 1. Looking at the cell 180 is the yarn 181 in subgroup 7, the yarn 186 is in subgroup 5, the yarn 188 is in subgroup 3, and the yarn 194 is in subgroup 1. The cell 180 has the same layout as the basic cell of 1E and 2A , To be in the cell 176 correct bond points from the upper subgroup 5 to form the non-overlapping lower subgroup 1, it must have a bond point 196 between the yarn 181 the group 5 and the yarn 182 Group 4 plus a bond point 198 between the yarn 182 and the yarn 194 give group 1. With the ultrasound bonding paths, as in 200 shown by the arrows, it becomes an additional bond point 202 between the yarn 181 subgroup 5 and the yarn 192 Subgroup 2 and a bond point 204 between the yarn 192 and the yarn 194 subgroup 1. Through a chain of bond points in cell 176 For example, the upper subgroup 5 is connected to the lower subgroup 1 although the upper and lower subgroups do not cross each other. The arrangement of ultrasonic bonding webs to achieve properly spaced bonds for the fabric 112 from 6 and 7 differs from the bonding webs for the textile product 174 from 9 ,

10A shows another apparatus for producing two-dimensional fabrics of the invention. It is suitable for producing a batch fabric instead of a continuous fabric. It is a simpler device than that of 6 , A single leader block 206 is by an actuator 207 over a table 208 back and forth, which also by an actuator 209 is oscillated in a direction at right angles to the pendulum direction of the block 206 , Parallel rows of pins 210 and 212 Keep the yarn at the reversal points. If desired, can also vacuum on the plate will be created. The block and table reciprocate numerous cycles in a coordinated fashion to create dense groups of yarns that intersect each other. Thereafter, a single ultrasonic bonding funnel 211 repeated in tracks parallel to the pendulum direction of the table 208 passed over the fabric to make interstitial bonding sheets to join the upper and lower subgroups of yarns together. Thereafter, the fabric of the edge pins 210 . 212 stripped. By adding a movement of the guide 206 in a vertical direction by an actuator 205 could be over one at the table 208 attached three-dimensional shape 203 a three-dimensional fabric can be produced. 10B shows the crooked yarn paths in a fabric 213 which can be used to cover a three-dimensional shape.

11A shows another apparatus for producing two-dimensional batches of a fabric structure. It is the device of 10 similar, except that the yarn through a guide block 216 on a thorn 214 instead of laying down yarn on a table. In place of the leader block 216 who like in 10 Shuttling back and forth is the leader block 216 fixed, and the thorn 214 shuttles, as if by an arrow 217 indicated, in a rotary motion by a motor 215 , at the same time, while the table 208 ' the mandrel through the actuator 209 ' moved past the guide block. A single row of pens 218 holds the yarn between reversal points in both directions as the mandrel rotates. The result is a fabric that has a cylindrical tubular shape during manufacture. After all the yarns are laid down, a single ultrasonic funnel follows 219 repeating an axial trajectory along the mandrel at various circumferential positions over the fabric as it is reciprocated across the table and mandrel. This results in parallel bondlines to interconnect the upper and lower groups. Alternatively, the funnel could follow a revolving path at different axial positions along the mandrel. If it's from the pins 218 is the result of a flat textile product. This manufacturing on a cylindrical mandrel has opposite the flat plate of 10A the advantage that the yarn tension can be used to hold the yarns securely to the mandrel.

11B shows a device similar to that in FIG 11A except that the cathedral 214 would rotate unidirectionally in one direction to make a cylindrical fabric batch. In 11B is a spinning spine 220 at a mobile table 208 '' , reciprocated by an actuator 209 '' , attached, A circular twine guide pad 222 holds a variety of guides, such as a yarn guide 224 with space around the perimeter of the spine 220 are arranged. The edition 222 is held stationary relative to the mandrel and the table. A skein, such as a skein 226 from a fixed roll 228 , is guided by any guide, such as 224 , fed and will be at one end 230 attached to the mandrel where the support and mandrel are aligned before the mandrel begins to rotate and the table begins to move. Since the yarn packages are stationary, the yarn can be fed endlessly using a supply reel (not shown) and yarn transfer tails on the reels. The thorn 220 has, as shown, a variety of rings 232 and 234 of closely spaced pins near the ends 230 respectively. 236 of the thorn. These engage the yarn at the ends of the link when the table reverses direction. At the end of each traverse, when the yarn engages the pin rings, the table stops moving and the dome is moved a few degrees of rotation to ensure that the yarn is firmly engaged by the pins before the table reaches the end Direction reverses. The mandrel may be driven by a stepper motor, such as a motor 238 to be moved exactly. The yarn must also be aligned with the desired offset position of the cell before laying down adjacent yarn.

The yarn laydown pattern and the movement of the table and the mandrel will be further described with reference to FIG 11C which is an imaginary view of the thorn, as if flattened into a two-dimensional shape. On the left in the picture are the thorns 236 and the pin ring 234 , and on the right in the picture are the thorns 230 and the pin ring 232 , The dashed lines in the figure follow the yarn paths on the back of the flattened spine, the solid lines trace the yarn paths on the front. The illustrated yarns are the ones starting at the front of the figure at the points 240 . 242 . 244 , and 246 and of these only the point will be seen 240 starting yarn traced in its orbit by completely depositing. These starting points are those where the yarn passes through guides, such as the guide 224 in the edition 222 , is deposited. Four other yarns from the pad 222 would track similar trajectories starting at the back of the flattened mandrel with the same spacing as the yarns shown on the front. These points represent the first yarn position 0/4 of four possible positions for a first group in a cell space for the fabric. The yarn at the point 240 follows a train 248 when the thorn 220 in relation to the twine guide pad 222 turns and shifts while the yarns to the points 242 . 244 and 246 traces 250 . 252 respectively. 254 consequences. The train 248 following the laying down of yarn in a first group, the web goes 248 at 256 to the back of the flattened thorn and returns 258 back to the front and reaches the ring of pins 232 at 260 , Similarly, another yarn of the first group would be from the point 242 The ring 232 at one point 262 reach, a yarn from the point 244 would the ring 232 at one point 264 reach, and a yarn from the point 246 would the ring 232 at one point 266 to reach.

Suppose the yarn is going through the pin ring immediately 232 engaged, the mandrel rotation continued and the mandrel displacement immediately reversed, would the yarn path 248 ' back along the spine from the point 260 start laying down yarn in the second group. If this ideal situation does not exist, the displacement of the mandrel would stop as the mandrel rotation would continue for a few degrees to anchor the yarn in the pins. The points on the right end 230 of the mandrel represent the first yarn position 0/4 for a second group in a cell space for the fabric. The yarn path 248 ' goes with it 268 to the back of the flattened thorn and returns 270 back to the front and reaches the ring of pins 234 at one point 272 , It must now be decided which yarn pattern is desired in the fabric. Assuming the next desired yarn position is 1/4 position and the mandrel will continue to rotate in the same direction, that would be at the position 272 incoming yarn in one position 274 be before the displacement of the mandrel is reversed. The displacement of the mandrel will stop when the yarn reaches the point 272 reached, and will remain there while the thorn rotates a few degrees until the yarn reaches the point 274 and then the shift will reverse and the yarn becomes a web 248 '' consequences. This will cause the yarn at one point 276 , which is also in position 1/4 of the cell space, in the right pin ring 232 Arrive. If this is the desired pattern for the cell space of the second group, the mandrel displacement may immediately reverse and the yarn will travel along a path 248 ''' to return. If it is desired to change the yarn position for the cell, the displacement of the mandrel may stop, and the mandrel may continue to rotate a few degrees until the yarn is in the desired position in the cell space, and thereafter the displacement reverses, and the yarn follows on a new track. The yarn pattern in one cell may be different for the yarns of the first group and the yarns of the second group. This pattern will continue until the yarn is off the dot 240 at a position 278 again at the pin ring 234 arrives. At this point, all yarn positions for the cell space are occupied by subgroups of yarns, and the cylindrical charge of the fabric structure is ready to be bonded.

• (a) Bereitstellen einer länglichen Textilerzeugnis-Auflagefläche auf einem drehbaren Dorn, der eine Drehachse und einander gegenüberliegende Seitenenden wesentlich senkrecht zu der Achse hat, und
• (b) Ausrichten der Fläche angrenzend an einen umlaufenden Garnführungsring wesentlich senkrecht zu der Achse, wobei der Ring angrenzend an ein Seitenende der Textilerzeugnis-Auflagefläche angeordnet ist,
• (c) Bereitstellen einer Vielzahl von Führungen an dem Führungsring, wobei jede Führung geeignet ist, ein Garn von einer Garnquelle zu der Auflagefläche zu führen, wobei die Führungen mit gleichem Zwischenraum angeordnet sind, um Garn in gleichen Abständen um den Dornumfang niederzulegen,
• (d) Ineingriffbringen der Garne an einem Ende der Auflagefläche,
• (e) Bereitstellen einer relativen Bewegung zwischen der Auflagefläche und dem Führungsring, so daß der Ring Garn von den Führungen in einer ersten, im Verhältnis zu den Enden der Fläche diagonalen, Richtung von dem einen Ende zum gegenüberliegenden Ende und in einer vorher festgelegten Drehrichtung längs der Auflagefläche auf die Fläche niederlegt, wodurch die Textilerzeugnisfläche auf der Dornoberfläche dünn mit Garnen in der ersten Richtung bedeckt wird,
• (f) Ineingriffbringen der Garne an einem gegenüberliegenden Ende der Auflagefläche,
• (g) Umkehren der relativen Bewegung des Führungsrings und der Auflagefläche, so daß der Führungsring Garn von den Führungen in einer zweiten, im Verhältnis zu den Enden der Fläche diagonalen, Richtung von dem gegenüberliegenden Ende zu dem einen Ende und in der vorher festgelegten Drehrichtung längs der Auflagefläche auf die Fläche niederlegt, wodurch die Textilerzeugnisfläche auf der Dornoberfläche dünn mit Garnen in der zweiten Richtung bedeckt wird,
• (h) Anordnen des Führungsrings und der Führungen und Anordnen der relativen Bewegung so, daß, wenn die Garne von den Führungen an dem Führungsring aufeinanderfolgend auf der Fläche niedergelegt werden, die diagonalen Positionen nachfolgend niedergelegter Garne zu vorher niedergelegten Garen in jeder ersten und zweiten diagonalen Richtung versetzt sind, um dadurch die Auflagefläche in einem Zyklus relativer Bewegung von dem einen Ende zum gegenüberliegenden Ende und zurück zu dem einen Ende dicht mit den Garnen zu bedecken.

An ultrasonic bonding funnel (not shown, but similar to the funnel 219 in 11 ) can make repeated passes along the axis of the mandrel by translating the mandrel without rotation under the fixed funnel and rotating the mandrel several degrees at the end of each pass. Alternatively, the bonding can be done along circumferential paths. After bonding, the pin rings can be removed (by retraction or other means) and the fabric pushed off the mandrel. Alternatively, one end of the fabric may be trimmed on one pint ring and only the opposite pint ring removed. By pushing the fabric it will expand, as the fabric is oriented on a slope relative to the mandrel axis, it will be easy to push the fabric off the mandrel. Generally speaking, the method just described for forming a woven fabric structure includes:

• (a) providing an elongated fabric support surface on a rotatable mandrel having a pivot axis and opposite side ends substantially perpendicular to the axis, and
• (b) aligning the surface adjacent a circumferential yarn guide ring substantially perpendicular to the axis, the ring being disposed adjacent a side end of the fabric support surface;
• (c) providing a plurality of guides on the guide ring, each guide being adapted to guide a yarn from a yarn source to the support surface, the guides being equally spaced so as to place yarn equidistant around the mandrel periphery;
• (d) engaging the yarns at one end of the support surface,
• (e) providing relative movement between the support surface and the guide ring such that the ring receives yarn from the guides in a first direction diagonal relative to the ends of the surface, from one end to the opposite end and in a predetermined direction of rotation depositing the support surface onto the surface, thereby thinly covering the fabric surface on the mandrel surface with yarns in the first direction,
• (f) engaging the yarns at an opposite end of the support surface,
• (g) reversing the relative movement of the guide ring and the support surface such that the guide ring receives yarn from the guides in a second diagonal direction relative to the ends of the surface, longitudinally from the opposite end to the one end and in the predetermined rotational direction laying the support surface on the surface, whereby the fabric surface on the surface of the mandrel with thin Yarns in the second direction is covered,
• (h) arranging the guide ring and the guides and arranging the relative movement such that when the yarns are successively laid down by the guides on the guide ring on the surface, the diagonal positions of subsequently laid down yarns become previously laid down yarns in each first and second diagonal Direction are offset, thereby to cover the support surface in a cycle of relative movement from the one end to the opposite end and back to the one end tightly with the yarns.

In some cases, the same circular guide pad is desired 222 ( 11B ) for structures having different numbers of yarns per cell, so that no other guide pad needs to be incorporated for routine changes in yarn count or the like. One way to achieve this flexibility is to use a special laydown pattern for yarns, as discussed above with reference to the gapped cell / single step method, which would work well with this device to make cells that would appear to have lower calipers Numbers of yarns in each cell and behave as if they were.

• a. Drehen des Dorns im Uhrzeigersinn, wie durch den Pfeil 221 bezeichnet, und Verschieben des Dorns an der Führungsauflage 222 vorbei, wie gezeigt, so daß eine dünne Garnteillage, wie beispielsweise eine aus Garnen, wie beispielsweise den Garnen 226 und 226', geformte Null-Grad-Teillage, vom Stiftring 232 bis zum Stiftring 234 auf dem Dom niedergelegt wird,
• b. Anhalten der Verschiebung und Weiterdrehen des Dorns um den halben Abstand zwischen den Garnführungen 224,
• c. Umkehren der Drehung des Dorns, um den Dorn gegen den Uhrzeigersinn zu drehen und an der Führungsauflage 222 vorbei zu verschieben, so daß das Garn, wie beispielsweise die Garne 226 und 226', vom Stiftring 234 bis zum Stiftring 232 auf dem Dorn und zwischen den Garnen mit durchgehenden Linien niedergelegt wird, um der dünnen Null-Grad-Teillage Garne hinzuzufügen,
• d. Anhalten der Dornverschiebung und Fortsetzen der Drehung des Dorns gegen den Uhrzeigersinn um einen Abstand, um eine Garnführung 224 in Position für die nächste Teillage, wie beispielsweise eine Neunzig-Grad-Teillage, zu bringen,
• e. Fortsetzen der Drehung des Dorns gegen den Uhrzeigersinn und Verschieben des Dorns an der Führungsauflage 222 vorbei, so daß eine dünne Garnteillage, ausgerichtet in einer aus Garnen, wie beispielsweise den Garnen 226 und 226', geformte Neunzig-Grad-Teillage, vom Stiftring 232 bis zum Stiftring 234 auf dem Dorn niedergelegt wird,
• f. Anhalten der Verschiebung und Weiterdrehen des Dorns gegen den Uhrzeigersinn um den halben Abstand zwischen den Garnführungen 224,
• g. Umkehren der Drehung des Dorns, um den Dorn im Uhrzeigersinn zu drehen und an der Führungsauflage 222 vorbei zu verschieben, so daß das Garn, wie beispielsweise die Garne 226 und 226', vom Stiftring 234 bis zum Stiftring 232 auf dem Dorn und zwischen den gerade niedergelegten Garnen der Neunzig-Grad-Teillage niedergelegt wird, um der dünnen Neunzig-Grad-Teillage Garne hinzuzufügen,
• h. Anhalten der Dornverschiebung und Fortsetzen der Drehung des Dorns im Uhrzeigersinn um einen Abstand, um eine Garnführung 224 in Position für die nächste Teillage, wie beispielsweise eine weitere Null-Grad-Teillage, zu bringen,
• i. Wiederholen des eben beschriebenen Verfahrens a bis h, um nach Wunsch mehr Teillagen hinzuzufügen.

Another possibility is a method of operating the mandrel motor 238 and the table actuator 209 '' to make a multiple pass of yarns from the guide pad 222 to make actual changes in the number of yarns per sub-layer in the structure. For example, to double the number of yarns per part-layer, the yarns, such as yarns, could be used 226 and 226 ' in a dashed line 227 designated path which would add a yarn between the original yarns laid down by the guide. This would be done as follows:

• a. Turn the mandrel clockwise as indicated by the arrow 221 referred, and moving the mandrel on the guide pad 222 passing, as shown, so that a thin yarn layer, such as one of yarns such as the yarns 226 and 226 ' , molded zero-degree-part-layer, from the pin ring 232 to the pin ring 234 is deposited on the cathedral,
• b. Stopping the displacement and further rotation of the mandrel by half the distance between the yarn guides 224 .
• c. Inverting the rotation of the mandrel to rotate the mandrel counterclockwise and to the guide pad 222 to move past so that the yarn, such as the yarns 226 and 226 ' , from the pin ring 234 to the pin ring 232 on the mandrel and between the yarns is laid down with continuous lines to add yarns to the thin zero-degree sub-layer,
• d. Stopping the mandrel displacement and continuing the counterclockwise rotation of the mandrel a distance to a yarn guide 224 to bring in position for the next sub-location, such as a ninety-degree sub-location,
• e. Continue to rotate the mandrel counterclockwise and move the mandrel against the guide pad 222 passing so that a thin yarn layer oriented in one of yarns such as the yarns 226 and 226 ' , formed ninety-degree sub-layer, from the pin ring 232 to the pin ring 234 is laid down on the spine,
• f. Stopping the displacement and turning the mandrel counterclockwise by half the distance between the yarn guides 224 .
• G. Inverting the rotation of the mandrel to rotate the mandrel in a clockwise direction and on the guide pad 222 to move past so that the yarn, such as the yarns 226 and 226 ' , from the pin ring 234 to the pin ring 232 is laid down on the mandrel and between the ninety degree part laydown yarns just laid down to add yarn to the ninety degree thin layer
• H. Stopping the mandrel displacement and continuing the rotation of the mandrel clockwise by a distance about a yarn guide 224 in position for the next sublayer, such as another zero-degree sublayer, to bring
• i. Repeating the above-described method a to h to add more partial layers as desired.

This modified method differs from the single-cell method in the form of partial layers on the mandrel 220 where the guide has all the yarns needed for a part lay and the mandrel turns in the same direction as it puts yarn back and forth between the pin rings. The modified method just described adds yarn to a partial layer by the continued rotation of the mandrel half the distance (or other fraction) between the yarn guides 224 and then reversing the rotation of the mandrel to add yarn to that part of the layer. If, instead of the one yarn just described in the example above, two more yarns were to be added between the guided yarns, the continued rotation would only amount to one third of the distance between the guides, and this step would be repeated on the next pin ring. Similarly, if three more yarns were to be added, the continued rotation would be only one quarter of the distance between the guides, and this step would be repeated on the next two pin rings. When yarns are laid down in this manner, reversing the direction of rotation of the mandrel, it is important to minimize play in the apparatus and to minimize the stated yarn length between the yarn guide and the mandrel surface.

There is a concern when laying down yarn on the spine of 11B in that the path from the guide to the surface of the mandrel is as short as possible, so that the depositing position on the mandrel can be accurately predicted and controlled. This is a concern for each of the yarn laydown devices. One way to lay down the yarns with precision is to use the device in 11D to use that in a side view of a spine 230 ' and a circular guide pad 222 ' will be shown. To illustrate a general case, the dome 230 ' shown as an oval shape. It will be appreciated that the mandrel shape can also vary along its axis. The edition 222 ' holds a variety of guides, such as the guide 224 ' that the yarn 226 leads. With reference to the leadership 224 ' every leadership wears a hollow shaft 280 , a rounded leadership tip 282 , a feather 284 and a holder 286 one. The shaft goes through a hole 288 in the edition 222 ' therethrough. The feather 284 is above the shaft 280 between the edition 222 ' and the top 282 arranged to thereby the tip to the spine 230 ' to push. The yarn 226 goes through the hollow shaft 280 through and through the top 282 out and directly on the thorn 230 ' , In the same way, the yarn is placed directly on the mandrel as if it were "painted" on the mandrel surface, thus ensuring an accurate arrangement of the yarn on the mandrel, the shaft moving freely in the hole 288 in the edition 222 ' to allow the guide tip to slide over all variations in the shape of the mandrel while the spring is the tip 282 and the yarn coming out of it 226 securely in contact with the mandrel surface. The summit 282 For example, the ease of sliding over the mandrel and the yarns lying thereon can advantageously be coated with a low-friction coating.

20 Figure 4 shows another apparatus for accurately laying down yarns on a composite curvature, such as a spherical surface, when using a robot or other mechanical actuator. There is the problem that the robot does not always follow complex curved paths in an uninterrupted smooth motion and some irregular stepped motion is generated. It is useful to have some compliance in a yarn guide tip to hold it in contact with a curved mandrel surface during deviations in the trajectory of the guide actuator or robot. A yarn guide 470 is on a slider 472 attached to a robot disk 474 is attached. The slider is useful for fine positioning adjustments by means of a screw 476 for adjusting the initial deflection of the guide when the robot track is programmed. The leadership 470 includes a frame 478 holding a hollow shaft 480 to rotate. One on the shaft 480 attached block 482 wears four thin flexible springs 484 . 485 . 486 and 487 (Behind 486 ) Are arranged. At the intersection of the feathers is a hollow top 488 with a hemispherical end 489 attached. The springs allow movement of the tip in the axial direction 490 and in one by one angle 492 defined conical direction. Turning the shaft 480 allows the tip to roll over any surface it touches, while also allowing it to flex freely in the axial and angular directions. This allows the tip to be a yarn 494 placed exactly on the surface while the yarn passes through the hole 496 in the hollow shaft 480 and the hole 498 in the hollow top 488 passes.

12 FIG. 12 shows an apparatus used to make a simple three-dimensional tubular batch fabric using a loading device or a textile yarn winding apparatus in which the mandrel 290 uninterrupted by a motor 291 is rotated, but without displacement, and the circular guide pad 292 back and forth along the mandrel axis, driven by a cam or a spindle 294 , shot by a motor 293 , The tuning of the engines 291 and 293 ensures regulation of the textile product structure. The pin rings of 11B may be omitted by providing paragraphs 295 and 296 for engaging the yarn at the reversal points and by keeping the skew angle low relative to the heel. This is a variation of in 11B shown device, which can allow the production of fabrics of the invention with a slight modification of existing mandrel systems.

13 shows a device used to make a continuous fabric, wherein the two yarn groups are parallel and perpendicular to the direction of movement of the laying down belt. One group of yarns is supplied as a plurality of subgroups each comprising a plurality of yarns in a warp direction, and another group of yarns is supplied as a plurality of subgroups each comprising a plurality of yarns in a weft direction. A plurality of spaced ultrasonic bonding webs interconnect the upper and lower subgroups. The weft yarns are produced by a method and apparatus similar to those described in U.S. Pat US 4030168 to Cole, which is incorporated herein by reference.

In 13 becomes a device 500 shown for laying down subgroups of yarns 502 . 504 . 506 and 508 in the machine direction (MD) and joining them to subgroups of yarns 510 . 512 . 514 and 516 in the cross machine direction (XD) on a conveyor surface 517 to continuously form a prebonded fabric structure 518 to shape. The subgroups of yarns 502 . 504 . 506 and 508 Be guided by guides that stretch across the area 517 extend, such as a guide rod 503 for the subgroup 502 on the conveyor surface 517 guided. The guides, such as the guide bar 503 , may include rollers each having circumferential guide grooves (not shown) for acting as single yarn guides to guide each of a plurality of yarns spaced above the guide between the opposite edges of the conveyor surface to the subassembly of yarns with respect to other MD yarns laid down on the conveyor surface. The guides, such as the guide bar 503 , may also include a group of spaced eyelets on a pole to guide each of a plurality of yarns in the subgroup of the group disposed in the machine direction. The subgroups of yarns 510 . 512 . 514 and 516 are looped along the two opposite edges of the belt 517 such as loop guides 505 on the near side and 507 on the far side to lead the subgroup 510 on the conveyor surface 517 guided. The loop guides have spaced yarn holders or clamps (not shown) to maintain the spacing relationship between the yarns in the sub-group of the group arranged in the XD direction. The retainers or clamps would release the yarn after it is laid down on the fabric support surface of the conveyor and on any MD yarns already placed thereon. Preferably, the XD yarns are not released by the clamps until they are engaged by the next MD yarns. In some cases, the MD yarns may be placed under tension and be able to provide sufficient support for the XD yarns so that a separate support surface is not required. An alternative to the illustrated endless conveyor surface may be a circular drum support surface as long as the yarns can be adequately held on the surface during rotation of the drum, such as MD yarn tension or vacuum. The conveyor would be powered and would be similar to the one in FIG 6 described conveyor an applied vacuum. The textile product 518 is solidified and connected by a plurality of spaced connectors which are in one position 520 be arranged to be a continuous fabric 522 to form the invention. A leadership role 524 pushes against a transport role 526 To ensure the fabric safely without slipping on the conveyor surface 517 drive. The subgroup 502 comprises a thinly spaced plurality of yarns arranged at a repeatable cell pitch and directly onto a conveyor surface 517 be placed. The subgroup 504 comprises a thinly spaced plurality of yarns also arranged at the same cell pitch and about a yarn position (into the drawing) to the subgroup 502 are offset, the subgroup 506 comprises a thinly spaced plurality of yarns which are arranged at the same pitch and both to 502 as well too 504 are offset, and the subgroup 508 comprises a thinly spaced plurality of yarns arranged at the same cell pitch and to all subgroups 502 . 504 and 506 are offset. The subgroup 510 comprises a thinly spaced plurality of yarns, all yarns such as the yarns 526 and 528 , with a repeatable cell spacing 530 are arranged, this distance for the gap of all yarns in the other subgroups 512 . 514 and 516 the same is. This gap determines the number of possible yarn positions for the yarns in the subgroups 510 . 512 . 514 and 516 ,

• (a) Bereitstellen einer länglichen Textilerzeugnis-Auflagefläche, die eine Längsachse und einander gegenüberliegende Seitenkanten hat, wobei eine Maschinenrichtung (MD) in der Richtung der Längsachse definiert wird und eine Maschinenquerrichtung (XD) zwischen den einander gegenüberliegenden Seitenkanten definiert wird,
• (b) Niederlegen einer Vielzahl von Garnuntergruppen, die in der MD ausgerichtete Garne haben, auf der Auflagefläche, wobei jede Untergruppe an mit Zwischenraum angeordneten Positionen längs der Längsachse niedergelegt wird, wobei die Garne in jeder MD-Untergruppe an versetzten Positionen angeordnet ist, die sich in der XD von anderen MD-Untergruppen unterscheiden,
• (c) Niederlegen einer Vielzahl von Garnuntergruppen, die in der XD ausgerichtete Garne haben, auf der Auflagefläche, wobei jede Untergruppe an mit Zwischenraum angeordneten Positionen längs der Längsachse niedergelegt wird, eine XD-Untergruppe mit Zwischenraum zu einer jeweiligen MD-Untergruppe angeordnet, wobei die Garne in jeder XD-Untergruppe an versetzten Positionen angeordnet ist, die sich in der MD von anderen XD-Untergruppen unterscheiden,
• (d) Bewegen der Auflagefläche in einer vorher festgelegten, mit der Längsachse ausgerichteten Richtung, um die von allen MD- und XD-Untergruppen niedergelegten Garne zusammenzubringen, um einen Stapel zu formen,
• (e) Zusammendrücken der Untergruppen und Verbinden der obersten Untergruppe in dem Stapel mit der untersten Untergruppe in dem Stapel, um dadurch eine verwebte Textilerzeugnisstruktur zu formen.

This controlled spacing and offset is best seen when the subgroups come together to form a fabric structure. The yarns in the subgroup 510 are at 532 arranged with a cell spacing, the yarns in the subgroup 512 are to subgroup 510 at a repeatable offset 534 offset and are at 536 arranged with the cell spacing, the yarns in the subgroup 514 are to the subgroup 512 by a repeatable offset 538 offset and are at 540 arranged with the cell spacing, and the yarns in the subgroup 516 are to the subgroup 514 by a repeatable offset 542 offset and are at 544 arranged with the cell spacing. These yarns are in the order of the subgroup 510 up to the subgroup 516 shown in a position pattern of 0/4, 1/4, 2/4 and 3/4. This sequence could be different depending on the pattern and the desired structure, such as 0/4, 3/4, 1/4 and 2/4. The same sequence variations are regardless of the patterns in the subgroups 510 to 516 also in the subgroups 502 . 504 . 506 and 508 possible. Sheets and other fibrous materials can be inserted between yarn subgroups as shown in FIG 6 was proposed. Generally speaking, the method just described for forming a woven fabric structure includes:

• (a) providing an elongated fabric support surface having a longitudinal axis and opposite side edges, wherein a machine direction (MD) is defined in the direction of the longitudinal axis and a cross machine direction (XD) is defined between the opposite side edges,
• (b) depositing a plurality of yarn subgroups having MD aligned yarns on the support surface, each subgroup being deposited at spaced positions along the longitudinal axis, the yarns in each MD subgroup being located at staggered positions differ in XD from other MD subgroups,
• (c) depositing a plurality of yarn subgroups having yarns aligned in the XD on the laydown surface, each subgroup being deposited at spaced positions along the longitudinal axis, an XD subgroup spaced from a respective MD subgroup, wherein the yarns in each XD subgroup are located at staggered positions that differ in the MD from other XD subgroups,
• (d) moving the support surface in a predetermined direction aligned with the longitudinal axis to bring together the yarns deposited by all the MD and XD subgroups to form a stack,
• (e) compressing the subgroups and connecting the top subgroup in the stack to the bottom subgroup in the stack to thereby form a woven fabric structure.

A variation of in terms of 13 described method is the two mutually perpendicular and adjacent subgroups, such as the subgroups 502 and 510 Pre-assemble to form a scrim. The four scrims 502 / 510 . 504 / 512 . 506 / 514 and 508 / 516 would be linked to the above-described dislocations between subgroups to produce the same fabric structure. The pre-assembled subgroups could be temporarily mounted to the scrims with a size adhesive removed after final assembly and joining of the top and bottom subgroups, or the bonds between the pre-assembled subgroups could be retained in the finished fabric structure.

The flexible fabric of the present invention can be described with reference to 15 to 18E be made directly into a three-dimensional shape. A flexible fabric can be made directly in the form by placing each subgroup directly on a shaped surface. 15 shows an example of the use of a generalized donor system to produce the fabric. A generalized actuator, in this case a robot 401 with six degrees of freedom, carries a single yarn donor 402 , similar to the one in 20 shown, to the desired positions and alignments to a yarn 403 on a shaped spike 404 lay down. The robot may also carry a plurality of yarn dispensers for simultaneously depositing a plurality of spaced yarns onto the formed mandrel.

For a general form, each group of yarns will include yarns that are curved in space. Preferably, adjacent yarns in the group are generally parallel and the yarns of a group densely cover the area of the surface area bounded by the outermost yarns of that group, a given group may not necessarily cover the entirety of the desired final shape. 16A shows a top view of the mandrel, 16B and 16D show outages and 16C an isometric view. With reference to the figures, tracks are 410 curved space in space for a subgroup of a group of yarns on a spherical mandrel 411 , This subgroup train 410 consists of bows 412 . 413 . 414 . 415 . 416 . 417 . 418 . 419 . 420 . 421 . 422 . 423 , connected by connectors 424 . 425 . 426 . 427 . 428 . 429 . 430 . 431 . 432 . 433 . 434 , 16B clearly shows how the connectors the arcs of the subgroup track 410 connect, such as the connector 424 that the bow 412 with the bow 413 combines.

The orientation of the subgroup tracks 410 in relation to the thorn 411 is given by two angles: a rotation about the Z-axis 435 and a tilt around the XY plane 436 , Around the angle 435 to find, is at the beginning of the arc 412 at one point 437 bottom right in 16D began. It becomes a tangent vector 438 defined, extending along the arc 412 in 16D to the left to the first connector 424 moved. The orientation of this tangent vector at Y = 0 is in 16D in the vector 439 who is also in 16A can be seen, shown. The angle 435 is defined as the angle of the positive X-axis 442 to the vector 439 , in the top view 16A which is -90 degrees for the case shown. The subgroup tracks 410 are at the XY level 440 at an angle 436 inclined, which in the case shown is +75 degrees. The angle 436 is inclined at less than 90 degrees to ensure that the yarns at the equator of this spherical mandrel intersect in a crossover relationship from subgroup to subgroup, rather than being nearly parallel if the angle 436 at 90 degrees.

17A to 17D show two other subgroup tracks 450 and 451 generated by rotating the subgroup lanes 410 around the Z axis. The top view angle, the angle 435 corresponds to + 30 ° for the web 450 and is + 150 ° for the track 451 , In this example, the three groups of subgroups are equally spaced, with the top view angle 435 the train 450 + 120 ° from the railway 410 is off and the top view angle 435 the train 451 -120 ° from the track 410 out amounts. The number of groups and the necessary angles 435 and 436 for each group can be changed to ensure the required structural properties of the formed fabric.

The subgroup railway 410 defines the skeleton of webs for the entire group of yarns in this general direction. Other subgroups in this group can be found by placing yarns in staggered positions along the surface, generally parallel to the thin yarns of the skeleton 410 , In general, the subgroups of a directional group are not simply shifted versions of each other, as in the flat case, they have slightly different shapes. Other subgroups for the yarns in the other group directions 450 and 451 can be found by similarly offsetting the subgroup tracks 450 and 451 along the surface of the spine for those general directions.

18A to 18E illustrate a summary and completion of what with reference to the yarn paths of 16A to D and 17A until D was discussed. 18A to 18E show the yarn progression from a single subgroup into 18A to the first subgroups of three groups in 18B , to the first two subgroups of three groups in 18C , to the first three subgroups of three groups in 18D , to four subgroups of three groups in 18E which in this case densely cover the desired surface area to form a shaped fabric structure 452 to shape. In this example, the yarns in each subgroup are spaced 4 yarns apart, and each subgroup is offset by a single position from the previous group. A similar process may be used for groups with different numbers of yarns (about 3 to 8 yarns) separating the yarns in each subgroup or a different dislocation sequence for successive subgroups (about 0/4, 2/4, 114, 3/4) the sequence shown 0/4, 1/4, 2/4, 3/4).

Every family of subgroup tracks 410 . 450 or 451 Making up each of the three groups of yarn paths does not have to cover the entire desired final surface area, and they do not have to resemble each other as in this example. For a general shape with less symmetry, the different groups will not be similar. One can choose as many groups in as many general directions as necessary to cover the desired surface area such that there are at least two sets of intersecting yarns at each point and the crossing angle is sufficient to meet the mechanical properties requirements of the textile product. 18E shows that the flexible fabric structure 452 triaxial areas 460 that have three yarn directions, with biaxial areas 461 which can have two yarn directions, can connect.

To fabricate the fabric can (with reference to 15 . 16A to D and 17A to D) the generalized actuator is taught or programmed to donate yarn along the subset groups defined for each subgroup. The dispenser can donate a single yarn by sequentially traversing the sheet 412 , then the connector 424 , then the bow 413 , then the connector 425 etc., then the bow 422 , then the connector 434 , then the bow 423 , Alternatively, a donor can use all bows 412 . 413 . 414 . 415 . 416 . 417 . 418 . 419 . 420 . 421 . 422 . 423 donate at the same time in one go. Alternatively, a dispenser may select selected numbers of the sheets, such as the sheets 412 . 413 . 414 to donate in one go and the remaining bows in successive passes of the bows 415 . 416 . 417 , after that 418 . 419 . 420 and then 421 . 422 . 423 complete, using some or all of the connectors 424 . 425 . 426 . 427 . 428 . 429 . 430 . 431 . 432 . 433 . 434 , As an alternative to laying down yarn in the panels of the connectors, the yarns may be trimmed at the end of one sheet and reattached to the mandrel at the beginning of the next sheet. In this way, yarn from subsequent subgroups would not accumulate on the connector webs.

Subgroups in the other directions may be taught by teaching or programming the robot along these paths, or in certain symmetrical cases, such as this, by rotating the mandrel about the Z axis 441 at the desired angle 435 and repeating the program for the web 410 be laid down. Generally, however, unbalanced shapes would be sequential Subgroups are independently taught or programmed, as they are not simple offsets of the trajectory 410 for the first subset of the first group.

During the Donation longitudinally These webs is a thread tension control important to the yarn up the generally curved Keep track. Excessive tension will cause that Yarn significant of the desired Course deviates. Preferably, a temporary, either mechanical or Adhesive, help on the spine surface and on previous yarns Subgroups used to keep the yarn on the desired path. To the For example, a pressure-sensitive adhesive may be applied initially to the Spiked and sprayed onto each successive yarn subgroup, to assist in keeping the applied yarns in place. to further support On each subgroup, a roll can be used to coat the adhesive Threads on the spine and press each other. These aids can be found in the finished fabric remain or after the final bonding step be removed.

Of the final Step is the last subgroup to be placed in each area, the top subgroup, at the crossings between the two Subgroups with the first subgroup to be placed in this subgroup Area, the lowest subgroup, to connect. In general the top and bottom subgroups are arranged so that they face each other cross. Because each group does not necessarily cover the entire surface (but covered a substantial section that is larger than 1/3 and preferably greater than 1/2 of the fabric area is) can the top and bottom subgroups have different subgroups of different groups in the triaxial and biaxial areas. It is also possible by connecting the top and bottom yarns with yarns in between Subgroups arranged in a variety of spaced Positions yarns in the top subgroup with yarns in the bottom Subgroup connect, rather than exact immediate connections between the yarns of the top and bottom subgroups. One such method has been described in describing the flat fabric product structures discussed.

Generally speaking, the above process produces a three-dimensional, shaped, woven fabric structure, comprising:
a stack of a first plurality of subgroups, a second plurality of subgroups, and a third plurality of subgroups, each subgroup having yarns spaced apart to define a thin coverage of a fabric area, the yarns are generally parallel, and the yarns follow a curved path in space,
wherein the stacked subgroups are arranged in a predetermined grouping with respect to a common axis and a common reference plane perpendicular to the axis,
wherein the first subgroups are disposed at a first angle in relation to the reference plane and positioned at a first rotational angle about the axis, the second subgroups are disposed at a second angle in relation to the reference plane and positioned at a second rotational angle about the axis third subgroups disposed at a third angle in relation to the reference plane and positioned at a third rotational angle about the axis, wherein the yarns in any one of the first, second and third subgroups, the yarns in another of the first, the second and the cross third subgroups,
wherein, within the first, second and third plurality of subgroups, the yarns of one subgroup are offset from the yarns of the other subgroups, thereby forming a group of yarns for each of the respective subgroups, the group denoting a fabric surface for any respective subgroup covered,
wherein the top subgroup in the stack is connected to the bottom subgroup in the stack to thereby form a three dimensional, shaped, woven fabric structure.

The fabric of the invention may also be wound on a composite rectangular parallelepiped shape, with reference to FIG 19A to produce Biaxial three-dimensional fabric structures. 19A shows a composite rectangular mandrel 300 , which is the general configuration of the desired shape, which in this case would be a short-sleeved shirt. The mandrel may be a solid form made of connected rectangular parallelepiped pieces, such as a hull piece 310 and a shoulder piece detachably connected to rods or screws or clips (not shown) 312 , The dome may also be a frame structure outlining the shape or an extendable / retractable structure to facilitate removal of the finished fabric.

To handle the shape of the ease of fabric molding and to handle them around three axes To rotate, there are three pairs of gripper devices, which are arranged in a frame surrounding the mandrel (not shown). A suitable framework for supporting the grippers for turning and shifting and a control motor for driving them may be provided by a person skilled in the art and will not be discussed further here. With reference to 19A is a first pair of opposing grippers 302 and 303 arranged to the thorn 300 for rotating about a first mandrel axis 314 to wear. A second pair of opposing grippers 304 and 305 is arranged to the thorn 300 for rotating about a second mandrel axis 316 to wear. With reference to 19B can the thorn 300 opposite the position in 19A reoriented by 90, and the second pair of opposing grippers 304 and 305 is arranged to the thorn 300 for rotating about a third mandrel axis 318 to wear. Each pair of grippers can be moved in the direction of rotation and in the axial direction toward and away from each other, that is, the gripper 302 can become the grapple 303 turn back and forth and move in the axial direction, and the gripper 303 can also become the grapple 302 turn back and forth and move in the axial direction.

In 19A have the grippers 304 and 305 both moved in the axial direction to the ends of the mandrel piece 312 to engage the thorn 300 around the axis 316 to turn. The surface of each gripper of the pair which engages the ends of the mandrel may be coated with a high friction elastic surface to securely grasp the mandrel and any fabric deposited there, or may be covered with pins or needles to engage the ends of the spine and the fabric. There is a first yarn guide 306 to a first yarn 307 around the axis 316 on the thorn 300 to wrap. The leadership 306 is made by a rotating threaded rod 320 for a transverse movement parallel to the axis 316 worn and propelled. The rod is supported by simple supports and is driven by a control motor, not shown. The rotation of the mandrel gripper 304 / 305 and the pole 320 is through a control unit 321 tuned so that the yarn 307 in one turn the gripper 304 / 305 by one cell spacing 322 along the spine 300 moves to a first thread subgroup in the direction 324 to lay down on the thorn. After covering the mandrel with a yarn subgroup, the winding stops, and the grippers 302 and 303 take the mandrel and gripper 304 and 305 retire. The grippers 302 / 303 turn the mandrel 90 degrees and stop, the grippers 304 and 304 engage the spine again, and the grippers 302 and 303 retire. This brings the cathedral into the 19B shown position.

With reference to 19B have the grippers 304 and 305 both moved in the axial direction to the sides of the mandrel piece 312 to engage the thorn 300 around the axis 318 to turn. The first yarn guide 306 is now arranged to the yarn 307 around the axis 318 on the thorn 300 to wrap. The leadership 306 is now through the rotating threaded rod 320 for a transverse movement parallel to the axis 318 worn and propelled. The rotation of the mandrel gripper 304 / 305 and the pole 320 is tuned so that the yarn 307 in one turn the gripper 304 / 305 by one cell spacing 332 along the spine 300 moves to a first thread subgroup in the direction 334 to lay down on the thorn.

When winding yarn around the axis 3L8 of the thorn 300 To lay down the yarn in the lower arm of the shirt form on the mandrel, a special Garnablenker is used, which is best in 19D to see which is a side view of the spine and the in 19B shown gripper is. If the thorn 300 is rotated, at one point lies the yarn 307 along the dashed path 336 and over a forearm 338 of the thorn. At this point, the Garnablenker moves 340 from a retracted position 342 to an extended position 344 and put the yarn in the forearm, where an insert 346 having temporary fasteners, such as hooks or glue, engaging the yarn and holding it in place in the forearm. After that the distractor returns 340 quickly to the retracted position 342 back, and the thorn continues to turn, and the yarn continues to lay down. If the mandrel continues to turn and the other forearm 348 near the distractor 340 comes, this cycle is repeated, and the deflector puts the yarn in the forearm 348 where it passes through a temporary fastener insert 350 is engaged.

With reference to 19C have the grippers 302 and 303 both moved in the axial direction to the ends of the mandrel 300 to engage him around the axle 314 to turn, and the grippers 304 and 305 have withdrawn. The area of each gripper of the pair 302 / 303 which engages the ends of the mandrel may be coated with a high friction elastic surface to securely grasp the dome and any fabric deposited there, or may be covered with pins or needles to secure the ends of the mandrel and the mandrel Textile product to be engaged. There is a second yarn guide 326 to a second yarn 328 around the axis 314 on the thorn 300 to wrap. The leadership 326 is made by a rotating threaded rod 330 for a transverse movement parallel to the axis 314 worn and propelled. The rotation of the mandrel gripper 302 / 303 and the pole 330 is tuned so that the yarn 328 in one turn the gripper 302 / 303 by one cell spacing 333 along the spine 300 moves to a first thread subgroup in the direction 335 to lay down on the thorn.

• – der Dorn wird, wie in 19B, durch die Greifer 304/305 ergriffen, und das Garn 307 wird an einer Ecke 352 des Dorns befestigt,
• – die Greifer 304/305 drehen den Dorn 300 um die Dornachse 318, und das Garn 307 wird durch Bewegen der Führung 306 verschoben, um einen Zellenabstand von 332 zu erzielen,
• – das Garn wird etwa an Position 354 angehalten und wird abgeschnitten und an dem Dorn befestigt,
• – die Greifer 302/303 nehmen den Dorn 300 in Eingriff, und die Greifer 304/305 ziehen sich, wie in 19C, zurück, und das Garn 328 wird an einer Ecke 356 des Dorns befestigt,
• – die Greifer 302/303 drehen den Dorn 300 um die Dornachse 314, und das Garn 328 wird durch Bewegen der Führung 326 verschoben, um einen Zellenabstand von 333 zu erzielen,
• – das Garn 328 wird etwa an Position 358 angehalten und wird abgeschnitten und an dem Dorn befestigt,
• – die Greifer 304/305 nehmen den Dorn 300 in Eingriff, und die Greifer 302/303 ziehen sich, wie in 19A, zurück, und das Garn 307 wird an einer Ecke 360 des Dorns befestigt,
• – die Greifer 304/305 drehen den Dorn 300 um die Dornachse 316, und das Garn 307 wird durch Bewegen der Führung 307 verschoben, um einen Zellenabstand von 322 zu erzielen,
• – das Garn 307 wird etwa an Position 362 angehalten und wird abgeschnitten und an dem Dorn befestigt,
• – die Greifer 302/303 nehmen den Dorn 300 in Eingriff, und die Greifer 304/305 ziehen sich zurück, und die Greifer 302/303 drehen den Dorn zu der Position in 19B,
• – die Greifer 304/305 nehmen den Dorn und die Greifer 302/303 ziehen sich, wie in 19B, zurück, und das Garn 307 wird nahe der Ecke 352, mit Ausnahme einer um einen, zwei oder drei Garndurchmesser gegenüber der Position 352 versetzten Position, befestigt,
• – das Garn wird an der versetzten Position noch einmal um die Dornachse 318 gewickelt und wird abgeschnitten und nahe der Position 354 befestigt,
• – die Greifer 302/303 nehmen den Dorn 300 in Eingriff, und die Greifer 304/305 ziehen sich, wie in 19C, zurück, und das Garn 328 wird nahe der Ecke 356 des Dorns, mit Ausnahme einer um einen, zwei oder drei Garndurchmesser gegenüber der Position 356 versetzten Position, befestigt,
• – das Garn wird an der versetzten Position noch einmal um die Dornachse 314 gewickelt und wird abgeschnitten und nahe der Position 358 befestigt,
• – die Greifer 304/305 nehmen den Dorn 300 in Eingriff, und die Greifer 302/303 ziehen sich, wie in 19A, zurück, und das Garn 307 wird nahe der Ecke 360 des Dorns, mit Ausnahme einer um einen, zwei oder drei Garndurchmesser gegenüber der Position 360 versetzten Position, befestigt,
• – das Garn wird an der versetzten Position noch einmal um die Dornachse 316 gewickelt und wird abgeschnitten und nahe der Position 362 befestigt,
• – der obige Vorgang setzt sich fort, wobei um eine gegebene Dornachse gewickelte nachfolgende Garne gegenüber vorhergehenden Garnen versetzt werden, bis der Dorn dicht mit den vier Untergruppen von Garnen in den drei Richtungen bedeckt ist. Auf einer gegebenen Seite des Dorns wird es Garne nur in zwei Richtungen geben, wodurch auf jeder Seite eine biaxiale Textilerzeugnisstruktur geformt wird,
• – auf jeder Seite des Dorns wird die äußerste Untergruppe von Garnen mit der innersten Untergruppe von Garnen verbunden, wo die äußersten Garne die innersten Garne kreuzen, durch Anwenden eines Ultraschalltrichters nur an den Überkreuzungen, wobei der Dorn als Ultraschallamboß wirkt. Alternativ dazu könnte eine Vielzahl von mit Zwischenraum angeordneten Ultraschalltrichtern in einer diagonalen Bahn im Verhältnis zu den Richtungen des Garns auf dieser Seite über jede Seite des Dorns verschoben werden, ähnlich dem, was bei den flachen Textilerzeugnisstrukturen gelehrt wurde,
• – nachdem das Verbinden vollendet ist, kann der Dorn von den Greifern entfernt werden, und die Ärmelenden des Textilerzeugnishemds können aufgeschnitten und das Dornstück 312 von dem Stück 310 gelöst und das Stück 312 aus der aufgeschnittenen Ärmelöffnung geschoben werden,
• – das Taillenende des Textilerzeugnishemds kann aufgeschnitten und das Dornstück 310 aus der aufgeschnittenen Taillenöffnung geschoben werden,
• – die abgeschnittenen Textilerzeugnisenden können entfernt werden oder können verwendet werden, um Aufschläge an den Ärmeln und der Taille des Hemds zu formen.

To make a densely-covered mandrel using four subgroups of yarns in each of the three dimensions, the following sequence of operations is preferable, although other sequences are possible:

• - the thorn becomes, as in 19B , through the gripper 304 / 305 grabbed, and the yarn 307 will be on a corner 352 attached to the thorn,
• - the grippers 304 / 305 turn the spike 300 around the mandrel axis 318 , and the yarn 307 is by moving the guide 306 moved to a cell spacing of 332 to achieve,
• - The yarn is about in position 354 stopped and is cut off and attached to the mandrel,
• - the grippers 302 / 303 take the thorn 300 engaged, and the grippers 304 / 305 tighten, as in 19C , back, and the yarn 328 will be on a corner 356 attached to the thorn,
• - the grippers 302 / 303 turn the spike 300 around the mandrel axis 314 , and the yarn 328 is by moving the guide 326 moved to a cell spacing of 333 to achieve,
• - the yarn 328 is about position 358 stopped and is cut off and attached to the mandrel,
• - the grippers 304 / 305 take the thorn 300 engaged, and the grippers 302 / 303 tighten, as in 19A , back, and the yarn 307 will be on a corner 360 attached to the thorn,
• - the grippers 304 / 305 turn the spike 300 around the mandrel axis 316 , and the yarn 307 is by moving the guide 307 moved to a cell spacing of 322 to achieve,
• - the yarn 307 is about position 362 stopped and is cut off and attached to the mandrel,
• - the grippers 302 / 303 take the thorn 300 engaged, and the grippers 304 / 305 retreat, and the grapple 302 / 303 turn the mandrel to the position in 19B .
• - the grippers 304 / 305 take the thorn and the grapple 302 / 303 tighten, as in 19B , back, and the yarn 307 gets near the corner 352 , except for one, two or three yarn diameters relative to the position 352 staggered position, attached,
• - The yarn is at the staggered position again around the mandrel axis 318 wrapped and is cut off and close to the position 354 fixed
• - the grippers 302 / 303 take the thorn 300 engaged, and the grippers 304 / 305 tighten, as in 19C , back, and the yarn 328 gets near the corner 356 of the spike, except for one, two or three yarn diameters from the position 356 staggered position, attached,
• - The yarn is at the staggered position again around the mandrel axis 314 wrapped and is cut off and close to the position 358 fixed
• - the grippers 304 / 305 take the thorn 300 engaged, and the grippers 302 / 303 tighten, as in 19A , back, and the yarn 307 gets near the corner 360 of the spike, except for one, two or three yarn diameters from the position 360 staggered position, attached,
• - The yarn is at the staggered position again around the mandrel axis 316 wrapped and is cut off and close to the position 362 fixed
• The above process continues with trailing yarns wound around a given mandrel axis being offset from previous yarns until the mandrel is densely covered with the four subgroups of yarns in the three directions. On a given side of the mandrel, there will only be yarns in two directions, forming a biaxial fabric structure on each side,
• On each side of the mandrel, the outermost subgroup of yarns is joined to the innermost subgroup of yarns, where the outermost yarns intersect the innermost yarns, by applying an ultrasonic funnel only at the crossings, the mandrel acting as an ultrasonic anvil. Alternatively, a plurality of spaced ultrasonic horns could be slid in a diagonal path relative to the directions of the yarn on that side across each side of the mandrel, similar to what has been taught in the flat fabric structures.
• - After the bonding is completed, the mandrel can be removed from the grippers, and the sleeve ends of the textile fabric shirt can be cut open and the thorn piece 312 from the piece 310 solved and the piece 312 be pushed out of the cut-open sleeve opening,
• The waist end of the fabric shirt may be cut open and the thorn piece 310 be pushed out of the cut waist opening,
• - The cut off fabric ends can be removed or used to form cuffs on the sleeves and waist of the shirt.

Using the above technique, garments of three-dimensional fabric can be readily made using relatively simple mandrels. By winding a bidirectional yarn about three axes of the mandrel in a simple manner, a three-dimensional textile can be produced product without cutting and sewing separate textile product pieces, as in the prior art. This produces unique fabric garments without seams.

19E illustrates the yarn pattern, seen at one corner of the spine at the end of a sleeve at the corner 364 as it is in 19A you can see. The spine axes are at 366 designated. Several of the first subgroup of yarns, around the mandrel axis 318 are denoted by 1, more of the second subgroup of yarns being around the mandrel axis 314 are laid down, are designated 2. Several of the third subgroup of yarns, around the mandrel axis 316 are laid down, are designated 3. The subgroups are named in the order in which they are placed on the spine. For subgroups above three, only one yarn is designated in the subgroup to illustrate the pattern that develops on the mandrel. The group of yarns that are around the mandrel axis 318 are denoted by the number 1 for the first subgroup, the number 4 for the fourth subgroup, the number 7 for the seventh subgroup, and the number 10 for the tenth subgroup. The group of yarns that are around the mandrel axis 314 are denoted by the number 2 for the second subgroup, the number 5 for the fifth subgroup, the number 8 for the eighth subgroup, and the number 11 for the eleventh subgroup. The group of yarns that are around the mandrel axis 316 are denoted by the number 3 for the third subgroup, the number 6 for the sixth subgroup, the number 9 for the ninth subgroup and the number 12 for the twelfth subgroup. Although yarns are wrapped around three axes of the mandrel, the yarns form on the mandrel side 368 a biaxial structure, forming the yarns on the spine side 370 a biaxial structure and form the yarns on the spine side 372 a biaxial structure.

• (a) Bereitstellen einer rechteckigen Parallelepiped-Textilerzeugnis-Auflagefläche, die in drei senkrechten Achsen drehbar ist, wodurch drei senkrechte Garnniederlegerichtungen X, Y und Z definiert werden,
• (b) Niederlegen einer ersten Untergruppen von Garnen, so daß sie die Auflagefläche in der X-Richtung dünn bedeckt,
• (c) Niederlegen einer zweiten Untergruppen von Garnen, so daß sie die Auflagefläche in der Y-Richtung dünn bedeckt und einen Stapel mit den Garnen in der X-Richtung bildet,
• (d) Niederlegen einer dritten Untergruppen von Garnen, so daß sie die Auflagefläche in der Z-Richtung dünn bedeckt und einen Stapel mit den Garnen in der X-Richtung und der Y-Richtung bildet,
• (e) Wiederholen des Niederlegens und Stapelns für jede der ersten, der zweiten und der dritten Untergruppe und Versetzen der Garne in nachfolgenden Untergruppen gegenüber allen Garnen in vorherigen Untergruppen, bis jede der Vielzahl von Untergruppen eine Gruppe von Garnen in der jeweiligen Richtung für diese Untergruppe bildet, welche die Dornoberfläche dicht bedeckt,
• (f) Verbinden der obersten Untergruppe in dem Stapel mit der untersten Untergruppe in dem Stapel, wodurch eine geformte verwebte Textilerzeugnisstruktur geformt wird.

The points 374 and 376 on the website 368 show some typical bond points between the outermost subgroup 11 and the innermost subgroup 1. The points 378 and 380 on the spine side 370 show some typical bonding points between the outermost subgroup 12 and the innermost subgroup 2. The points 382 and 384 on the spine side 372 show some typical bond points between the outermost subgroup 12 and the innermost subgroup 1. Generally speaking, the method just described for forming a woven fabric weave structure comprises:

• (a) providing a rectangular parallelepiped fabric support surface rotatable in three perpendicular axes defining three perpendicular yarn laydown directions X, Y and Z,
• (b) laying down a first subgroup of yarns so that it thinly covers the bearing surface in the X direction,
• (c) depositing a second subset of yarns so that it thinly covers the bearing surface in the Y direction and forms a stack with the yarns in the X direction,
• (d) depositing a third subset of yarns so as to thinly cover the bearing surface in the Z direction and form a stack with the yarns in the X direction and the Y direction,
• (e) repeating lay down and stacking for each of the first, second and third subgroups and offsetting the yarns in subsequent subgroups from all yarns in previous subgroups until each of the plurality of subgroups selects a group of yarns in the respective direction for that subgroup forms, which the thorn surface tightly covered,
• (f) joining the top subset in the stack to the bottom subset in the stack, thereby forming a shaped woven fabric structure.

EXAMPLES

EXAMPLE 1

A fabric product structure was made of a 710 denier sheath-core yarn total including a 400 denier core of nylon 6,6 denier continuous filaments of 6 denier per filament. The core was wrapped with a sheath of staple fibers comprised of a nylon 6,6 copolymer containing 30 weight percent of units derived from MPMD (2-methyl-pentamethylenediamine) having a lower melting point than the core polymer , The staple fibers wound on the core were a 3.75 cm (1.5 inch) staple length and 1.8 dpf. This yarn was produced on a "friction spinning machine DREF 3", manufactured by the textile machinery factory Dr. Ernst Fehrer AG of Linz, Austria The fabric structure had 16, as in 2A arranged, subgroups and was placed on a device such as in 11B wound. The fabric cell spacing contained 8 yarns. The bonds were made circumferentially using a Model No. 351 Autotrak Model No. 35 manufactured by Dukane Co. which operated at 40 kHz with a force of about 1.8 to 2.2 kg (4 to 5 pounds) against the dome has been. The funnel speed along the mandrel was such that about 0.2 joules of ultrasonic energy per bond was applied to the fabric. The bondlines were spaced about 0.51 cm (0.2 inches) apart and the funnel tip was about 0.25 cm (0.1 inches) wide and 1.9 cm (0.75 inches) long, with a slightly concave surface over the dimension of 0.1 inches for about 1.3 cm (0.5 inches) in length. At the concave end of the bond area, there was a rounding to clear the front corner, and the concavity followed the rounding. Due to the rounding of the mandrel, the funnel did not make complete contact along the 1.9 cm (0.75 inch) dimension. The funnel produced strongly bonded areas at the edges of the concave surface. It is believed that with a narrower funnel of about 0.10 cm (0.04 inch) width with a flat bonding surface instead of a concave, an improvement in bonding would be realized.

To In the bonding, the textile was removed from the thorn and in a direction parallel to a group of yarns a tensile test subjected. By multiplying the yarn strength of 2.1 kg (4.6 pounds) by 32 yarns per 2.5 cm (inch) was calculated to be the maximum theoretical tensile strength of this fabric without all bonds 2.59 N / cm (148 lbs / in). The bonded textile product The invention had an actual Grave resistance from about 120 pounds / inch. It is believed that the sheath-core yarn is replaced by primary Melting of the lower melting shell bonded, while the Core filaments remained substantially unimpaired, so that the strength of the textile product due to the bonding is not significantly reduced has been. Another attempt was made with nylon 6,6 multifilament yarn of 630 denier produced without the low melting shell structure Fabric was the theoretical tensile strength of the unbonded Fabric 61.7 N / cm (370 pounds / inch), and the actual bonded Grave resistance was 210 N / cm (120 pounds / inch). This showed a significant reduction in Strength for the bonded multifilament yarn compared with the strength reduction with the bonded low-melting envelope. The low-melting Case offers a significant improvement in strength when ultrasonic bonding is used to connect the yarns.

EXAMPLE 2

A fabric structure with limited permeability was made by inserting film webs into the fabric structure during manufacture. A pattern was made using continuous 630 denier multifilament yarn wrapped on the device of 11B and bonded with the ultrasound system described in Example 1. The fabric cell spacing contained 8 yarns. The film web was about 3 to 5 mils thick Bynel polypropylene film. The fabric was made by laying first two subgroups on the mandrel, followed by a film web, followed by 12 yarn subgroups, followed by another film web, followed by 2 yarn subgroups. Thereafter, the fabric was bonded in the manner of Example 1. The fabric was removed from the mandrel, and when tested by blowing air at the fabric, it was found that very little air passed through the fabric and this occurred only in the bonded area.

EXAMPLE 3

A reinforced fabric structure was made by adding a web of spunbond fabric to the structure during manufacture. The yarn was the same yarn as in Example 2. The nonwoven was a low melt copolymer polyamide weighing about 33,9 g / m ² (1 ounce / square yard). The fabric was made in the manner of Example 2. Fourteen sets of yarns were wound on the mandrel, the nonwoven web was laid on the mandrel and two sets of yarns were wrapped over the nonwoven fabric. The fabric was bonded in the manner of Example 1. The fabric was removed from the mandrel and found to have improved strength and reduced deflection in the skew direction.

EXAMPLE 4

A preform for a composite panel was made using a non-thermoplastic yarn and thermoplastic film webs. The yarn was a continuous multifilament aramid (Kevlar ^™ ) flat yarn of 840 denier. The film web was a 2 to 3 mil thick polyester film. The fabric was made in the manner of Example 2. Two sets of yarns were wound onto the mandrel, followed by one sheet of film, followed by four sets of yarns, followed by one sheet of film, followed by four sets of yarns followed by one sheet of film, followed by four sets of yarns, followed by one sheet of film, followed by two sets of yarns for one Total of 16 thread subgroups and four foil paths. The film accounted for about 15% of the weight of the fabric. The fabric was bonded in the manner of Example 1. The fabric was removed from the mandrel and found to have adequate integrity for handling as a composite preform.

EXAMPLE 5

It a textile product was made with a cotton spunbonded fabric inserted during manufacture, to produce a fabric that would be soft to the touch. The yarn was the same as used in Example 2. The cotton was one to one Tissue of about 8x11 Inches and about 0.5 ounces / square yard of weight-molded sliver. The fabric was made in the manner of Example 2. Eight yarn subgroups were wound on the mandrel, followed by the cotton fabric, followed by eight yarn subsets. The textile product was bonded in the manner of Example 1, and it was found that it a soft coherent one Structure had, but it could be longitudinal of the cotton fabric are separated. It is believed that the integrity of the structure by adding from some nylon 6,6 staple fiber or a low melting copolymer nylon 6,6 staple fiber to the Cotton spunbond by blending prior to making the cotton fabric could be improved. It is believed that this improve the bonding of the nylon yarns to each other through the cotton fabric would.

EXAMPLE 6

It became a fabric structure with natural fibers as inner subgroups and thermoplastic fibers produced as first and last subgroups. The structure used 8 lay-up yarns with 28 subgroups. The natural cotton yarns had a fineness of 1600 denier while the thermoplastic ones Yarns were nylon 6,6 with a total fineness of 630 denier. The Laydown sequence was as follows: the first subgroup was nylon 6,6, the next 26 subgroups were cotton, and the last subgroup was Nylon 6,6. After that, the structure was made by tracing the web each Yarns in the last subgroup bonded to the ultrasound funnel, being longitudinal the longitudinal was bonded to any overlap to bond the first and the last subgroup

EXAMPLE 7

A fabric structure was made of Dacron ^™ yarns (1.3 dpf, 255 denier in total) consisting of repeating groups of subgroups. The fabric consisted of a two-ply fabric structure in which the one ply is a stack of two groups of subgroups forming a densely covered area and the other ply is an identical group of subgroups forming a second dense area. The resulting fabric has a basis weight corresponding to a fabric consisting of the same number of total subgroups that were parallel but offset, with no subgroups one above the other, but was more voluminous in feel and appearance.

For comparison, three separate fabrics were made to explore the effect of different manufacturing techniques on the finished fabric volume. All fabrics were made using the above yarn, which was incorporated into 16 guides in the ring of the device of 11B was attached. All fabrics were bonded using the same circumferential bonding method of Example 1. The fabric A was composed of two groups of yarns, which have a combined total of 18 subgroups, and with 9 yarns per cell space to a fabric of 33.9 g / m ² (1 ounce / square yard) to manufacture. The fabric B consisted of two groups of yarns, which have a combined total of 36 subgroups, and with 18 to produce yarns per cell space to a fabric of 67.8 g / m ² (2 ounces / square yard). The yarns in fabric B were packed more densely in the same cell space than the yarns of fabric A were. The fabric C consisted of a two-ply fabric structure wherein a first ply such as the fabric A was formed and then a second ply such as the fabric A was formed on top of the first ply to make a fabric having a combined sum of 36 yarn subsets Fabric of 67,8 g / m ² (2 ounces / square yard). The two layers were first bonded after both layers were wound on the mandrel. The 3 fabrics were removed from the mandrel and examined visually and by hand for volume. The fabric A appeared to have the least volume, the fabric C had the most volume, the fabric B had a volume level between those of the fabric A and the fabric C. It was surprising that packing more yarn into a cell space produced more volume (Comparison of fabric A and fabric B) and that the two-ply structure with the same amount of yarn produced more volume (comparison of fabric B and fabric C). Since all fabrics were bonded the same way, this indicated that yarn package and layering can also be used to control the volume.

EXAMPLE 8

It Mixed samples were made using two-stranded bulked 2500 denier continuous filament nylon 6,6 carpet yarn 19 denier per filament and using staple nylon 6,6 carpet yarn. The bonding energy for This very fine yarn can handle up to 1 to 2 joules per yarn intersection be at ultrasonic energy. There were also mixed patterns made using textured polyester yarn of 150 denier, 0.75 denier per filament. It was also by hand flat and three-dimensional patterns made using of rope or cord from 0.3 cm to 0.6 cm (1/8 to 1/4 inch) in diameter and plastic hands for joining the yarns where the outermost subgroups intersect.

The Fabric product structure of the invention can be used in a variety of ways, including manual and automated means, either on a batch or in one pass, and using a wide one Variety of yarns and fasteners are produced.

Claims (8)

Interwoven fabric product structure, the following comprising: a Variety of first yarn subgroups with a variety of in one first angular direction free of cross-aligned yarns, wherein the first yarn subgroups form a stack with a Variety of second yarn subgroups with a variety of in a second angular direction aligned free of crossings yarns the yarn being substantially parallel in each subgroup Lanes following, in a repetitive pattern with space arranged to each other to a common predetermined Fabric surface sparse to cover, with the yarn subgroups alternately with a first Subgroup are stacked next to a second subgroup, where the yarns in the first subgroup the yarns in the second subgroup cross, the yarns in any subgroup of the Variety of first subgroups versus the yarns in all others Subgroups of the first plurality of subgroups are offset, in which the yarns in any subgroup of the plurality of second ones Subgroups opposite the yarns in all other subgroups of the second variety of Subgroups are offset, being stacking all of the variety from first subgroups forms a first group of yarns, the yarns contains which ones cover the predetermined fabric area tightly, and that Stacking all of the plurality of second subgroups a second Yarn group containing yarns which are the predetermined ones Fabric surface tightly cover, and with the yarns in the top subgroup in the stack with the yarns in the lowest subgroup in the Stack are connected to thereby the other subgroups in the Containing stacks in a woven fabric structure. Interwoven fabric structure according to claim 1, which includes: one Stack of a first plurality of subgroups, a second Plurality of subgroups and a third plurality of subgroups, wherein each subgroup has yarns spaced apart from one another are arranged so that they a sparse one Cover covering a fabric area, the yarns general parallel and the yarns follow a curved path in space, in which the stacked subgroups in a predetermined grouping in relation to a common axis and a common reference plane are arranged perpendicular to the axis, being the first subgroups arranged at a first angle in relation to the reference plane and are positioned at a first angle of rotation about the axis, the second subgroups arranged at a second angle with respect to the reference plane and positioned at a second angle of rotation about the axis, the third subgroups at a third angle with respect to Reference plane arranged and at a third angle of rotation about the axis with the yarns in any of the first, the second and the third subgroups the yarns in another the first, second and third subgroups, in which within the first, second and third plurality of subgroups the yarns of one subgroup over the yarns of the other Subgroups are offset, thereby for each of the respective subgroups to form a group of yarns, with the group for any respective subgroups densely covered a fabric area, in which the top subgroup in the stack with the lowest subset in the stack, thereby forming a three-dimensional, shaped, to make woven fabric. A three-dimensional molded, woven fabric structure according to claim 2, wherein the complete The fabric surface has a biaxial portion of the portion of that surface consisting of two pluralities of subgroups of the first, second or third subgroups, and a triaxial portion of the surface consisting of three pluralities of subgroups of the first, second or third subgroups. The fabric structure of claim 1, wherein the Connections between the top subgroup of the structure and the lowest subgroup of the structure either directly or through the yarns in other subgroups, such that a compound between crossing points of yarn groups at 0.3% to 80% of yarn Male occurs in which the yarns intersect. The fabric structure of claim 1, wherein separate unconnected regions of the compounds are such that the inherent flexibility maintaining the yarns in the structure in the unconnected areas becomes. The fabric structure of claim 1, wherein the Yarns in a subgroup of a group are turned over to to become the yarns in a subgroup of another group and to cross them. The fabric structure of claim 1, wherein a Film or a nonwoven web between two adjacent subgroups is arranged within the structure. Method for producing a woven fabric structure, comprising: resign a first yarn subgroup containing a plurality of in a first Has angular direction free of cross-aligned yarns, the yarns in the first subgroup being substantially parallel Trajectories follow in a repetitive pattern with space arranged to each other, so that they have a common before fixed textile product area sparse cover, Stack a second thread subgroup next to the first Garnuntergruppe, wherein the second yarn subgroup a variety of aligned in a second angular direction free of crossings Yarns, with the yarns in the second subgroup being essential parallel tracks follow in a repetitive pattern are arranged with space to each other so that they have a sparsely cover common predetermined fabric area, Continue alternately stacking a plurality of first yarn subgroups and a plurality of second yarn subgroups, the following substeps full: Offset the variety of yarns in any one Subgroup of the multiplicity of first subgroups opposite to the Yarns in all other subgroups of the first variety of subgroups and depositing all the yarns in one of the first plurality of subgroups before laying down the yarns in another subgroup; Offset the plurality of yarns in any subgroup of the plurality from second subgroups the yarns in all other subgroups of the second plurality of subgroups and depositing all the yarns in one of the second plurality of subgroups before laying down the yarns in another subgroup; Stop of stacking when all of the plurality of first subgroups one form the first yarn group containing yarns which are the predetermined ones Fabric surface tightly cover, and when stacking all the variety of second Subgroups forms a second yarn group containing yarns which cover the previously designated area of textile product tightly; and Connect the yarns in the top subgroup in the pile with the yarns in the bottom subgroup in the stack, thereby the others Contain subgroups in the stack and a woven fabric structure to build.