EP0819188B1 - Method of weaving a three-dimensionally shaped fabric zone - Google Patents

Abstract

PCT No. PCT/EP96/01397 Sec. 371 Date Dec. 15, 1997 Sec. 102(e) Date Dec. 15, 1997 PCT Filed Mar. 29, 1996 PCT Pub. No. WO96/31643 PCT Pub. Date Oct. 10, 1996A process and apparatus for weaving a fabric with a three dimensional bulging zone, which is formed by increasing the density of the crossing points of the warp and weft threads so as to naturally impart a bulging zone in the fabric. The density is changed by changing the number of threads and/or changing the weave pattern. The lengths of the warp threads can also be increased in the bulging zone. In a preferred embodiment, the threads include a material which is settable by thermal or chemical treatment, and such that upon being set a three dimensional rigid matrix is formed which includes the non-settable threads as a reinforcement. The apparatus for carrying out the process takes the form of a loom having the capability of individually drawing off selected lengths of the warp threads from a warp supply, and a jacquard head for forming the weaving sheds and which has a control for changing the number of threads woven and/or the weave pattern.

Description

The invention relates to a method for weaving a three-dimensional Tissue zone according to the preamble of claim 1.

Such a method is known from DE 39 15 085. In this known processes, the warp threads on the fabric formation edge subtracted at different speeds. This creates the three-dimensional arched tissue zone by increasing the spacing of the Weft threads, i.e. reduction in the number of crossing points. The 3D shape this tissue zone is not stable and the tissue structure depends on the 3D shape.

Other methods of weaving three-dimensional tissue shells work by varying the distances between the warp threads (US Pat. No. 3,132,671; EP 0302012 A1).

These known methods are based on the principle of bulging Tissue zone by increasing the thread spacing, i.e. by reducing it the number of crossing points per unit area. Therefore point the three-dimensional domed zones have a loosened structure so that possibly there is a network-like structure. For further processing is the Such areas have insufficient resistance to displacement. The physical, specifically the mechanical properties are different from other tissue areas reduced and not homogeneous in all directions.

Another method for the direct production of a three-dimensional Shell geometry weaves a cone as a two-layer surface. Subsequently the cone is cut out of the warp thread sheet and unfolded (Rothe, H., Wiedemann, G .; Deutsche Textiltechnik 13 (1963) pp. 95-101).

The invention has for its object to the above disadvantages avoid. It is supposed to be an arbitrarily three-dimensionally shaped tissue zone arise, their structures - regardless of the three-dimensional shape (3D shape) - can be specified and set as desired, in particular with regard to density and homogeneity in the warp and in the weft direction. In front the 3D shape should be stable.

This object is solved by claim 1.

A fabric is primarily defined by the number of its crossing points and the number of its binding points. The number of crossing points per unit area results as the product of the number of warp threads and the number of weft threads in this unit area. A point of intersection is understood as a point of intersection at which the warp threads involved have changed between the upper and lower shed.
According to this invention, the number of binding points in the three-dimensional tissue zone is changed. It is possible to work in smaller zones with constant take-off speeds of the warp threads passing through the fabric zone that are the same over the fabric width.
However, the take-off speeds of the warp threads passing through the fabric zone are preferably varied, ie: increased, for example in order to avoid the formation of pre-cloths (claim 2).
In order to compensate for the resulting increase in the spacing of the weft threads, that is to say a reduction in the number of crossing points, the formation of the 3D shape according to claim also results in an increase in the binding point density (claim 3).

The invention makes it possible not just a three-dimensional one Weave tissue zone, but at the same time the structure of this tissue zone by influencing, i.e.: increasing or decreasing the number of Binding points per unit area and - within limits also the number of Crossing points per unit area - to be controlled as required. This allows a wealth of parameters to be influenced, e.g. Strength, Elongation behavior, sliding resistance, fabric thickness, air resistance, Permeability and filtration properties to liquids, optical Effects (translucency, translucency).

The three-dimensional fabric is characterized by an adjustable Basis weight. Seams or double layers to hide Seams are not necessary. The fabric has a high mechanical Resilience because the density and homogeneity of the threads is adjustable and the threads are not damaged by subsequent stretching or overstretching are. Also a subsequent change in shape due to shrinkage of the threads due to frozen tensions is avoided. The bulge is through Calculation can be precisely specified and reproduced exactly. There is no waste and the process has high productivity.

The invention is based on the idea of three-dimensional bulging in a tissue through the targeted use of different bond point densities, i.e. different looping frequencies between To produce warp and weft. This is achieved by changing the Type of binding and / or by including or removing additional ones Threads.

In contrast to all previously known techniques, the generation of the three-dimensional fabric curvature takes place before the goods are taken off, irrespective of the number of crossings, ie: the number of warp threads and weft threads, namely through the arrangement of the warp and weft threads. An increase or decrease in the bond point density per unit area or an increase or decrease in the number of wraps leads to an increase in the surface of the tissue zone. A reduction in the bond point density per unit area leads to a reduction in the surface area. A tissue zone with a larger surface bulges inwards or outwards in relation to the rest of the tissue surface to form a three-dimensional shell. It is possible to enlarge the surface so much that cylindrical or even more elevated side areas of the three-dimensional tissue zone are formed.
If the zone under consideration has a reduced surface area compared to the enclosing zone, then the enclosing tissue arches around this zone.

The change in the type of binding and the addition or removal of threads can be combined with each other, be it to adjust the bulge, be it to adjust the tissue density in the tissue zone.

It has already been pointed out that an adjustment of the weft thread spacing expedient by changing the take-off speed of the warp threads can be. In addition to the spacing of the weft threads, the lateral distances between the warp threads can be varied. This training of The method of claim 2 has particularly in the very steep 3-D areas the purpose, the lateral spacing of the warp threads and / or weft threads distribute in a targeted manner in order to create freedom for the distribution of To gain attachment points. Warp threads and weft threads can thus over the Vault are distributed so that they follow certain stress zones. The faster removal of the warp threads in the places where a Larger surface is created, prevents pre-cloth formation. As a result of that The lateral distance of the warp threads can be controlled, targeted thread courses can be combined with 3D geometries generated by binding technology, like e.g. the mechanical requirements for a reinforced fabric Demand plastic component.

As stated, the spacing of the weft threads is adjusted by generating different take-off speeds of the warp threads.
The spacing of the warp threads is adjusted by controllable reeds. A fan-like reed is known as an example, in which the reed bars (rungs) diverge like a fan from the lower or upper longitudinal center of the reed. Weaves of this type have previously been used to influence the width of a fabric, in particular a woven tape, by changing the warp thread spacing (see: International Textile Bulletin p.2 / 1993). For this purpose, these fan-shaped reeds are moved more or less suddenly. According to the invention, the movement is essentially continuous and adapted to the desired changes in the 3-dimensional shape of the tissue.
Another example is a reed with controllably displaceable reed bars (DE-OS 41 37 082).

It is desirable that the resulting tissue be in both directions (Warp and weft) despite different distances between the crossing points is homogeneous. The method according to claim 3 serves this purpose. In each direction can now avoid network-like areas of the tissue and the physical Tissue properties are affected. This compensates for the bond point density or - what is the same - the number of wraps is not only different crossing distances along a warp thread, but also across it, i.e. along a weft.

The number of integrated warp threads and / or weft threads can thereby be varied so that individual warp threads or groups of warp threads on the Specialist training in areas of tissue does not participate, so the warp threads or weft threads only in other areas, in particular the 3-dimensional Areas that are involved, but float to the side of it. The warp threads that do not take part in the technical training remain preferably positioned in the sub-compartment so that the floating lengths of the Do not hang weft threads down into the weaving machine.

According to the invention it is therefore provided that in areas of the fabric which are formed three-dimensionally, the number of warp threads and / or weft threads incorporated varies or that a different type of binding is provided. In both cases, the process can be carried out using a multi-shaft machine. Machines with up to 24 shafts are in use today. By hanging in different shafts and controlling the shafts differently, it can be achieved that the groups of warp threads guided in different shafts participate in the shed formation in different ways.
It is particularly useful for this purpose to use a jacquard machine, by means of which all the warp threads can be raised and lowered individually according to the program for the purpose of forming the shed between the upper and lower shed.

The measure according to claim 4 warp threads as well Weft threads bound in certain areas of the fabric, floating in others she. Where the warp threads or weft threads are bound, enlarged in any case the density of the tissue, but possibly also that The surface of the fabric and, conversely, the density of the Fabric less, but possibly also the surface of the fabric smaller where the threads float.

The use of a shuttle loom offers the advantage that it depends from the width of the three-dimensional fabric zone - the weft threads only be entered in the three-dimensional tissue zone and in the do not float the remaining tissue areas (claim 5). These additional threads largely have the same effect as the floating threads mentioned above with the difference that their thread length to the width of the considered Tissue zone is aligned. Subsequent cutting is no longer necessary of partially long protruding thread ends. Farther the amount of material to be used is reduced because of the reduced Waste waste.

A very large number of threads can be found in the three-dimensional fabric zone are additionally involved according to the method of claim 6. To do this multilayer fabrics are produced. In the field of three-dimensional Tissue zones become threads from a dissolved or thinned out layer of tissue transferred and integrated into the fabric layer, which the determined three-dimensional shape of the tissue zone. The fabric density remains So essentially the same, since the number of threads included stays the same. However, the possibility of three-dimensional curvature becomes considerably enlarged by the large number of additional threads for the three-dimensional tissue zone is available.

The method of claim 7 is particularly effective to achieve a three-dimensional tissue zone. It allows a modified, ie: in general: a greater density of the binding points or a larger number of thread wraps to be used in the fabric zone than in the surrounding fabric zone.
The distance between two adjacent threads (eg warp threads) is influenced by how often the threads of the respective crossing thread system (eg weft threads) pass between them, since the threads are pressed apart at a wrap or tie point. The more passages or tie points per unit area, the greater the distances between the threads. In a plain weave, for example, the distances are maximum due to the highest binding point density, in a simple twill weave they are smaller and in a long floating satin weave they are even smaller. If an at least partially enclosed tissue zone with increased binding point density per unit area is produced in a fabric with a low binding point density per unit area, a three-dimensional shell shape is already created due to the larger surface area of this fabric zone. This method facilitates the creation of three-dimensional fabric curvatures in that the pre-blanket formation can be controlled at selectable points and only this pre-blanket has to be compensated for by generating different take-off speeds. There is no need to include additional threads. The homogeneity or other structural properties of the fabric can thus be controlled independently of the geometry of the fabric.

By changing the type of weave and / or the number of threads of the incorporated threads, the method according to the invention firstly results in the formation of a three-dimensional fabric zone; on the other hand, the changed crossing point distance of the three-dimensional tissue zone can be compensated; In addition, there are also advantageous design options for the textile, mechanical or physical properties of the fabric zone.
Through these designs according to claim 8 wide technical applications are opened up.
Strength, elongation behavior or sliding resistance, among other things, can also be set depending on the direction in the warp or weft direction. This is particularly advantageous if mechanical stresses are defined for a fabric, such as in the case of a load-bearing housing made of fiber composite materials.
With the help of the binding and filling thread techniques described above, the fabric structure, fabric thickness and local wall thickness can be adapted to mechanical requirements.
The fabric is suitable as a filter material for air, gas and liquid filters, as permeability and filtration are adjustable and independent of the geometry of the three-dimensional fabric zone.
Optical effects such as patterns can also be set independently of the geometry of the three-dimensional fabric zone, where not only technical properties of the seamless three-dimensional fabric are important, but also an attractive appearance and pattern.

The three-dimensional tissue zone can also be part of a hollow body. For this purpose, the tissue zone can be connected to a surface with a flat or another three-dimensional tissue zone, for example by sewing or gluing. This operation is replaced in favor of an automated method according to claim 9. Here, a fabric is woven from at least two layers, which are guided separately in the area of the three-dimensional fabric zone and are only brought together again behind the three-dimensional fabric zone and are closely connected or integrated with one another. So there is a distance or a cavity between the fabric layers. Such cavities are advantageous, for example, if individual layers of fabric are to shift or move away from one another during further processing or during use. The structure proposed here no longer has to be composed of individual pieces.
The space between the connected layers of tissue would assume a largely arbitrary shape when filled with gas, liquid or bulk material. This is avoided according to claim 10. Here, binding warp threads are warp threads that are partially floating in one or the other fabric layer in regular or irregular alternations and have a predetermined length. These binding warp threads are subjected to tensile stress when the cavity is inflated with gas, liquid or bulk material and thus limit the local distance between the two fabric layers. The distances between the layers of fabric lying one above the other can therefore be adjusted by the floating length of the binding warp threads. As a result, the two fabric layers can have defined spacing profiles. It is particularly advantageous here to simultaneously use the binding warp threads as filler threads to control the three-dimensional shape and / or fabric density. The three-dimensional fabric zone can seamlessly enclose a large part of the airbag envelope.
The production of two fabric layers, which are connected by binding warp threads and are incorporated alternately between the upper and lower layers as spacers, is known, for example, from the production of velvet. There, these binding warp threads serve as pile threads after the fabric layers have been separated.

Such a double fabric is advantageous as an air bag Avoidance of injuries in motor vehicle accidents applicable. By the length and tensile stress of the binding warp threads is the shape of the inflated air bags so limited that the driver or passenger Explosion does not hit his face and injures him (claim 23). The airbag according to the invention contains significantly less seams than previously. Above all, the total weight of the airbag is reduced Places where a person hits the airbag.

When filling with a liquid, solid, bulk-like or foaming (expanding) material or with a hardening liquid or when the bloated tissue is impregnated with a hardening liquid can be used to produce bodies with a fabric covering without seams become. (Claim 11).

The threads used for the method according to the invention can consist of natural materials, especially linen, cotton, hemp, jute etc. exist. It can also be synthetic threads. Because the three-dimensional Shape is made by weaving in one operation the threads do not need to be plastically deformable or only slightly. For such materials are the methods and proposed according to the invention Products are particularly cheap because they are initially very low in deformability of the material no longer during the creation of a bulge affects.

The three-dimensional design can be strengthened and promoted by the measure according to claim 12. The curvature, which can be cylindrical or hemispherical, for example, is thus within a two-dimensional tissue environment, the two-dimensional environment enclosing the curvature in a ring completely or partially.
The two-dimensional tissue environment can then be completely or partially cut away or recycled. Such a structure can in particular be designed as a hat, the two-dimensional ring-shaped fabric surrounding the three-dimensional, for example hemispherical or cylindrical, curved fabric zone serving as a brim.
Versatile forms of such a tissue zone result in particular from claims 13 and 14.
The fabric zone designed as a hemisphere or spherical zone is particularly suitable for parts of clothing items which are adapted to the shape of the body during weaving according to the weaving method of this invention and subsequently have no disruptive seams in the region of the arch.

An important area of application for such tissues are orthopedic and medical support tissues that seamlessly fit a body part, e.g. Head, Align chin or foot. Such seamless support fabrics with adjustable Densities are particularly beneficial when the tissue is used for support of parts of the body must remain firmly on the body for a long time (e.g. after a broken jaw or skull). The support tissues also cause prolonged wear no pressure marks.

Another important area of application is parts of the outer clothing, the Underwear or swimwear, especially for women. So can a spherical shell-shaped tissue zone in the chest area as a support or as Part of the bra can be used. This support has the advantage that no seam and no metal reinforcements are needed anymore prolonged wearing are uncomfortable and press. Claim 20.

Elongated fabric profiles can also be formed. A practical one Application of such a tissue zone is a sail that is in one Area receives the shape of a wing profile. Otherwise they are omitted usual seams, so that the current fits better on the sail and the Energy is better implemented because there is less turbulence. claim 22.

Another important area of application is filter cloths. This creates the Advantage that a seamless, homogeneously designed filter surface with the desired three-dimensional shape and with certain filtration properties for the passage or retention of substances and / or Particles are produced.

Finally, the method can be used to produce self-supporting shells, vessels, containers or the like with a fabric reinforcement, which are used either as such or as reinforcing inserts for plastic bodies and plastic profiles. In the simplest case, such a shaped body can be produced according to claim 18.
According to claim 15 or 16, in particular in the embodiment according to claim 17, such a molded body is produced in a simple manner in only one or two operations -weaving and thermal treatment-.
As fiber reinforcements, such three-dimensional fabric zones and moldings have the advantage that they are constructed homogeneously and with uniform quality without deep-drawing or cutting work. The weight distribution of fibers and matrix materials is already predetermined by the production of the fabric.
A fabric zone in the embodiment according to claim 13 can serve primarily as a fiber reinforcement for a hub of a wheel or for a rim.

Shell-shaped fiber reinforcements according to this invention are suitable for containers or crash helmets or safety helmets.
Such a container can contain two such tissue zones which are attached to the inside and outside of the matrix of the helmet. Since the fiber reinforcement according to this invention has neither seams nor has to be adapted to the three-dimensional helmet shape by overlapping several flat layers, and the fiber guidance is therefore not interrupted anywhere, especially not on the front or head sides, the fiber reinforcement holds the despite the small amount of material Loads stood. Since manual intervention is hardly necessary in the production process, the fiber insert can always be produced in the helmet shell with the same and pre-calculated quality and position.
The invention thus ensures the production of three-dimensional fabrics with freely selectable geometries and closed surfaces or surfaces that can be adjusted to different requirements. Geometries and thread structures can be freely controlled using the existing binding devices. In particular, freely programmable, electronically controlled jacquard machines in the configuration according to claim 26 are a suitable means for carrying out the method according to the invention. The control programs entered allow the precise reproduction of predetermined tissue curvatures with predetermined tissue structure as often as desired.
The embodiment of the weaving machine according to claim 27 serves for additional variation of the warp thread distances.
The quality of the fabric also depends in particular on the uniformity or the precise setting of the warp thread tensions. This uniformity or precise setting can only be achieved with the embodiment according to claim 28.
This design has its particular meaning in combination with claim 29, which allows the warp thread tensions to be controlled individually according to the program and to be adapted to the rest of the control in order to achieve the 3D shape of the fabric.

Fig. 1

eine Webmaschine,

Fig. 2

als Detail die Bremseinrichtung,

Fig. 3

als Detail die Positionierung der Kettfäden,

Fig. 4

die Positionierung der Kettfäden durch Schraubenfeder,

Fig. 5

die Kettfädenführung mit/ohne Positioniereinrichtung,

Fig. 6

das Programm- und Steuerschema,

Fig. 7

eine Gewebezone mit erhöhter Bindepunktdichte pro Flächeneinheit, umgeben von einer Zone mit geringerer Bindepunktdichte pro Flächeneinheit,

Fig. 8

Schnitt und Bindungspatrone einer Leinwandbindung,

Fig. 9

Schnitt und Bindungspatrone einer Köperbindung,

Fig.10

Schnitt und Bindungspatrone einer Atlasbindung,

Fig.11

Verwendung streckenweise eingebundener Zusatzfä den,

Fig.12

Schnitt und Bindungspatrone einer Leinwandbindung ohne gespeicherte Fäden,

Fig. 13

Schnitt und Bindungspatrone eines zweilagigen Gewebes mit einem Zusatzfaden zwischen jedem zweiten Schuß- und Kettfäden,

Fig. 14

Schnitt und Bindungspatrone eines zweilagigen Gewebes mit einem Zusatzfaden für jeden Schuß- und Kettfäden,

Fig.15

Schnitt durch eine Bindung mit flottierenden Fäden,

Fig.16

eine gewebte Halbkugel,

Fig. 17

Vortuchbildung,

Fig.18

ein Segel, und

Fig.19

ein sackförmiges Gewebe.

The invention is explained in more detail below on the basis of exemplary embodiments with the aid of drawings. Show it:

Fig. 1

a loom,

Fig. 2

as a detail the braking device,

Fig. 3

as a detail the positioning of the warp threads,

Fig. 4

the positioning of the warp threads by coil spring,

Fig. 5

the warp thread guide with / without positioning device,

Fig. 6

the program and control scheme,

Fig. 7

a tissue zone with increased binding point density per unit area, surrounded by a zone with lower binding point density per unit area,

Fig. 8

Cut and binding cartridge of a plain weave,

Fig. 9

Cut and binding cartridge of a twill weave,

Fig. 10

Cut and binding cartridge of an atlas binding,

Fig. 11

Use of additional threads integrated in places,

Fig. 12

Cut and binding cartridge of a plain weave without stored threads,

Fig. 13

Cut and tie cartridge of a two-layer fabric with an additional thread between every second weft and warp threads,

Fig. 14

Cut and binding cartridge of a two-layer fabric with an additional thread for each weft and warp thread,

Fig. 15

Cut through a tie with floating threads,

Fig. 16

a woven hemisphere,

Fig. 17

Pre-cloth formation,

Fig. 18

a sail, and

Fig. 19

a sack-shaped fabric.

In Fig. 1 a weaving machine is shown with its elements, which are necessary for the implementation of this invention. Individual warp bobbins 1 are presented to the weaving machine. The warp coils 1 are plugged onto gate 16. The warp threads 2 are drawn off the bobbins and then individually guided through the individual elements of the weaving machine. In this application only one warp thread is spoken of; however, it should be noted that this can always mean two or three or a group of warp threads.
First, each warp thread is passed through one of the brakes 3. Each brake can be set individually. This can be done by hand.

2, each brake 3 consists of a saucer 3.1 and a top plate 3.2. Each warp thread 2 is between one such saucer and saucer pulled through. The saucer 3.2 is arranged in a fixed position; the top plate 3.1 is on the plunger of an electromagnet 36 attached and can be set against the saucer 3.2 are pressed. The electromagnets 36 are individually Brake device 14 and brake program 21 (Fig. 6) controlled. Thereby the braking force and the thread tension in the warp threads 2.1 can be different be set. On the other hand, the set is individual Warp thread tension also from the fabric take-off 11 and its individual The take-up speed of each individual warp thread depends on the program steps the brake program unit depending on the pull-off speed of the warp thread. This becomes closer to Fig. 6 explained. As a result, the brakes are individual in the course of the weaving process controllable. It goes without saying that the brakes during Web process are also constantly adjustable.

The jacquard control 4 is used to move the warp threads up and down. Harness threads 18 are suspended in this jacquard control 4. Strands hang on the harness threads 18 and on these eyelets 6. The harness threads and the jacquard control move the eyelets upwards and bring them into an upper position (upper compartment). The eyelets 6 are connected at the bottom with rubber threads 33 - shown in FIG. 3 - through which the eyelets are pulled into a lower position (lower compartment) against the force of the jacquard control.
The strands 19 are small elongated metal tongues, which can be seen in Fig.3. The warp thread positioning device 5 is arranged in front of the eyelets 6. By means of this warp thread positioning device, the harness threads 4 or strands 19 or eyelets 6 are laterally positioned such that the eyelets are at substantially the same distance as the warp threads running through the reed 7 (see below).
Each warp thread is guided behind its brake through an eyelet of the eyelets 6. The jacquard control 4 moves each warp thread independently of the other warp threads into the upper compartment or the lower compartment according to the program of the jacquard program unit 22.
The type of weave of the fabric as well as the number of threads involved depend on the jacquard control, ie on which of the warp threads are moved into the upper or lower compartment in each weft.

The reed 7 is arranged behind the jacquard device.
The reed 7 is a frame in the form of a trapezoid or parallelogram. Between the upper edge and the lower edge parallel to it, the reed bars 8 (rungs) are clamped in such a way that the reed bars strive for a fan shape from the top edge. Such a reed is shown, for example, in DE 39 15 085 A1. Each warp thread is passed through a space between the reed bars 8. The forward movement 15.1 (FIG. 3) of the reed, by means of which the last weft thread is pressed against the fabric edge after each weft, and the return movement of the reed 15.1 is effected by the machine control, for example a crank drive (not shown).
The lateral distance of the warp threads in the reed and behind it is determined by the slow up or down movement 15.2 of the reed (FIG. 3).

The positioning device 5 already guides the warp threads through the eyelets of the jacquard device at the lateral distance specified by the reed.
The up and down movement 15.2 is controlled by the reed control according to a predetermined program.
The weft thread 9 is inserted behind the reed. The weft thread is pulled off, for example, from the weft bobbin 10 and guided through the compartment by means of a gripper. However, any other weft insertion systems are also possible, in particular weft insertion by shooters (weaving ship).

The resulting tissue 12 can be pulled off by individual grippers. A witness tree 11 is used here. The stuff tree 11 is broken down into individual and individually drivable roller segments, ie: rolls of small width. The resulting tissue is clamped between the rollers and the freely rotating counter rollers. The individual roller segments are now individually driven by the trigger control 25 and the trigger program 26 (FIG. 6). To form a flat fabric or a flat fabric region, the roller segments are moved at the same speed after each shot 9. When forming a three-dimensional fabric zone, it is advantageous to move the roller segments after each shot 9 at different speeds.
This gives the warp threads of the fabric zone an individually controllable take-off speed.
A suitable witness tree broken down into segments and its drive is likewise shown and described in DE 39 15 085 A1.
As stated, the brake control is operated synchronously with and depending on the trigger control.
The fabric can then be wound up on the fabric tree 17.

The positioning of the warp threads before entering the reed 7 is shown in detail in FIGS. 3 and 4. From the reed, only the frame and two reed bars 8 are shown. The reed bars 8 diverge from the top edge in a fan shape. Furthermore, only the warp thread 2 is shown, which runs through the space between the reed bars 8 shown.
A set of parallel guide rods 32, which extend essentially parallel to the chain 2, is used to position the strands 19 with eyelets 6 or harness threads. For the sake of clarity, only the guide rod 32 is shown, which serves to guide the strand and the warp thread shown. Like each of the guide rods, this guide rod 32 also projects with its front end into the same space between two reed rods 8 through which the warp thread 2 to be guided in each case also runs. The other end of each guide rod 32 is held by an individual elastic band 34 in the warp direction and by a common elastic band 35 in the weft direction. The common elastic band 35 can be stretched more or less elastically by positioning control 5. As a result, the distance between the fastening points of the guide rods 32 on the elastic band 35 changes. Alternatively, the common elastic band 35 can be replaced by an identically directed guide strip (in the weft direction) on which the guide rods 32 slide. In this case, the positioning of the guide rods is carried out with sufficient accuracy only by the horizontal spacing of the reed rods which guide the front ends of the guide rods. The height-horizontal distance of the guide rods is therefore only determined by the vertical position of the reed, without any further positioning control being necessary.
The common elastic band 35 can also be replaced by a coil spring 35 (FIG. 4). The coil spring extends in the weft direction. With its turns, it reaches between adjacent positioning rods
22. The coil spring 35 is tensioned by the positioning control 5 with force F more or less. This changes the slope of the turns and thus the distance between the rear end of the positioning rods 22.
The distance between the front ends of the guide rods is predetermined by the respective vertical position of the reed 7. Both distances are coordinated with each other by the vertical reed control on the one hand and the positioning control 5 on the other.
Since each guide rod bears against a strand 19 and guides it laterally, the strands are spaced apart from the reed rods 8. As a result, the warp threads run through the reed without substantial deflection. Friction and the occurrence of unwanted thread tension is avoided. The thread tension can be specified solely by braking and pulling off.

Fig. 5 shows a top view of this warp thread guide between the jacquard device and the fabric edge of the fabric 12. Only a few parts of the weaving machine are shown in supervision, namely the reed 7 with reed rods 8, the eyelets 6 of the jacquard control, some warp threads 2 and the Edge of the fabric 12. On the left side the top view with the guiding of the warp threads without a positioning device can be seen. The warp threads are deflected both on the eyelet 6 of the jacquard control and on the rung 8 of the reed 7 if the distance between the warp threads is widened by the fan reed - as shown here as an example.
On the right side, the warp thread guide with positioning device 5 is shown in supervision. The strands and eyelets 6 are held at a distance from one another by the positioning rods 22, which distance corresponds to the distance of the warp threads at the instantaneous vertical position of the reed.
Due to the deflection of the warp threads, which results without the positioning device, an uneven warp thread tension is built up in the warp thread family. It has been found that deviations of the three-dimensional tissue zone from the pre-calculated shape have their cause here. The positioning device also avoids wear and tear on the warp threads.

• das Bremsprogramm 21; durch dieses wird die Bremssteuerung 14 angesteuert. Die Bremsen 3 für jeden Kettfaden 2 können individuell oder in Gruppen oder insgesamt und in Abhängigkeit von den Befehlsschritten des Abzugsprogramms 25 eingestellt werden.
• das Jacquard-Programm 22; durch dieses wird die Jacquard-Steuerung 4 betätigt. Jeder Harnischfaden 16 kann für sich oder in Grupen mit anderen zur Bildung des Oberfachs hochgezogen oder durch den Gummifaden zur Bildung des Unterfachs nach unten gezogen. Das Jacquard-Programm ist so vorgegeben, daß im Laufe der Gewebebildung die Art der Bindung und/oder die Zahl der eingebundenen Fäden entsprechend der vorgesehenen drei-dimensionalen Form der zu bildenden Gewebezone verändert und eingestellt wird.
• das Webblatt-Programm 23; durch dieses wird die Webblatt-Steuerung 24 angesteuert und damit die vertikale Position des Webblattes in Richtung 15.2 vorgegeben. Dadurch wird der seitliche Abstand der Kettfäden und damit die Dichte der Kreuzungspunkte beeinflußt. Gleichzeitig wird die Positionier-Steuerung 5 so gesteuert, daß der seitliche Abstand der Kettfäden vor dem Webblatt demjenigen Abstand entspricht, den die Kettfäden durch die jeweilige vertikale Postion des Webblattes erhalten.
• das Abzugsprogramm 25; durch dieses wird die Abzug-Steuerung 26 angesteuert und damit die Geschwindigkeit der Walzensegmente des Warenabzugs 11 individuell oder in Gruppen oder in ihrer Gesamtheit vorgegeben. Synchron mit den Schritten des Abzugsprogramms erfolgt die Auslösung des Bremsprogramms. Dadurch wird die Bremsung des einzelnen Fadens seiner Abzugsgeschwindigkeit angepaßt.

Fig. 6 shows schematically the interaction of the individual controls and the associated programs. The control of the weaving machine is done by the superordinate weaving program 20. This is predetermined by the three-dimensional fabric that is to be manufactured. The individual program steps of the subordinate programs 21, 22, 23, 25 are called up by the web program. The subordinate programs are

• the brake program 21; this controls the brake control 14. The brakes 3 for each warp thread 2 can be set individually or in groups or in total and depending on the command steps of the draw-off program 25.
• the Jacquard program 22; the jacquard control 4 is actuated by this. Each harness thread 16 can be pulled up by itself or in groups with others to form the upper compartment or pulled down by the rubber thread to form the lower compartment. The Jacquard program is predefined in such a way that the type of weave and / or the number of incorporated threads is changed and adjusted in accordance with the intended three-dimensional shape of the tissue zone to be formed.
• the reed program 23; This controls the reed control 24 and thus specifies the vertical position of the reed in the direction 15.2. This influences the lateral distance between the warp threads and thus the density of the crossing points. At the same time, the positioning controller 5 is controlled so that the lateral distance of the warp threads in front of the reed corresponds to the distance that the warp threads receive from the respective vertical position of the reed.
• the deduction program 25; This controls the take-off control 26 and thus the speed of the roller segments of the take-off 11 is specified individually or in groups or in their entirety. The braking program is triggered synchronously with the steps in the trigger program. As a result, the braking of the individual thread is adapted to its take-off speed.

In order to carry out the invention, a flat tissue which is homogeneous over length and width is first produced. This fabric is characterized by the number of crossing points per unit area, by the number of binding points with a loop of one warp and one weft thread, by the number and length of the floating threads, and - if desired - by the number of fabric layers.
In order now to form a three-dimensional fabric zone 13 - for example according to FIG. 7 ff.-, the weave number, that is to say: the number of weave points with one loop each, is in a zone of the weave, be it on the longitudinal edge or be it in a central region of the web of warp and weft, increased or decreased. This is done by changing the type of weave and / or changing the number of threads involved.
The number of incorporated threads can be increased by floating threads in the flat fabric area or in other fabric layers and thus holding a "supply" from which threads can be "taken" and integrated in the three-dimensional fabric zone. As a result, increased lengths of weft and / or warp threads are incorporated in the fabric zone. As a result, the mutual repulsion of the warp and weft threads changes in this fabric zone and the fabric zone bulges three-dimensionally.
Therefore, with regard to the warp threads, it is advisable to increase or decrease the take-off speed of the affected roller segments of the take-off in order to avoid excess fabric on the take-off.
It should be noted that in the prior art the difference in the speed of the warp threading leads to the three-dimensional bulging of the fabric. This three-dimensional bulge is therefore based on a change in the number of crossing points. It can only be relatively weak; above all, it leads to a "thinning and thinning" of the tissue and is therefore not very stable.
According to the invention, however, the three-dimensional shape is forced on the tissue by changing the bond number and thus by changing its internal structure. The change in the speed of the warp thread pull-off is not the cause of the three-dimensional shape, but merely a secondary possible, but not necessary measure, which is preferably compensated for in terms of the fabric density by a further change in the weave number. It is not necessary to change the speed of the warp thread draw-off, especially in the case of smaller 3D shapes or if the shed is large.
To support and modify the three-dimensional formation of the fabric zone, the warp thread spacing and thus the number of crossings per unit area can also be changed by moving the reed up or down. This measure can also be compensated for with regard to the fabric density by a further change in the weave number.

The change in the type of weave or the number of threads incorporated happens by changing the rhythm of the subject training (up and down movement the jacquard eyelets 6).

Further details are described with reference to FIGS. 7 to 17.

Figure 7 illustrates a fabric that has a tissue zone with increased bond point density (Bond number) encloses. As an example, this is inclusive Fabric in twill weave. The enclosed three-dimensional Fabric zone has a plain weave. The frequency is in this zone the warp / weft wrap over the enclosing one Tissue increased. This pushes the threads further apart and take up a larger surface area than the surrounding body tissue. The canvas-bound zone therefore curves towards the surroundings on or forms a constantly growing scarf during weaving. In the area of this canvas-binding zone, it is advantageous to use the fabric subtract increased speed so that this pre-form does not increase Leads to interference. The intersection points deducted at increased speed would have greater spacing if the plain weave would not increase the number of wraps at the same time. The Plain weave has a compensating effect on the enlargement of the intersection distances.

8 to 10 represent three types of weave, each of which has different looping frequencies and thereby entails different space requirements for the processed threads.
Fig. 8 shows a plain weave, which gives the greatest thread spacing both in the warp and in the weft direction.
In contrast, the twill weave according to FIG. 9 has fewer loops and smaller thread spacings. Without changing the number of threads, this results in smaller fabric areas than with plain weave.
10 brings the threads very close together and therefore requires an even smaller area.
The bond point density of the three bonds shown in FIGS. 8 to 10 decreases from top to bottom in the arrangement of the figures. The different bond point densities per unit area and thus the bond-specific space available are used to maintain closed surfaces in the area of three-dimensional arches and to avoid geometry-related network-like points.

Fig. 11 shows the procedure when using sections integrated additional threads supports a three-dimensional shell geometry or is adjusted to special requirements. Before the bowl arch are in the tissue in a below or above the later arched level lying layer of warp and weft threads that are not in this plane be involved. These are carried at certain points Threads e.g. Warp threads 2.1 in plain weave in the fabric plane / layer to be arched inserted. If the distances between the intersections remain unchanged, displace them those previously bound below or above the level to be arched Now thread the existing threads in the plane and lead to them an enlargement (when threads are removed from this level to a Reduction) of the area size. This process leads to the desired one Bulge. On the other hand, it can also change the properties of the fabric despite changing take-off speeds and changing Crossing point distances can be set, e.g. mechanical behavior, Permeability and sliding resistance.

FIGS. 12 to 14 use three exemplary types of weave to show how three-dimensional shell geometries are built up, filled in and adjusted in structure and density with the aid of multi-layer weave weaves.
A single layer plain weave is shown in FIG. No threads are "stored" in it.
13 contains in a second plane 27 between each second weft 9.2 a weft "additional thread" 9.3 and between every second warp thread 2.2 a warp "additional thread" 2.3. The "additional threads are inserted into the upper layer to form the 3D shape.
14 are each a weft "additional thread" 9.3 and 9.4 and for each warp thread 2.1 and 2.2 each a warp "additional thread" 2.3 and 2.4 are incorporated as a second fabric layer 27 for each weft 9.1 and 9.2.
Depending on how large the curvature should be, more or fewer threads from the additional layer 27 have to be integrated into the fabric plane 28 which is to cause the curvature.
Depending on how large the later intended curvature of the three-dimensional fabric level 28 should be, more or fewer threads must be carried in additional layers 27 until they enter the curved level 28. In addition to the formation of a plurality of additional layers 27, FIG. 15 also shows floating, not tied threads (warp threads 2.1 or weft threads 9.1) which are integrated into the plane / layer 28 to be arched over desired distances, ie fabric zone 13.

16 shows the structure of a woven hemisphere.
16a (left) shows a fabric section according to the prior art, in which no binding technology has been used to compensate for increased crossover point distances or to set certain fabric properties, ie: only the distances between the crossover points have been changed; in the area of the 3D shape, the tissue becomes less dense or mesh-like.
16a (right) shows a tissue section in which additional threads have been integrated into the surface. The density of the fabric does not depend on the 3D shape. In such an embodiment, the fabric can be used, for example, as a breast area or breast support for women's clothing, as a vessel, as a fiber reinforcement for a plastic part, for example a helmet shell.

17 shows the example of additionally integrated weft threads 9 Pretreatment. It is based on the fact that in the three-dimensional Fabric zone by reducing weft spacing and densification of the tissue results in excess tissue. A deduction process which realizes different take-off speeds across the fabric width, is advantageous because it helps to compensate for pre-cloth formation can be.

Fig. 18 shows a sailboat with sail 30 in supervision. On the from The sail bulges in the shape of an airplane wing, facing away from the wind out. This bulge 29 of the sail in the area of the mast 31 is a 3D shape created according to this invention, without seams and subsequent deformation is produced.

Fig. 19 shows the section along a warp thread through a three-dimensional Fabric in the form of a sack. Such a sack can, for example. as an air bag or serve as shaped bodies, the gaseous, liquid, foaming, solid Material or bulk goods is filled. By means of an appropriate tight type of binding and by incorporating many additional weft or warp threads bag-like bulge. However, some warp threads 2.1 are in the area largest bulge not involved. Rather, these warp threads float with relatively high thread tension. Form these floating warp threads thus a movement limitation for the air bag and give the shape in the inflated state before.

REFERENCE SIGN LIST

1

Warp spools

2nd

Warp threads

3rd

Brakes

4th

Jacquard control

5

Warp thread positioning device

6

Eyelets, end eyelets

7

Reed

8th

Reed bars, rungs

9

Weft

10th

Weft

11

Stuff tree, goods deduction

12th

Tissue, goods deduction

13

Tissue zone, three-dimensional tissue zone

14

Brake control

15

Reed movement

16

gate

17th

Winding up

18th

Harness thread, harness cord

19th

Heald, heald

20th

Weaving program

21

Braking program

22

Jacquard program

23

Reed program

24th

Reed control

25th

Deduction program

26

Trigger control

27

Tissue level, tissue layer

28

Fabric plane, 3D fabric layer

29

Bulge

30th

sail

31

mast

32

Management staff, postioning staff

33

Elastic band, elastic thread

34

Elastic band, elastic thread

35

Elastic band, elastic thread, coil spring, guide bar

36

Electromagnet

Claims (27)

1. A method for weaving a three-dimensionally formed fabric zone (13), characterized in that, within the fabric zone (13), the fabric is subjected to a forced change of its inner structure by controlled use of different binding point densities, for thereby generating a controlled three-dimensional bulging of the fabric zone (13), with the number of the binding points being changed by changing the number of tied warp threads (2) and weft threads (9), respectively, and/or by changing the type of the binding.
2. The method according to claim 1, characterized by performing, within the fabric zone (13), in addition to the change of the number of the binding points, a change of the distances of the crossing points in the warp thread direction by generating different take-off speeds of individual warp threads (2), and/or a change of the distances of the crossing points in the weft thread direction by changing the lateral distances of the warp threads (2).
3. The method according to claim 2, characterized in that, within the fabric zone (13), the change of the distances of the crossing points is wholly or partially compensated for by the change of the number of the binding points.
4. The method according to any one of claims 1-3, characterized in that the change of the number of the tied threads is performed in that threads which float in the fabric adjacent to the fabric zone (13), are tied in the region of the fabric zone (13).
5. The method according to any one of the preceding claims, characterized in that the change of the number of the tied threads is performed in that threads are tied in the region of the fabric zone (13) which have their length adapted to the fabric zone (13).
6. The method according to claim 4, characterized in that, in case of multi-layered fabrics, for changing the number of the tied threads in the region of the fabric zone (13) of the fabric layer (28), threads from the fabric layer (27) are transferred into the fabric layer (28) and are tied in the fabric layer (28).
7. The method according to any one of the preceding claims, characterized in that, for changing the number of the tied threads in the region of the fabric zone (13), use is made of a binding type with changed, preferably enlarged, density of the binding points and a correspondingly changed and respectively larger number of thread loops.
8. The method according to any one of the preceding claims, characterized in that the changes of the binding type and/or of the number of the tied threads are performed, in addition to the purpose of a three-dimensional bulging of the fabric zone, also for setting mechanical and/or physical properties of the fabric zone (13), particularly for setting any one of the following properties: strength, elongation behavior or resistance to displacement, fabric thickness, atmospheric resistance, permeability, filtration properties, optical effects such as appearance, permeability to light, patterning, translucence.
9. The method according to any one of the preceding claims, characterized in that the fabric at least in one region of the fabric zone (13) comprises two layers, which layers have a mutual distance and respectively form a hollow space between them.
10. The method according to claim 9, characterized in that so-called binding warp threads (2.1) are tied in a regularly or irregularly alternating manner between the upper and the lower layer with a predetermined floating length.
11. The method according to claim 9 or 10, characterized in that the hollow spaces between the fabric layers are filled by a liquid material, a liquid foamable material or a solid material.
12. The method according to any one of claims 1-11, characterized in that the fabric zone (13) is formed within a two-dimensional fabric, with the two-dimensional fabric enclosing the fabric zone (13) wholly or partially, preferably in an annular configuration.
13. The method according to any one of claims 1-12, characterized in that the fabric zone (13) has the shape of a cylinder which is open on one end side and on the other end side is provided with a flat or semispherical end portion and preferably with a centric opening.
14. The method according to any one of claims 1-12, characterized in that the fabric zone (13) has the shape of a spherical bowl or semi-sphere.
15. The method according to any one of claims 1-14, characterized in that, within the fabric zone (13), threads of a first material and threads of a second material are interwoven with each other.
16. The method according to claim 15, characterized in that the weft threads (9) and/or the warp threads (2) have fibers or threads of a second material admixed thereto, particularly by covering, flocking or mixing.
17. The method according to claim 15 or 16, characterized in that the fibers or threads of the second material are reshaped by thermal or chemical treatment to form a cohesive matrix having the threads of the first material distributed therein.
18. The method according to any one of the preceding claims, characterized in that, for producing a shaped body, the fabric zone (13) is coated and/or soaked with the liquid phase of a curable synthetic material.
19. A shaped body of a synthetic material, particularly a container, a bowl, a helmet shell, a rim, provided with a fiber reinforcement arranged as a fabric with a three-dimensional fabric zone (13), characterized in that the fabric zone (13) is bulged by the controlled use of different varying point densities, with the varying binding point density being obtained by changing the number of tied warp threads (2) and respectively weft threads (9) and/or by changing the type of the binding according to any one of claims 1-17.
20. A woven piece of clothing, particularly a brassiere or breast support or an orthopedic or medical support fabric comprising a three-dimensional fabric zone (13) adapted to the shape of the body, characterized in that the fabric zone (13) is bulged by the controlled use of varying binding point densities, with the varying binding point density being obtained by changing the number of tied warp threads (2) and respectively weft threads (9) and/or by changing the type of the binding according to any one of claims 1-17.
21. A hollow profile comprising a fabric with a three-dimensional fabric zone (13), particularly an air bag, characterized in that the fabric zone (13) is bulged by the controlled use of varying binding point densities, with the varying binding point density being obtained by changing the number of tied warp threads (2) and respectively weft threads (9) and/or by changing the type of the binding according to any one of claims 1-17, and that the fabric zone (13) is connected to a further parallel fabric which particularly in the region of the fabric zone (13) comprises an upper and a lower layer, wherein the layers have a mutual distance and respectively form a hollow space between them, and wherein so-called binding warp threads are tied in a regularly or irregularly alternating manner between the upper and the lower layer with a predetermined floating length.
22. A sail comprising a region (31) provided to bulge out on the side facing away from the wind and to bulge out particularly in the shape of an airfoil profile, characterized in that said region (31) is a fabric zone (13) bulged by the controlled use of varying binding point densities, with the varying binding point density being obtained by changing the number of tied warp threads (2) and respectively weft threads (9) and/or by changing the type of the binding according to any one of claims 1-17.
23. A hat comprising a bowl-shaped three-dimensional fabric zone (13) and a two-dimensional woven brim wholly or partially enclosing the three-dimensional fabric zone (13), characterized in that the three-dimensional fabric zone is bulged by the controlled use of varying binding point densities, with the varying binding point density being obtained by changing the number of tied warp threads (2) and respectively weft threads (9) and/or by changing the type of the binding according to any one of claims 1-17, and is woven to form an integral piece with the two-dimensionally woven brim.
24. A weaving machine comprising a creel (16) with warp bobbins (1) from which the warp threads (2) can be pulled off individually at differently controllable speeds, further comprising a respective brake (3) for each of the warp threads (2), a product take-off device (11) arranged to take off the completed fabric (12) and divided into conveying segments provided to be driven for respectively one warp thread or a group of warp threads (2) separately from each other with a varying and controllable speed; and a jacquard device; characterized in that the jacquard device is provided with a control unit (4) arranged to change the number of tied threads and/or the type of the binding for performing the method according to any one of claims 1-17.
25. The weaving machine according to claim 24, characterized by a distributing means (7) arranged downstream of the jacquard device for continuously controlled adjustment of the lateral warp thread distances, particularly a weaving reed (7) with its reed dents (8) being continuously and substantially steadily adjustable relatively to each other during the weaving process, or a weaving reed (7) with fixed dents (8) which in the vertical direction are arranged to converge in a fan-like manner, with the weaving reed arranged to be moved horizontally and to be moved substantially continuously up and down as well as to be positioned according to the weft thread insertion.
26. The weaving machine according to claim 24 or 25, characterized by a guide means (5) for guiding the warp threads (2) into the guide eyelets (6) of the jacquard device which is controllable in such a manner according to the position of the distributing means (7) that the warp threads (2) pass through the guide eyelets (6) of the jacquard device and through the distributing means (7) without substantial reversal.
27. The weaving machine according to claim 24, 25 or 26, characterized by a brake control unit (14) by which each of the brakes (3) assigned to the individual warp threads (2) is controllable individually in a predetermined manner, preferable according to a program.

Images