WO2014066128A1

WO2014066128A1 - Fan out textile structure

Info

Publication number: WO2014066128A1
Application number: PCT/US2013/065389
Authority: WO
Inventors: Charles A. Howland
Original assignee: Warwick Mills, Inc.
Priority date: 2012-10-22
Filing date: 2013-10-17
Publication date: 2014-05-01

Abstract

A loom that continuously produces a fabric that varies in width over a range of at least 3:2, and preferably 1:2, has a reed with pairs of dividing elements separated by fixed dents, the pairs being separated from each other by variable dents. Warp yarns pass through only the fixed dents, and the variable dents widths are varied as the fabric is woven. Variable dents widths can be adjusted by rotating cams having flat extensions disposed in the variable dents, and/or by using sliders to translationally move the pairs. Alternatively, a variable width fabric is produced by vertically constraining the fibers of a uniform-width fabric, and horizontally compressing the warp fibers at desired locations. In other embodiments, a variable width fabric is produced by dividing a tail section of a uniform-width fabric into strips, and then overlapping the distal ends of the strips.

Description

FAN OUT TEXTILE STRUCTURE

Inventor:

Charles A. Howland

RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 61/716,673, filed October 22, 2012, which is herein incorporated by reference in its entirety for all purposes.

FIELD OF THE INVENTION

[0002] The invention relates to fabric production, and more particularly, to production of fabrics having significant variations in width.

BACKGROUND OF THE INVENTION

[0003] In textile manufacturing, the weaving process has not been able to produce a variable width woven in a continuous process. In particular, it has not been possible using a continuous process to produce a woven having continuous warp yarns that fan out or otherwise include significant changes in width.

[0004] What is needed, therefore, is an apparatus and method for

manufacturing a woven having continuous warp yarns and being variable in width.

SUMMARY OF THE INVENTION

[0005] One general aspect of the present invention is an apparatus configured for producing a textile web or fabric, also referred to herein as a "woven," having a large continuous change in width in the cross machine direction. The ratio of wide section of web or head to the narrow section of the web or tail is greater than 3 :2. In embodiments, the fabric is produced by an apparatus that includes a reed with variable width dents. The warp yarns are passed through pairs of dividing elements in the reed, which are typically wire elements, and the dents between the pairs of wire elements are varied as the fabric is woven. In some of these embodiments, rotating cams are used to rotate flat extensions that are disposed in at least some of the dents, thereby widening or narrowing the dents. In other embodiments, sliders are used to translationally move the pairs of wire elements.

[0006] Another general aspect of the present invention is a method for producing a variable width fabric in a post-processing step by constraining the fibers of a fabric that is initially uniform in width, so that the fibers cannot shift in a direction normal to a plane of the fabric, and then compressing the fibers at desired locations in the warp or weft direction so as to narrow the fabric width at the desired locations.

[0007] Yet another general aspect of the present invention is a method for producing a variable width fabric in a post processing step by dividing a fabric having an initially uniform width into strips, and then overlapping the strips at desired locations so as to narrow the fabric width at the desired locations.

[0008] The head and/or tail of the fabric can be stabilized by weaving or bonding of cross machine yarns using a leno technique, and/or by applying a coating. Warp or weft fibers can be soluble, and can be dissolved by the coating. A heated drawing method can be used to narrow monofilament warp yarns and/or to form necked sections at weft locations on the warp yarns, so that the warp yarns can be more closely packed, thereby reducing the minimum, close-packed fabric width.

[0009] The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims.

Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a functional diagram of an apparatus embodiment of the present invention;

[0011] Figure 2A illustrates a reed in an embodiment that includes cams mounted on sliders, shown in a fully expanded configuration;

[0012] Figure 2B illustrates the reed of Figure 2A in a half-compressed configuration wherein the cams have been rotated but the sliders have not moved;

[0013] Figure 2C illustrates the reed of Figure 2A in a fully compressed configuration where the cams have been rotated and the sliders have been moved closer together;

[0014] Figure 2D illustrates a top view of the reed of Figure 2A, showing dent compression from the center line;

[0015] Figure 3 A is a top view of a fan-out variable width woven fabric produced by the embodiment of Figure 1 , having pluralities of stabilized head and tail sections;

[0016] Figure 3B is a functional diagram illustrating a method for producing the woven fabric of Figure 3 A;

[0017] Figures 4 is a photograph illustrating stabilization of yarns using a leno- looper construction;

[0018] Figures 5A and 5B illustrate closest-packed fibers in a minimum width portion of a variable width fabric in an embodiment of the present invention;

[0019] Figures 6 A - 6D illustrate a method of the present invention for postprocessing variation of the width of a fabric by sliding of fibers in an initially uniform-width fabric; and [0020] Figures 7A - 7C illustrate creation of a variable width fabric by overlapping of tape sections of an initially uniform-width fabric.

DETAILED DESCRIPTION

[0021] One general aspect of the present invention is an apparatus configured for producing a textile web or fabric, also referred to herein as a "woven," having a large continuous change in width in the cross machine direction. The ratio of wide section of web or head to the narrow section of the web or tail is greater than 3 :2.

[0022] Figure 1 illustrates a weaving machine used to produce variable width fabrics in an embodiment of the present invention. The apparatus includes a novel, variable position reed 100 that can adjust the spacing of the warp threads 104 dynamically during the weaving process.

[0023] Most types of weaving machine use a reed 100 to form the fabric after the insertion of a cross machine yarn (i.e. "weft" thread) by pushing the weft thread securely into place as it is woven. Reeds 100 are formed of smooth dividing elements, typically wire elements, that are assembled in a parallel "comb" arrangement with a well-controlled spacing 102 between them. The spaces 102 formed between the wire elements in the reed are called the "dents." Typically, one warp yarn passes through each of these spaces 102. The reed 100 thereby separates the threads 104 and keeps them in their positions, thereby preventing tangling. The warp threads pass through the dents 102 after going through the heddles 106 and before becoming woven cloth.

[0024] Conventionally, the wire elements in a reed 100 have a fixed spacing 102 (i.e. the dents 102 are all equal) and as a result the weaving machine produces a uniform woven width. With reference to Figures 2 A through 2D, in

embodiments of the present invention the reed 100 is assembled from dividing elements having dents 200 that are dynamically variable in spacing during the weaving process, thereby producing a woven having a fan out textile structure or some other variable width pattern. Figure 2A illustrates a reed 100 in an embodiment where the warp threads 104 pass between pairs of reed wires having a fixed spacing 102, i.e. through fixed-width dents 102, and where these pairs of wires are separated from each other by variable dents 200 that are variable in width. Note that none of the warp threads 206 pass through the variable dents.

[0025] In the embodiment of Figures 2A-2D, the widths of the variable dents 200 are controlled by cams 202 that are mounted on sliders 202. The cams 202 include flat extensions 204 that are inserted into every other variable dent 200, referred to herein as the "cam-controlled" dents 200. The cam-controlled dent widths are varied by rotating the cams 202, thereby rotating the flat extensions 204. The widths of the variable dents that are not cam-controlled dents are varied by using the sliders 204 to translationally move the cams 202.

[0026] With the cams 202 and sliders 206 configured as shown in Figure 2A, the warp threads 104 are widely spaced by the reed 100. Figure 2B illustrates a half-compressed configuration wherein the cams 202 have been rotated but the sliders 204 have not been moved, and Figure 2C illustrates a compressed configuration wherein the cams 202 and sliders 204 are in their "collapsed" positions, the warp threads 104 are moved together as closely as possible, and the fabric width is reduced to a minimum. Figure 2D is a top view that compares the reed widths of Figures 2A 100A and 2C l OOC, both being aligned with a common center line 208.

[0027] Figure 3A illustrates a continuous woven web 300 produced by an embodiment of the present invention. The web 300 has variable width fan-out sections 302 that can vary in length. Woven sections at the head 306 and tail 304of each fan-out section 302 maintain fiber alignment. Cut points are indicated 308 that can be used to separate the fan-out sections and remove them from the continuous woven web 300.

[0028] Another general aspect of the present invention is a method for producing a variable-width woven. The continuous woven web 300 illustrated in Figure 3A is produced according to an embodiment illustrated by the functional diagram of Figure 3B :

1. The head of the fan textile is woven with at least one cross machine fiber 308;

2. The reed drive 108 moves the expanded reed to form a pick in the

textile 310;

3. The warp is advanced to form the fan section and set the desired

distance from the head to the tail of the fan 312;

4. The reed 100 is compressed to its narrow width configuration 314;

5. The tail of the woven fan is formed with at least 1 cross machine fiber 316;

6. The reed drive 108 moves the compressed reed to form a pick in the textile 318;

7. The reed drive 108 moves the compressed reed 100 to form a pick in the textile 320;

8. The reed 100 is expanded to its wide width configuration 322; and

9. Repeat

[0029] In some fan-out embodiments, the woven sections at the head of the fan are stabilized with leno weaving techniques such as are illustrated in Figure 4 using simple leno or leno looper yarns to help stabilize the warp yarns in an open mesh weave. Figure 4 illustrates a double looper weaving with Leno looper construction in an open mesh with large interstices between warp yarns.

[0030] In embodiments, the minimum-width of the fabric is limited by the diameter of the warp yarn 104. At the point that the warp fibers 104 are close- packed, as illustrated in Figures 5A and 5B, there is no further compression possible in the fabric. As shown in Figures 5A and 5B, the filling or cross machine yarns 500 tend to spread out the warp spacing. In some embodiments, soluble fibers are used for the stabilization of the tail, and after the web is woven and is in post weaving processing, the coating process that is used dissolves the cross machine yarn and allows for close packing of the warp in the tail of the fan. The coating then becomes the stabilization mechanism for keeping the warp fiber in place after the dissolution of the filling fiber. In other embodiments, the tail warp fibers approach a close-packed configuration but the heat and pressure 106 that forms the warp fiber is used to create local necking 502 around the filling fibers, as shown in Figures 5 A and 5B.

[0031] Certain embodiments include a novel fiber drawing section 106 included in the warp feed train. In some of these embodiments, the feeding section for the warp fiber is from a creel (warp beam 1 10 shown in Figure 1 for clarity). The warp fibers 104 are let off from the creel spools 1 10 and run in to a heated drawing section 106. Using this drawing section, monofilament yarn 104 can be drawn down and reduced in diameter to further increase the ratio of close packed tail fiber to the width of the head section. In embodiments, the drawn, smaller diameter fiber sections are used only in the tail area to increase the ratio of widths in the fan. Because the drawing section 106 is local and clamps draw the entire section of the warp at a controlled location, this necked warp section can be positioned in the tail section of the fan.

Continuous production of the Fan Web

[0032] The fan web shown in Figure 3 is as it comes off the weaving machine in embodiments. The production of the fans is continuous, as shown. The tails of two fans are produced at the same time, and the head sections of two fans are likewise produced at the same time. When the fan sections are produced, the warp advance between the head section and the tail section need not be uniform, and can be varied for each fan produced in this manner.

Alternative Embodiment: Cross Warp Post Processing

[0033] With reference to Figures 6A through 6D, in other embodiments a fan structure is fabricated by using a novel post processing method. The fan fiber is inserted into a carrier yarn warp that may include warp fiber made from soluble carrier fiber. These insertions are made at the fiber spacing desired in the head of the fan structure. As in the warp oriented embodiments, leno or leno looper tie yarns or warp knitting or other stabilization methods can be helpful in maintaining fiber spacing accurately. Also, as in the warp oriented embodiments, the use of loom setting (on machine) with polymer coatings is also useful for stabilization. As shown in Figure 6A, the un-fanned textile structure 600 is removed from the fiber forming equipment 602 and prepared for post processing by a fiber compressing apparatus 604 into the fan structure, as illustrated in Figure 6B.

[0034] Post processing in these embodiments is based on sliding fiber 104 under controlled conditions. In order to close the spacing of the fiber 104, the filling must be constrained normal to the fiber mat 600, and the fiber mat 600 put under controlled compression, as illustrated in Figure 6C. This configuration prevents yarns 104 from crossing over each other and becoming disordered in the compression process. As illustrated in Figure 6D, the constrained fill fibers 104 are then compressed in the plane of the fiber mat 600. In some embodiments, so as to increase the compression in the plane, the warp yarns 104 are dissolved or lubricated, such as with hot water and surfactant. Under these conditions the tail of the fan can be formed to the desired compression factor relative to the head of the fan.

Alternative Embodiment: Stacked Tapes

[0035] With reference to Figures 7A-7C, the fan structure can also be produced by a patterned weave or warp knit. In these embodiments, the fan structure can be achieved in either the warp or the cross machine direction. An initially uniform- width woven is produced using the same methods described for other

embodiments above. A head section 700 of the woven is reserved, and tapes 702 are formed in the remaining tail section by methods such as on-machine slitting. Narrow fabric methods are used in some of these embodiments where multiple shuttles tapes can bifurcate from the head section as fully woven tapes without the need for on loom slitting. In other embodiments, slitting on machine is all that is required. [0036] The tail section of the fan is produced in these embodiments by stacking the distal ends of the taped sections 702 of the textile structure, as illustrated in Figure 7B. This method does not achieve an equal thickness structure in the head 700 and tail sections, since the tail section will include a plurality of stacked layers 702, as shown in Figure 7C. However in cases where the width ratio between head and tail is high, for example greater that about 4: 1 , this method has advantages in that the stacking of tapes overcomes the close pack width limit in the tail for a mono-layer of fibers. By stacking the distal ends of the taped sections 702, the width ratio can be increased without drawing or necking the fibers.

Fiber Alternatives

[0037] Given the many applications for a woven having a fan-out structure, there are a wide range of fiber types that are applicable. Multi-filament, staple fiber, mono-filament fiber, and combinations thereof all provide desired

performance for the various applications of the present invention. Materials that can be used include all the polymeric fibers, both natural and synthetic.

Applications also include inorganic fiber of glass or ceramic materials. The range of denier is only limited in embodiments by the close packing of the fiber diameters at the tail section of the fan.

[0038] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many

modifications and variations are possible in light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.

Claims

What is claimed is: 1. A weaving apparatus for continuous production of a variable width textile, the apparatus comprising:

a reed having a plurality of dividing elements disposed in a parallel arrangement, the dividing elements being grouped in pairs of dividing elements that are separated by fixed dents having fixed dent widths, the pairs being separated from each other by variable dents having variable dent widths, warp threads being directed through the fixed dents, the reed being configured to push weft yarns securely into place as the textile is produced; and

a variable dent adjustment mechanism configured to vary the variable dent widths as the textile is produced, thereby varying a width of the textile, said variable dent adjustment mechanism being able to cause a ratio between maximum and minimum widths of the textile to be at least 3 :2.

2. The apparatus of claim 1 , wherein the dent adjustment mechanism includes rotatable cams from which flat extensions are directed into at least some of the variable dents, rotation of the cams thereby adjusting widths of the variable dents into which the extensions are directed.

3. The apparatus of claim 1 , wherein the dent adjustment mechanism includes sliders that can translationally reposition at least some of the pairs of dividing elements, and thereby adjust widths of at least some of the variable dents.

4. The apparatus of claim 1 , wherein said dent adjustment mechanism is able to cause the ratio between maximum and minimum widths of the textile to be at least 2: 1.

5. The apparatus of claim 1 , wherein the apparatus is able to stabilize at least one of the maximum width and the minimum width of the fabric using a leno weaving technique.

6. The apparatus of claim 1 , wherein at least one of the maximum width and the minimum width of the fabric is stabilized by a coating.

7. The apparatus of claim 1 , further comprising a drawing section included in a warp feed train, said drawing section being configured to draw down

monofilament warp threads and reduce the warp threads in diameter, thereby reducing a minimum close-packed width of the fabric.

8. The apparatus of claim 7, wherein the drawing section is heated.

9. The apparatus of claim 7, wherein the drawing section is able to

dynamically vary the diameter of the warp threads during weaving.

10. The apparatus of claim 1 , wherein heat and pressure that forms the warp fiber is used to create local necking around the weft fibers.

1 1. A method for continuous production of a variable-width fabric, the method comprising:

drawing warp fibers through fixed dents having fixed dent widths that separate pairs of dividing elements disposed in a reed in a parallel arrangement, the pairs of dividing elements being separated by variable dents having variable dent widths,

using the reed to push weft yarns securely into place as the textile is produced; and

using a variable dent adjustment mechanism to vary the variable dent widths of the variable dents as the textile produced, thereby varying a width of the textile, said dent adjustment mechanism being able to cause a ratio between maximum and minimum widths of the textile to be at least 3 :2.

12. The method of claim 1 1 , wherein varying the variable dent widths includes rotating cams from which flat extensions are directed into at least some of the variable dents.

13. The method of claim 1 1 , wherein varying the dent widths includes using sliders to translationally reposition at least some of the pairs of dividing elements.

14. The method of claim 1 1 , wherein said variable dent adjustment mechanism is able to cause a ratio between maximum and minimum widths of the textile to be at least 2: 1.

15. The method of claim 1 1 , further comprising stabilizing at least one of the maximum width and the minimum width of the fabric using a leno weaving technique.

16. The method of claim 1 1 , further comprising stabilizing at least one of the maximum width and the minimum width of the fabric by applying a coating.

17. The method of claim 16, wherein at least some of the weft yarns are soluble, and the soluble weft yarns are dissolved by the applied coating.

18. The method of claim 1 1 , further comprising drawing down monofilament warp threads using a drawing section included in a warp feed train, thereby reducing the warp threads in diameter and reducing a minimum close-packed width of the fabric.

19. The apparatus of claim 18, wherein the drawing section is able to

dynamically vary the diameter of the warp threads during weaving.

20. A method for post processing production of a variable-width fabric, the method comprising:

forming a fabric having a uniform width, the fabric including interwoven warp yarns and weft yarns;

constraining the warp yarns so that they are not able to shift in a direction normal to a plane of the fabric; and

compressing the warp yarns together at desired locations, thereby reducing the width of the fabric at the desired locations.

21. The method of claim 20, further comprising lubricating the yarns.

22. The method of claim 21 , wherein the yarns are lubricated using hot water or a surfactant.

23. The method of claim 20, wherein at least some of the yarns are soluble, and the method further includes dissolving the soluble yarns.

24. A method for continuous production of a variable-width fabric, the method comprising:

forming a fabric having a uniform width, the fabric having a head section and a tail section, the fabric including interwoven warp yarns and weft yarns; dividing the tail section into parallel tapes with separated distal ends; and shifting the distal ends of the tapes into an overlapping configuration, thereby narrowing the fabric at the desired locations.

25. The method of claim 24, wherein dividing the tail section into parallel tapes includes on-machine slitting of the fabric.

26. The method of claim 24, wherein dividing the tail section into parallel tapes includes forming the parallel tapes as fully woven tapes during weaving of the fabric.