U.S. patent number 3,818,951 [Application Number 05/291,068] was granted by the patent office on 1974-06-25 for loom.
This patent grant is currently assigned to The Secretary of State for Defence, in Her Britannic Majesty's. Invention is credited to Kurt Greenwood.
United States Patent |
3,818,951 |
Greenwood |
June 25, 1974 |
**Please see images for:
( Certificate of Correction ) ** |
LOOM
Abstract
The invention relates to special structures, which may be
generally descrd as three-dimensional fabrics, that is to say
fabrics which have substantial measurements in three dimensions as
compared with conventional fabrics having substantial measurements
in only two dimensions. The structures have special application aa
reinforcing materials in composites such as resin-carbon fibre
composites, and consist of ground warps in a matrix of binder warps
and wefts, which three sets of components extend in three
directions substantially at right angles to each other and lying
substantially straight in the body of the structures. The invention
also includes a method of producing such structures involving
progressing the ground warps longitudinally in three dimensional
array and inserting the binder warps and wefts appropriately. The
invention also includes a machine for carrying out this method,
constructed generally along the lines of a loom, and having the
necessary instrumentalities for manipulating the three sets of
components in appropriate manner.
Inventors: |
Greenwood; Kurt (Dissbury,
EN) |
Assignee: |
The Secretary of State for Defence,
in Her Britannic Majesty's (London, EN)
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Family
ID: |
26786266 |
Appl.
No.: |
05/291,068 |
Filed: |
September 21, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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92982 |
Nov 27, 1970 |
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Current U.S.
Class: |
139/20;
139/35 |
Current CPC
Class: |
D03D
23/00 (20130101); D03D 41/004 (20130101) |
Current International
Class: |
D03D
23/00 (20060101); D03D 41/00 (20060101); D03d
041/00 () |
Field of
Search: |
;139/11,12,13,20,22,23,35,139,141 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Jaudon; Henry S.
Attorney, Agent or Firm: Cushman, Darby & Cushman
Parent Case Text
This is a division, of application Ser. No. 92,982 filed Nov. 27,
1970.
Claims
I claim:
1. A weaving machine adapted to produce a structure comprising
straight group warps extending longitudinally of said structure in
three dimensional array, said array being rows of ground warps and
columns thereof at right-angles to the rows, a plurality of binder
warps, and a single continuous weft extending alternately back and
forth in substantially straight paths across the width of said
structure and throughout the depth of said array, the machine
comprising in combination, means for holding each ground warp in
position in its respective row and column during commencement of
weaving, ground warp row separating means operative to separate
each successive ground warp row from its adjacent row independently
and in sequence, weft-insertion means adapted to lay successive
straight portions of a single continuous weft between successive
separated ground warp rows in opposite directions each of which is
generally and substantially at right angles to the longitudinal
extent of said ground warps and across the width of said array, and
guide means adapted to lay-in said binder warps with said ground
warps and said wefts in a direction generally and substantially at
right angles to the longitudinal direction of said ground warps and
through the depth of said array.
2. A weaving machine according to claim 1, in which the
weft-insertion means comprises, in combination, first and second
drive means for respectively passing a shuttle between two
separated ground warp layers and adjusting the shuttle height
relative to the structure.
3. A weaving machine according to claim 2, in which the first drive
means comprises at least one pair of shuttle-carrying rapiers
simultaneously inserted from opposite sides of the structure, the
shuttle being transferred from one rapier to the other while in the
gap between separated ground warp layers, respective arms pivotally
supporting said rapiers for reciprocating movement into and out of
said gap, and links connected to said arms and to crank means for
imparting reciprocating motion to the arms and hence to the
rapiers.
4. A weaving machine according to claim 1, in which the guide means
comprises a heald frame carrying heald wires for the binder warps,
means for reciprocating the heald frame to produce the laying-in
motion for the binder warps, and a spring-loaded tension bar over
which the binder warps are fed prior to passing through the heald
frame.
5. A weaving machine according to claim 4, in which means for
reciprocating the heald frame comprise a bell crank mechanism
actuated through linkages by a cam adapted to operate in
synchronism with the weft-insertion means.
6. A weaving machine according to claim 1, further comprising a
reed, and means for reciprocating the reed for beat-up
purposes.
7. A weaving machine adapted to produce a structure having a
three-dimensional array of ground warps arranged in a series of
rows and columns, a plurality of binder warps and a plurality of
wefts, the machine comprising in combination, means for holding
said ground warps in said three-dimensional array during
commencement of weaving, ground warp layer separating means
comprising two columns of separating bars arranged in pairs
disposed so that successive rows of ground warps may pass between
the two bars of each successive pair and means for raising said
pairs of bars independently in sequence, weft-insertion means
adapted to lay straight spaced wefts between separated ground warp
layers in a direction which is generally and substantially at right
angles to the longitudinal extent of said ground warps and across
the width of said array, guide means adapted to lay-in said binder
warps with said ground warps and said wefts in a direction
generally and substantially at right angles to the longitudinal
direction of said ground warps and through the depth of said array,
and means for linearly progressing said structure as it is
woven.
8. A weaving machine according to claim 7, in which each pair of
bars form one end of a rectangular framework, each framework being
independently pivotable about a common axis with the other
frameworks, said shedding bars being disposed to one side of the
pivot axis, the other end of each framework being connected at the
other side of the pivot axis to the jacks of a dobby.
9. A weaving machine adapted to produce a structure having a
three-dimensional array of ground warps, a plurality of binder
warps and a plurality of wefts, the machine comprising in
combination, means for holding said ground warps in said
three-dimensional array during commencement of weaving, ground warp
layer separating means, weft-insertion means adapted to lay
straight spaced wefts between separated ground warp layers in a
direction which is generally and substantially at right angles to
the longitudinal extent of said ground warps and across the width
of said array, said weft-insertion means including first and second
drive means for respectively passing a shuttle between two
separated ground warp layers and adjusting the shuttle height
relative to the structure and further including means operatively
connecting the second drive means with the first drive means and
means for operating the second drive means to adjust the height of
the shuttle in timed relationship with operation of the first drive
means, guide means adapted to lay-in said binder warps with said
ground warps and said wefts in a direction generally and
substantially at right angles to the longitudinal direction of said
ground warps and through the depth of said array, and means for
linearly progressing said structure as it is woven.
10. A weaving machine adapted to produce a structure having a
three-dimensional array of ground warps, a plurality of binder
warps and a plurality of wefts, the machine comprising: in
combination, means for holding said ground warps in said
three-dimensional array during commencement of weaving; ground warp
layer separating means; weft-insertion means adapted to lay
straight spaced wefts between separated ground warp layers in a
direction which is generally and substantially at right angles to
the longitudinal extent of said ground warps and across the width
of said array, said weft-insertion means including first and second
drive means for respectively passing a shuttle between two
separated ground warp layers and adjusting the shuttle height
relative to the structure, said first drive means comprising at
least one pair of shuttle-carrying rapiers simultaneously inserted
from opposite sides of the structure, the shuttle being transferred
from one rapier to the other while in the gap between separated
ground warp layers, respectively arms pivotally supporting said
rapiers for reciprocating movement into and out of said gap, and
links connected to said arms and to crank means for imparting
reciprocating motion to the arms and hence to the rapiers, and said
second drive means comprising a pinned plate intermittently driven
in synchronism with the rapiers by a double pallet mechanism which
is movable to reverse the direction of rotation of said pinned
plate, a nut mounted on said pinned plate, a lead screw mounted in
said nut for rotation and axial movement as said pinned plate
rotates, and support means mounted on said lead screw for
supporting the rapier support arms so that the rapier and shuttle
height relative to the structure is adjusted as said lead screw
rotates in said nut; guide means adapted to lay-in said binder
warps with said ground warps and said wefts in a direction
generally and substantially at right angles to the longitudinal
direction of said ground warps and through the depth of said array;
and means for linearly progressing said structure as it is
woven.
11. A weaving machine adapted to produce a structure having a
three-dimensional array of ground warps, a plurality of binder
warps and a plurality of wefts, the machine comprising in
combination, means for holding said ground warps in said
three-dimensional array during commencement of weaving, ground warp
layer separating means, weft-insertion means adapted to lay
straight spaced wefts between separated ground warp layers in a
direction which is generally and substantially at right angles to
the longitudinal extent of said ground warps and across the width
of said array, guide means adapted to lay-in said binder warps with
said ground warps and said wefts in a direction generally and
substantially at right angles to the longitudinal direction of said
ground warps and through the depth of said array, and means for
linearly progressing said structure as it is woven, including a
pair of driven spaced horizontal rollers and a pair of driven
spaced parallel vertical rollers, the spacing of the rollers of
each pair being adjustable to suit the fabric dimensions.
Description
This invention concerns apparatus for producing structures which
have component threads extending in three directions all
substantially at right angles to each other.
The main object of the present invention is to provide apparatus
for producing fabrics which are suitable as reinforcing structures
in composite materials (for example a resin-carbon fibre composite)
where high tensile strength is required in three such directions
producing such fabrics.
According to the present invention there is provided a weaving
machine adapted to produce a structure having a three-dimensional
array of ground warps, a plurality of binder warps and a plurality
of wefts, the machine comprising in combination, means for holding
said ground warps in said three-dimensional array during
commencement of weaving, ground warp layer separating means,
weft-insertion means adapted to lay straight spaced wefts between
separated ground warp layers in a direction which is generally and
substantially at right angles to the longitudinal extent of said
ground warps and across the width of said array, guide means
adapted to lay-in said binder warps with said ground warps and said
wefts in a direction generally and substantially at right angles to
the longitudinal direction of said ground warps and through the
depth of said array, and means for linearly progressing said
structure as it is woven.
In the structure to be produced it is preferred that each ground
warp is a continuous thread extending longitudinally of the
structure, the ground warps being disposed in horizontal rows and
vertical columns. It is also desirable that each binder warp is a
continuous thread lying between adjacent pairs of vertical columns
of ground warps, extending alternately upwardly and downwardly
vertically through the depth of the structure and embracing between
each pair of successive vertical portions thereof a complete
vertical series of wefts; and that the wefts are formed from a
continuous thread extending alternately in one direction and the
other across the width of the structure alternately throughout the
depth of the structure from top to bottom and from bottom to top
and embracing between each pair of successive horizontal portions
thereof a complete horizontal row of ground warps.
The use of the word "three-dimensional" in connection with the
structures produced by the present invention means that they have
substantial measurements in three dimensions, as compared with,
say, conventional textile fabrics having substantial measurements
in two dimensions only.
The invention will now be described further, by way of example
only, with reference to the accompanying drawings, in which,
Fig. 1 is a perspective view of a short length of fabric structure
which is to be produced by apparatus according to the invention,
the thread spacings being somewhat exaggerated in the interests of
clarity;
Fig. 2 is a side view, to a reduced scale, of the fabric structure
of FIG. 1;
Fig. 3 is a plan view to the same scale as FIG. 2 of the fabric
structure of FIG. 1;
Fig. 4 is a diagrammatic side view of a weaving machine according
to the invention, for producing the fabric of FIGS. 1, 2 and 3;
Fig. 5 is an elevation of the reed of the machine of FIG. 3,
showing the thread distribution therein;
Fig. 6 is a diagrammatic side view of part of the weaving machine
of FIG. 4 showing the arrangement for progressing binder warps;
Figs. 7 and 8 are, respectively, diagrammatic side and perspective
views of part of the weaving machine of FIG. 4 showing an assembly
of separating bars and its manner of operation;
Fig. 9 is a diagrammatic end view of part of the weaving machine of
FIG. 4 showing a heald frame and its manner of operation;
Fig. 10 is a diagrammatic side view of part of the weaving machine
of FIG. 4, showing the reed and its method of operation;
Fig. 11 is a diagrammatic perspective view of part of the weaving
machine of FIG. 4 showing a take-up mechanism, and
Figs. 12 and 13 are, respectively, diagrammatic end and plan views
of part of the weaving machine of FIG. 4 showing a weft insertion
mechanism and its method of operation.
The fabric of FIG. 1 consists of three systems of parallel threads
as follows:
1. The ground warp threads GW, running in the longitudinal
horizontal direction (the x-direction).
2. The weft threads W, running in the transverse horizontal
directions (the y-direction).
3. The binder warp threads BW, running in the vertical direction
(the z-direction).
The arrangement of the three systems of threads is shown more
clearly in FIGS. 2 and 3. This arrangement is such that the threads
are firmly bound into the fabric at the upper and lower and the two
side surfaces.
In order to achieve the arrangement shown in these figures, it is
necesary that the total number of binder warp threads should be one
less than the total number of vertical columns of ground warp
threads so that at each side of the fabric there should be a
vertical columns of ground warp threads.
Furthermore, it is necessary that the total number of weft threads
in a vertical columns should be equal to the total number of ground
warp threads in a vertical columns, and that alternate vertical
columns of weft threads should have their uppermost weft thread
above and below the uppermost horizontal row of ground warp threads
respectively, and their lowermost weft thread below and above the
lowermost horizontal row of ground warp threads respectively.
The laying-in of the binder warp must be synchronised with the weft
insertion so that at each reversal of direction of the binder warps
they embrace a weft which in turn lies above or below, as the case
may be, a horizontal row of ground warps.
A weaving machine suitable for producing the type of fabric
described above is shown in FIG. 4. A warp beam BG carries the
ground warp threads, although for some fabrics it may be necessary
to use several such beams. A warp beam BB carries the threads of
the binder warp although for some fabrics it may be necessary to
use a creel of yarn packages. Both warp beams are fitted with
suitable braking devices (not shown) so that the warp threads are
unwound under tension.
The ground warp threads GW pass over a roller RL and through two
sets or columns of horizontal spacing or separating bars SBR (1 -
5) and SBL (1 - 5) arranged in pairs. They pass then between heald
wires HW which are attached to a heald frame HF. The threads then
pass through the reed RD which is capable of carrying out an
oscillating beating-up motion as indicated by the arrows, by virtue
of a mechanism (not shown in FIG. 4).
The horizontal bars SBR, SBL are designed to open a warp gap
between adjacent horizontal rows or layers of ground warp threads
to facilitate the insertion of weft W by a weft-insertion mechanism
(not shown in FIG. 4). For each such horizontal row, two bars are
required:-- One (SBR) which is under the appropriate row of threads
and which serves to raise it, and one (SBL) above, which serves to
lower it.
In order to facilitate the accommodation in depth of all these
bars, the raising bars are slightly offset horizontally in the
direction of the length of the in relation to the lowering
bars.
The binder warp threads BW pass from the beam BB over a tension bar
TB. This bar (as illustrated in FIG. 6) is capable of carrying out
a vertical oscillating motion as indicated by the adjacent arrows
and serves to keep the tension in the binder warp threads
substantially constant as the heald frame HF carries out its
vertical oscillating motion as indicated by the adjacent arrows.
The binder warp threads pass through the eyes EY of the heald wires
HW so that these threads are raised or lowered as the heald frame
HF is raised or lowered. The binder warp threads also pass through
the reed RD.
The number of dents per cm of the reed is equal to twice the number
of vertical columns of ground warp threads per cm. FIG. 5 shows how
the ground and binder warp threads respectively are drawn through
the reed. There is always one binder warp thread in each alternate
dent. In the remaining dents there are as many ground warp threads
per dent as there are horizontal rows of such threads.
Before weaving commences, the ends of all ground and binder warp
threads are drawn off the beams to a wire mesh WM at the front of
the machine and are attached to the mesh by means of knots,
adhesive tape or any other suitable means. A take-up mechanism (not
shown in this figure) is provided to advance the fabric as it is
produced. It has an advancing movement which is intermittent and
takes place whenever a complete vertical row of weft threads has
been inserted into the fabric. The rate at which the take-up
mechanism advances the fabric determines the number of vertical
rows of weft threads per cm fabric length. If, for instance, the
fabric is advanced by 1 mm when one vertical row of weft threads
has been inserted there will be 10 such rows per cm of fabric
length.
Mechanism (not shown in FIG. 4) is also provided for carrying out
the vertical movement of the heald frame HF and vertical movement
of the individual bars SB.
For the commencement of weaving, the heald frame HF is in the
lowered position. All the bars SB are also in the lowered position
with the exception of SBR1 and SBL1 which are in the raised
position thus forming a warp gap into which the weft W is inserted.
(The mechanism for inserting the weft is not shown in FIG. 4).
After the first weft thread W has been inserted, the second bars
SBR2 and SBL2 are raised and join SBR1 and SBL1 in the raised
position. The second weft thread is then inserted into the newly
formed gap. This process is continued until the last weft thread
(in the diagram the fifth weft thread) of the first vertical row of
weft threads has been inserted. The reed RD now moves forward and
carries out the beat-up of the whole first vertical row of weft
threads. The heald frame HF is then raised to insert the vertical
binder warps, the lowest bars SBR5 and SBL5 are lowered to form the
gap for the next weft thread and the fabric moves forward. The next
weft thread is now inserted and pair by pair all the bars are
lowered and after each such lowering, the corresponding weft thread
is inserted until the second vertical row of weft threads is
complete. The second row is then beaten up by the reed and once
again the heald frame HF is lowered to insert the vertical binder
warps and the highest bars SBR1 and SBL1 are raised to form the gap
for the next weft thread, and so on.
In order to prevent fraying of the fabric on its surfaces it is
desirable but not essential that a shuttle method of weft insertion
should be used. Since the fabric produced here is of considerably
greater depth than fabrics produced on conventional looms, it is
not practicable to have the conventional type of race board to
support the shuttle. It is therefore convenient to have a means of
propelling the shuttle which provides positive control and support
for the shuttle during the whole of its journey across the fabric.
Furthermore, with very thick fabrics, weft insertion takes place
over a considerable range of heights, and therefore with such
fabrics it is desirable to have a means of weft insertion which can
insert the shuttle at different heights. A mechanism which meets
these requirements is shown in FIGS. 12 and 13 and will be later
described in more detail.
Reference will now be made to FIGS. 6 to 13 in which are shown
details of certain parts of the weaving machine illustrated
diagrammatically in FIG. 4.
FIG. 6 illustrates the manner in which the tension bar TB is
enabled to carry out its vertical oscillating motion in order to
keep the tension in the binder warp threads BW substantially
constant as the heald frame HF oscillates vertically.
The tension bar TB is rotatably mounted at one end of a lever 10
which itself is pivotally supported about an intermediate point,
the other end of the lever being connected to a low-modulus tension
spring 12. The tension spring 12 has the effect of urging the
tension bar into contact with the binder warps BW passing over the
tension bar TB, irrespective of the vertical displacement of the
heald frame HF through which the binder warps BW pass. FIG. 6 shows
in full line the position of the heald frame HF, the binder warps
BW, the tension bar TB and the lever 10 at the upper extremity of
the movement of the heald frame HF, and in broken line their
positions at the lower extremity of movement of the heald frame
HF.
Referring to FIGS. 7 and 8, it will be seen that each pair of bars
SBR, SBL form part of an independent rectangular framework 14
pivotally mounted about a common axis with the other frameworks.
Thus in the present machine there are five such frameworks 14, all
of which are shown in FIG. 7, but two only of which for the sake of
clarity are shown in FIG. 8. The bars are disposed transversely of
the respective frameworks to one side of the pivot axis, and the
other end of each framework is connected by wires 16 at the other
side of the pivot axis to the jacks of a conventional dobby,
whereby the required movements of the bars are controlled. In FIG.
7 all five frameworks are shown in the lowermost position in full
line, whilst the raised position of two only are shown in broken
line. This type of construction is suitable where a small number of
horizontal rows of ground warps is involved. For larger numbers a
different mechanism less demanding in terms of space would be
desirable.
FIG. 9 illustrates the mechanism for raising and lowering the heald
frame HF. The heald frame HF itself is of conventional construction
embodying the appropriate number of heald wires HW through the eyes
of which the binder warps BW pass. The vertical oscillation of the
heald frame HF in guides G is accomplished via a linkage motivated
by a cam 18 driven through gearing at the appropriate speed by the
prime mover of the weaving machine. The cam 18 rotates in the
direction indicated by the adjacent arrow, and the linkage consists
of a main link 20, the movement of which is controlled by a cam
follower 22 carried thereby and running in a groove 24 in the cam
18, and two subsidiary sets of links 26, 28 connecting the main
link 20 to the heald frame HF. Oscillatory movement of the main
link 20 is indicated by the adjacent arrows and as will be obvious
from the drawing this results in a vertical oscillatory movement of
the heald frame HF, as indicated by the adjacent arrows, by virtue
of the auxiliary links 26, 28.
FIG. 10 illustrates the mechanism by which the reed RD performs its
beat-up function. The reed RD is mounted on one extremity of a
lever 30 which is pivotally supported at its other extremity. The
lever 30 is connected by a link 32 to a rotating crank 34 driven
from the prime mover of the weaving machine through appropriate
gearing so that the beat-up motion of the reed RD occurs each time
a complete series of weft threads is laid in the fabric structure
in a vertical plane.
The take-up mechanism is illustrated in FIG. 11. This mechanism is
diposed between wire mesh WM and a fell control which is not
illustrated, but which merely consists of a pair of adjustable
horizontal restraining bars disposed above and below the fabric
near the beat-up point. Basically the take-up mechanism consists of
two pairs of rollers 36, 38. The first pair of rollers 36 are
vertically disposed and rotatably mounted between two plates 40,
the upper one only of which is shown for the sake of clarity. Each
is mounted on a shaft 42 which is journalled in the two plates 40.
The shaft of one roller may be disposed in any one pair of a series
of alternative pairs of holes 44 in the plates 40, whilst the shaft
of the other is mounted in slots 46 in the plates 40 and retained
therein by means of a compression spring 48, the loading of which
can be adjusted by means of a screw 50. In this way this pair of
rollers 36 constrains the fabric F issuing from the weaving machine
at each side thereof. The other pair of rollers 38 are mounted
horizontally. Each is supported on a shaft 52, which is journalled
in two side plates 54, the shaft 52 of the upper roller 38 being
carried in slots 56 and retained therein by compression springs 58,
the loading of which is adjustable by means of a screw 60, and the
shaft 52 of the lower roller 38 being journalled in the appropriate
pair of a series of alternative pairs of holes in the plates 54.
These two rollers 38 constrain the top and bottom of the fabric F
issuing from the weaving machine. All the rollers are driven in the
directions indicated by the arrows thereon by the prime mover of
the machine. Their motion is intermittent because the drive from
the prime mover is transmitted in synchronism with the movement of
the heald frame HF, so that the fabric F is progressed by the
rollers in the intervals between the laying-in of the binder warps
BW. The drive of the rollers is effected by means of shafts 62, 64
suitable bevel gearing 66, chain wheels 68 and chains 70.
FIGS. 12 and 13 illustrate the weft insertion mechanism. It
consists basically of two rapiers RA, RB which can carry out a
horizontal movement into and out of the warp gap as indicated by
the adjacent arrows. The shuttle S is held at the end of one rapier
by suitable prongs and springs, and when the ends of the two
rapiers meet inside the warp gap the shuttle is passed from the
rapier which has carried it into the gap, to the other rapier which
carries it out of the gap as it is withdrawn. In addition to the
drive for the horizontal movement of the rapiers, there is a
vertical drive which serves to adjust the rapier height to
correspond to the height at which any particular weft thread needs
to be inserted. With this in view, the rapiers RA, RB are supported
on arms 72 pivotally mounted at each end of a transverse bar 74
supported by a vertical lead screw 76. The appropriate movement of
the arms 72 is effected by means of links 78 connected at one end
to the respective arms 72 at an intermediate point thereof and at
the other end to opposed crank pins on a gearwheel 80 driven by a
gearwheel 82 on the end of a vertical shaft 84 having a keyway
coupling with a hollow shaft 86 which is driven through suitable
gearing from the machine's prime mover. The gearwheel 80 is mounted
at the upper end of the lead screw 76, the threaded lower end of
which is mounted in a nut 88, the rotation of which is controlled
by a pinned plate 90 on which it is mounted. The pinned plate 90 is
intermittently driven by a double pallet mechanism 92 which
oscillates in a horizontal plane by virtue of two cams 94, 96
driven by the machine's prime mover and under the influence of
springs 98, 100. Cam 96 rotates continuously to reciprocate the
pallet and index the plate 90 so that the rapiers move vertically
to enable weft insertion to take place at the various heights. Cam
98 rotates intermittently to adjust the position of the pallet
mechanism so that the direction of movement of the plate 90 and
thus of the rapier assembly is reversed as required.
The design of various parts of the machine depends to some extent
on the dimensions, structure and shape of the fabric it is intended
to produce. The general principles are as follows:
The width of the reed must be slightly in excess of the maximum
width of the fabric.
The vertical clearance of the reed must be slightly in excess of
the maximum thickness of the fabric.
The number of dents per cm of the reed must be twice the number of
vertical columns of ground warp ends per cm of fabric width.
The height range over which weft insertion will take place must be
equal to the maximum thickness of the fabric.
The number of warp beams required for the ground warp depends on
the number and denier of the ground warp ends.
Whether the binder warp is supplied to the machine from a creel or
from beams depends on the shape of the cross-section of the fabric.
If the thickness of the fabric is uniform, beams can be used. If
the thickness of the fabric varies along its width, a creel must be
used. The number of beams or the size of the creel depends on the
number and denier of the binder warp ends.
The number and denier of the ground and binder warp ends and the
denier of the weft can be calculated from the yarn strength and
from the strength required from the fabric in the x, y and z
directions respectively. In these calculations, the basic structure
of the fabric is determined by the following three independent
variables:
Ny = no. of ground warp threads per cm per transverse row
= No. of binder warp threads per cm per transverse row
Nz = no. of ground warp threads per cm per vertical column
= No. of weft threads per cm per vertical column
Nx = no. of binder warp threads per cm per longitudinal row
= No. of weft threads per cm per longitudinal row.
From these definitions it follows that:
No. of ground warp threads per cm.sup.2 = NY .times. NZ
No. of binder warp threads per cm.sup.2 = NX .times. NY
No. of weft threads per cm.sup.2 = NX .times. NZ
IF SX, SY, and SZ represent the desired strength in grammes per
cm.sup.2 of the fabric in the three directions and if DX, DY and DZ
represent the denier of the ground warp, the weft, and the binder
warp respectively, and if sx, sy and sz represent the strength in
grammes per denier of the ground warp, weft and binder warp
respectively, then the following relations apply:
SX = DX .times. NY .times. NZ .times. sx
SY = DY .times. NX .times. NZ .times. sy
SZ = DZ .times. NX .times. NY .times. sz
Furthermore, in any one horizontal or vertical plane the number of
threads per cm and the yarn denier must be related in such a way
that adjacent threads touch each other in order to ensure the
stability of the structure. This condition is fulfilled when the
following approximate relationships apply:
NX .times. (.sqroot.DY + .sqroot.DZ) = 800
NY .times. (.sqroot.DX + .sqroot.DZ) = 800
NZ .times. (.sqroot.DX + .sqroot.DY) = 800
Once the required strengths of the fabric have been fixed and a
choice has been made of the materials to be used in the three
systems of threads, it is necessary to reduce the number of
unknowns to 4, for example by choosing two of the six unknowns NX,
NY, NZ, DX, DY and DZ. The other four can then be calculated.
EXAMPLE I
It is desired to produce a fabric of 20 cm width and 10 cm
thickness with a strength of 150,000 grammes per cm.sup.2 in all
three directions. The same yarn is to be used in all directions and
its strength is 1 gramme per denier.
From the dimensions of the fabric it follows that the reed must be
approximately 22 cm wide and have a vertical clearance of
approximately 12 cm. The height range over which weft insertion
must take place is 10 cm.
Having decided to use 3,000 denier yarn for the ground and binder
warps then by substituting in the six equations the values SX = SY
= SZ = 150,000 and sx = sy = sz = 1 one finds that the equations
are satisfied when:
NX = NY = NZ = 7 threads per cm per row of threads
DY = 3,000 denier.
Because NY = 7, the number of dents per cm in the reed must be 2
.times. 7 = 14. The number of vertical columns of ground warp
threads is 20 .times. 7 = 140 and therefore the total number of
binder warp ends is 140 - 1 = 139.
The total number of ground warp ends is 140 .times. 10 .times. 7 =
9,800.
Because the thickness of the fabric is uniform, the binder warp can
be supplied to the machine from beams and since the total number of
binder warp ends is small, one beam will be sufficient.
The number of ground warp ends, however, is large for a yarn of
3,000 denier and therefore several ground warp beams have to be
used. (In this case approximately ten).
The total length of ground warp yarn required for a given length of
fabric is, however, approximately equal to the total length of
binder warp yarn and since the two yarns are of equal denier, the
total weight of yarn on the one binder warp beam must be
substantially the same as the total length of yarn on all the
ground warp beams.
EXAMPLE II
It is desired to produce a fabric of 30 cm width and 5 cm thickness
with different strengths in the three directions viz:
Sx = 250,000, sy = 160,000, sz = 80,000. the same yarn is to be
used in all directions and its strength is 1 gramme per denier.
In this case, the reed must be 32 cm wide and have a vertical
clearance of 7 cm.
The height range over which weft insertion takes place is 5 cm.
Having decided to use 6,500 denier yarn for the ground warps and
1,500 denier yarn for the binder warps the six equations are
satisfied when:
NX =8.0
NY = 6.7
NZ = 5.7
DY = 3,500
Because NY = 6.7, the number of dents per cm in the reed must be 2
.times. 6.7 = 13.4. The number of vertical columns of ground warp
threads is 30 .times. 6.7 = 201 and therefore the total number of
binder warp ends is 201 - 1 = 200.
The total number of ground warp ends is given by the product of the
number of vertical columns (201) and the number of ends in each
vertical column (5 .times. 5.7). The latter quantity must be an
integral number and therefore a choice has to be made between 28
ends per vertical column which would result in a fabric of slightly
less than 5 cm thickness or 29 ends per vertical column resulting
in a fabric of slightly more than 5 cm thickness. The total number
of ground warp ends is thus either 201 .times. 28 = 5,628 or 201
.times. 29 = 5,829.
As in Example I, the binder warp can be supplied from one beam and
the ground warp from several beams.
The invention is of course not limited to particular details set
out hereinbefore by way of example. For instance, the invention is
by no means restricted to the production of fabrics of rectangular
cross-section as the cross-sectional shape can clearly be selected
as desired by varying the number of ground warp threads contained
in a vertical column and horizontal row. The following example
illustrates such a case:
EXAMPLE III
It is desired to produce a fabric which in its basic structure
corresponds to the fabric described in Example I but has a circular
cross-section of 10 cm radius.
The principles involved in producing circular or other
non-rectilinear section fabrics are basically the same as those
involved in producing rectangular fabrics, but apply to each
individual horizontal row or vertical column of ground warps rather
than to the array of ground warps as a whole.
The maximum width and maximum thickness of this fabric are 20 cm
and therefore the reed must be 22 cm wide and have a vertical
clearance of 22 cm.
The height range over which weft insertion takes place is 20
cm.
Because NY = 7, the number of dents per cm in the reed must be 2
.times. 7 = 14.
The maximum number of vertical columns of ground warp ends is 20
.times. 7 = 140 and therefore the total number of binder warp ends
is 140 - 1 = 139.
The number of ground warp ends per cm.sup.2 of cross-sectional area
is 7.sup.2 = 49 and therefore the approximate total number of
ground warp threads will be 49 .times. 10.sup.2 .times. .pi. =
15,386. The accurate number of ground warp ends has to be found by
drawing a circle on point paper and filling it in with vertical and
horizontal rows of points of density 7 per cm.
Because the thickness of the fabric varies along its width, being a
minimum at the two sides and a maximum at the centre, the amount of
binder warp required for a given length of fabric is also at a
minimum at the sides and at a maximum at the centre. It is
therefore not possible to withdraw all the binder warp ends from
one beam and each end will have to come from a separate package
mounted on a creel.
Since the fabrics produced by the present invention will usually be
of much greater thickness and rigidity than conventional fabrics,
they cannot normally be coiled up on a roller in the conventional
manner. They must be withdrawn from the weaving machine in a
substantially rectilinear path. When using the fabric (made say
from carbon fibre threads) as reinforcements for relatively short
components of metal or plastics material, means could be provided
at the output end of the weaving apparatus for cutting off
appropriate lengths of fabric and incorporating them as
reinforcements in suitable materials while under such tension and
by such means as will cause the desired fabric dimension to be
maintained. Adhesive may be applied to the ends of each length to
prevent fraying.
On the other hand, if it is desired to produce long lengths for
storage against future use additional mechanism must be provided to
support the fabric as it is withdrawn from the weaving apparatus so
as to prevent sagging. The length of fabric which can be produced
in one piece will normally be limited by space considerations.
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