Textiles: weaving – Special-type looms
Reexamination Certificate
2001-03-23
2001-11-13
Calvert, John J. (Department: 3765)
Textiles: weaving
Special-type looms
C139SDIG001
Reexamination Certificate
active
06315007
ABSTRACT:
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to fabric formation and, more particularly, to a method for high speed three-dimensional woven fabric formation of structures including three substantially orthogonal yarn systems and a machine that incorporates this method.
(2) Description of the Prior Art
In general, it is known in the art to manufacture multi-layer fabrics, including three-dimensional woven fabrics, particularly for use in aerospace and industrial applications and for use in resin-infused composite structures incorporating the same. Additionally, it is known in the art to use specialized machines for making three-dimensional woven fabrics, particularly incorporating high performance fibers to improve the characteristics of the overall woven structure.
However, overall, these prior art methods and related machines are not capable of producing three-dimensional woven fabric at high speeds. While traditional weaving machines can provide high speed weaving and fabric production, these machines are not capable of providing true three-dimensional fabric structures. Typical speeds for two-dimensional weaving machines, specifically for rapier machines, are between about 200 picks per minute to about 350 picks per minute. However, these machines are only capable of producing standard two-dimensional fabrics or “crammed” fabrics that have some additional picks or filling yarns. In the case of “cramming,” additional picks are inserted during a single phase of harness action such that instead of inserting a single pick during a single phase, an extra pick or so is added. Moreover, “cramming” fabric is not used for large fabric dimensions; rather, it is used primarily as a border for towels and handkerchiefs. One significant problem with “crammed” fabric is a substantial lack of stability and control within the fabric due to the addition of picks without providing a warp or other angular interlocking of the picks. Uncontrolled shrinkage and wrinkling are prevalent in areas where “crammed” fabric is used. Thus, neither the two-dimensional fabrics nor the “crammed” fabrics that can be produced from a traditional two dimensional weaving machine at high speeds can provide adequate fabric characteristics to match those of true three-dimensional fabric structures.
While prior art three-dimensional weaving machines are capable of providing true three-dimensional fabric structures, including complex-shaped structures, the machine speeds are very slow. Typical speeds for specialized three-dimensional weaving machines are about 30 insertions per minute. Also, prior art 3-dimensional weaving machines require simultaneous stack filling insertion and continuously filing yarns. Therefore, no prior art has been capable of providing a high speed means for manufacturing true three-dimensional woven fabrics having three substantially orthogonal yarn systems. Thus, there remains a need for a method and machine for producing three-dimensional woven fabrics at reasonably high speeds. Furthermore, no prior art provides a high speed method or machine for forming three-dimensional fabric structures having a range of dimensions. Thus, there remains a need for a high speed method and machine for making three-dimensional woven fabric in a range of dimensions.
SUMMARY OF THE INVENTION
The present invention is directed to a method for high speed formation of three-dimensional woven fabrics. Additionally, the invention is directed to a machine for making the same. The invention is applicable to the products made from the method and machine described, as no other machine is capable of making these products at high speeds.
Advantageously, the invention includes a method for providing at least two warp yarn systems having approximately zero crimp and at least three filling insertions having approximately zero crimp, wherein the warp and filling yarns are non-interlacing with each other, and are secured as an integral fabric via at least one vertical or Z yarn system provided via two harness frames. As such, the present invention provides a method and machine for high speed formation of true three-dimensional woven fabric with substantially orthogonal yarn systems having superior structural uniformity and/or continuity and performance characteristics than any prior art structure or substitute. Also, the present invention provides a method of manufacturing three-dimensional fabrics in a limited range of dimensions and densities using a single fabric-forming machine with no additional equipment or separate processes required, these dimensions are limited to the rapier machine width and to fabrics having only two or three warp yarn layers.
Also, the three-dimensional woven fabrics produced by the method and machine according to the present invention are suitable for forming rigid composite structures that do not require joining, splicing, or otherwise connecting, patterning, creating cut-out regions or overlapping material to form the final structure, shape or dimensions in order to conform to a predetermined shaped structure or component. Also, the shaped three-dimensional fabric structure may be formed into a rigid composite structure via the addition of a resin or similar hardening material.
Accordingly, one aspect of the present invention is to provide a method for high speed formation of three-dimensional woven fabric structures by providing at least two warp yarn systems having approximately zero crimp and at least three filling insertions having approximately zero crimp, wherein the warp and filling yarns are non-interlacing with each other, and are secured as an integral fabric via at least one vertical or Z yarn system provided via two harness frames. Another aspect of the present invention is to provide a high speed machine for forming three-dimensional woven fabric structures by providing a rapier machine that is modified to include at least two distinct warp yarn systems having approximately zero crimp and at least three filling insertions having approximately zero crimp per insertion cycle or series, wherein the warp and filling insertions are non-interlacing with each other, and are secured as an integral fabric via at least one vertical or Z yarn system provided via two harness frames. Additionally, it is an aspect of the present invention to provide a three-dimensional woven fabric structure formed via the high speed method and machine according to the present invention.
Other objects and advantages of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment and the accompanying drawings, which are merely illustrative of such invention.
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Mohamed Mansour H.
Salama Mahmoud M.
3TEX, Inc.
Calvert John J.
Glasgow Law Firm
Muromoto Jr. Robert H.
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