Systems and methods for creating three-dimensional woven textile products

• US 10,392,731 B2
• Filed: 12/18/2015
• Issued: 08/27/2019
• Est. Priority Date: 03/29/2015
• Status: Active Grant

• Current Assignee: Unspun, Inc.
• Original Assignee: Unspun, Inc.
• Inventors: Esponnette, Elizabeth, Hovorka, Griffin
• Primary Examiner(s): Hurley, Shaun R
• Assistant Examiner(s): Sutton, Andrew Wayne
• Application Number:
  US14/974,408
• Publication Number:
  US 20160281277A1
• Time in Patent Office: Days
• CPC Class Codes: D03C 9/0633 Heald bars or their connection to other frame parts
• CPC Class Codes: D03D 37/00 Circular looms looms for weaving separate fabrics disposed in a circle or polygon D03D33/00
• CPC Class Codes: D03D 41/00 Looms not otherwise provided for, e.g. for weaving chenille yarn; Details peculiar to these looms
• CPC Class Codes: D03J 1/00 Auxiliary apparatus combined with or associated with looms
• CPC Class Codes: D03J 5/02 Construction of shuttle body

Abstract

Described herein are techniques for creating a three-dimensional woven textile products. A method includes rotating strands of warp yarns, where each strand of warp yarn is in a direction away from a surface, in a circular motion while moving a strand of weft yarn forwards and backwards in a direction parallel to the surface so as to cause the strand of weft yarn to alternately weave in and out of the strands of warp yarn. The method includes moving the strand of weft yarn in a direction away from the surface so as to cause the strand of weft yarn to alternately weave in and out of the strands of warp yarn at a different height to create a three-dimensional woven textile product. The method includes supplying at least one of the strand of warp yarn or the strand of weft yarn with a yarn generator.

Claims

1. An apparatus for creating a three-dimensional woven textile product, comprising:

a base;

a baseplate mounted on a top surface of the base;

the baseplate having a two-dimensional configuration of holes along a top surface of the baseplate, wherein each of the holes has a strand of warp yarn that extends from the hole in a direction away from the top surface of the baseplate, and

the baseplate having an axis around which the baseplate is configured to rotate in a circular motion;

an actuator configured to move a strand of weft yarn forwards and backwards in a direction parallel to the top surface of the baseplate so as to cause the strand of weft yarn to alternately weave in and out of the strands of warp yarn;

a weaving arm, having mounted thereon the actuator, and mounted on the top surface of the base, the weaving arm configured to move the actuator in a direction away from the top surface of the baseplate so as to cause the strand of weft yarn to alternately weave in and out of the strands of warp yarn at a different height to create a three-dimensional woven textile product; and

a controller configured to control operation of the baseplate, the actuator, and the weaving arm.

2. The apparatus of claim 1, wherein the direction that the strand of warp yarn extends from each hole away from the top surface of the baseplate is the same for at least two of the strands of warp yarn.

3. The apparatus of claim 1, wherein the direction that the strand of warp yarn extends from each hole away from the top surface of the baseplate is different for at least two of the strands of warp yarn.

4. The apparatus of claim 1, wherein the direction that the strand of warp yarn extends from each hole away from the top surface of the baseplate is dynamically adjustable for at least two of the strands of warp yarn.

5. The apparatus of claim 1, wherein a location of each of the holes along the top surface of the baseplate is dynamically adjustable.

6. The apparatus of claim 1, wherein the baseplate comprises at least one hole dynamically added or removed along the top surface of the baseplate, and the at least one hole has a strand of warp yarn that extends from the at least one hole in a direction away from the top surface of the baseplate.

7. The apparatus of claim 1, wherein the baseplate is configured to permit the strand of warp yarn extending from each hole to be dynamically added or removed.

8. The apparatus of claim 1, wherein the weaving arm is further configured to move the actuator in the direction away from the top surface of the baseplate after the actuator has caused the strand of weft yarn to alternately weave in and out of the strands of warp yarn approximately once at a particular height.

9. The apparatus of claim 1, wherein the actuator includes two arms configured to alternately hold a ball that is coupled to the strand of weft yarn, wherein at least one of the two arms is configured to move the ball forwards and backwards in a direction parallel to the top surface of the baseplate so as to cause the strand of weft yarn to alternately weave in and out of the strands of warp yarn.

10. The apparatus of claim 1, further comprising a yarn generator configured to supply at least one of the strand of warp yarn or the strand of weft yarn.

11. The apparatus of claim 10, wherein the yarn generator comprises:

a container containing a solution;

a spinneret having a plurality of holes, and is configured to receive the solution and to output a plurality of continuous filaments from the plurality of holes;

a plurality of rollers configured to receive and stretch the plurality of continuous filaments; and

a spinner coupled to receive and twist the stretched plurality of continuous filaments to form yarn.

12. The apparatus of claim 11, wherein the spinneret is submerged in a second solution, wherein the solution and the second solution interact to form a polymer.

13. The apparatus of claim 11, wherein the container has a heating element and is configured to receive and melt at least one type of polymer to become the solution.

14. The apparatus of claim 13, wherein the at least one type of polymer comprises one or more of plastic, wood pulp, protein, or mineral.