Patent Grant
11047074
The invention relates to the field of weaving, and more specifically to the field of weaving machines and industrial weaving methods for manufacturing fabrics, notably composite fabrics designed for use as strengthening elements for tyres.
Industrial weaving machines are known for manufacturing fabrics for multiple applications, such as making textile products.
Conventionally, a weaving machine has a structure bearing a plurality of warp threads extending in a first direction. A heddle mechanism selectively moves at least some of the plurality of warp threads to form first and second sheets of warp threads.
An industrial weaving machine also has a weft-thread feed spool mounted on the structure and means for laying this thread, for example a needle. The needle catches an end of the weft thread from the spool such as to move this weft thread between the first and second sheets of warp threads in a second direction perpendicular or oblique to the first direction. The needle releases the end of the weft thread once said thread has passed the plurality of warp threads. The weft thread is then cut at a portion located at the end opposite the end that has just been released. The needle is returned to the starting position thereof, the warp threads are moved selectively to form sheets according to a different arrangement, then the actions described above are repeated to lay in new portion of weft thread between the sheets.
Such industrial weaving machines enable production of fabrics at a high rate while enabling a satisfactory laying quality of the weft thread.
However, a drawback of industrial weaving machines is that the diversity of fabrics produced using such machines is limited. Notably, a conventional industrial weaving machine of the type described above only enables production of fabrics with a discontinuous weft thread.
In consideration of the foregoing, the invention is intended to propose an industrial weaving machine and an industrial weaving method that overcomes the aforementioned drawbacks.
More specifically, the invention is intended to provide an industrial weaving machine and an industrial weaving method that is able to produce a significant range of fabrics at a fast rate, in particular continuous weft thread fabrics, without complicating the design of the weaving machine or complicating the work of the operator.
For this purpose, a weaving machine is proposed, comprising a structure able to support a plurality of warp threads extending in a first direction, a heddle mechanism capable of selectively moving at least some of the plurality of warp threads to form first and second sheets of warp threads, at least one weft-thread feed spool, and at least one support shuttle for said feed spool.
According to a general feature, this weaving machine also includes an actuating device able to control a movement of said shuttle between the first and second sheets of warp threads in at least one second direction transverse to the first direction, and in both senses relative to said second direction, to continuously lay the weft thread coming from the feed spool between said sheets and in said second direction.
Such a weaving machine helps to improve the diversity of fabrics that can be produced, in particular continuous weft thread fabrics, at a fast production rate, while maintaining a simple design of the weaving machine and without complicating the work of the operator. ‘Second direction transverse to the first direction’ means that the second direction is secant to the first direction, i.e. not parallel to the first direction. Unlike a discontinuous weft-thread fabric, a continuous weft-thread fabric is a fabric in which the weft thread makes several passes between the plurality of warp threads, said weft thread being a single continuous portion, i.e. unbroken.
According to one embodiment, the weaving machine has means for adjusting a weaving angle corresponding to the angle formed between the second direction and the first direction.
The weaving machine according to this embodiment also makes it possible to vary the weaving angle, the angle formed between the direction of the weft thread and the direction of the warp threads, such as to further increase the diversity of fabrics that can be obtained.
Advantageously, said adjustment means are designed to enable a variation in the weaving angle between 40° and 90°.
According to one embodiment, the adjustment means include a mechanical pivot link designed to enable the actuating device to pivot about a direction perpendicular to the direction of the movement of the shuttle.
Advantageously, the adjustment means include a sliding mechanical link designed to enable the translational movement of a stop element for stopping the movement of the shuttle.
Preferably, the actuating device includes a rack actuator and means for hitching a movable element of the rack actuator to said shuttle.
The use of a rack actuator coupled to hitching means makes it possible to simply and reliably move the shuttle between the sheets of weft threads. Furthermore, the rack guides the movement of the shuttle, which makes the weaving machine particularly suited to large diameter weft threads (in the range 0.5 mm to 1.4 mm), such as those typically used in tyre strengthening fabric.
According to one embodiment, the hitching means include a first ferromagnetic element designed to cooperate with a second ferromagnetic element mounted on said shuttle, at least one of the first and second ferromagnetic elements being an electromagnet or a permanent magnet.
Throughout the present application, the term ‘ferromagnetic’ is used according to the normal sense, i.e. a ferromagnetic material is a material that can be magnetized under the effect of an external magnetic field.
The use of hitching means including ferromagnetic elements helps to keep the design of the weaving machine simple, without complicating the work of the operator and maintaining a satisfactory level of reliability when using the machine.
According to one embodiment, the structure has a device for disconnecting said shuttle from the actuating device, said disconnection device having an electromagnet or a permanent magnet.
The use of such a disconnection device notably including an electromagnet and/or a permanent magnet, like the hitching means including ferromagnetic elements, makes it possible to optimize the compromise between simplicity of design, complexity of the work of the operator and usage reliability of the machine.
In an advantageous embodiment, the hitching means and the disconnection device together have three permanent magnets and one electromagnet. This simplifies the design of the machine.
According to one embodiment, the machine also has a slatted beater, said beater being removable.
Slatted beaters are particularly suitable for weaving machines used to manufacture composite fabrics intended for use in tyres, in consideration of the stiffness of the materials used to form the warp threads and/or the weft threads, and the resulting friction. Furthermore, the use of removable beaters enables the use of beaters that are particularly suited to a particular type of fabric to be obtained using the weaving machine, such as a fabric having a specific weaving angle, for example.
Advantageously, the structure has at least one clamp positioned on one side of the plurality of warp threads in line with the second direction, said at least one clamp being designed to capture a weft thread when said weft thread is laid between the warp threads.
Preferably, the spool has means for orienting the output direction of the weft thread from the spool.
According to another aspect, a weaving method is proposed that uses a weaving machine including a plurality of warp threads extending in a first direction, in which at least some of the plurality of warp threads are moved selectively to form first and second sheets of warp threads, then an actuating device is controlled to move at least one support shuttle for at least one feed spool for weft thread between the first and second sheets of warp threads in at least one second direction transverse to the first direction, and in both senses relative to said second direction, to continuously lay the weft thread coming from the feed spool between said sheets and in said second direction.
In an advantageous embodiment, the following steps are implemented:
Preferably, the warp thread is made of metal and/or the weft thread is made of a textile material. The metal warp thread is advantageously made of steel.
According to another aspect, a fabric obtained using a method such as the one described above is proposed.
According to yet another aspect, a tyre is proposed that has a crown comprising a belt reinforcement and a sculpted tread extended by two flanks, in which at least one tyre zone is reinforced by a fabric obtained using the method.
Other objectives, features and advantages of the invention are set out in the description below, given purely by way of non-limiting example and with reference to the attached drawings, in which:
For the sake of clarity and comprehension, an orthonormal vector base 6 relating to the structure 4 is provided. The base 6 comprises a vector {right arrow over (x)}, a vector {right arrow over (y)} and a vector {right arrow over (z)}. As shown in the figures, the vector {right arrow over (x)} is oriented parallel to a transverse direction of the structure 4, the vector {right arrow over (y)} being parallel to a longitudinal direction of the structure 4. The weaving machine 2 is designed to be installed such that the vector {right arrow over (z)} relating to the structure 4 is vertical and oriented upwards. In other words, the vector {right arrow over (z)} is parallel to a vertical direction defined in relation to the structure 4. In these conditions, the plane formed by the vectors {right arrow over (x)} and {right arrow over (y)} is horizontal.
In the present application, the expressions ‘downwards’, ‘upwards’, ‘lower’ and ‘upper’ shall be understood with reference to the base 6 with the weaving machine 2 installed normally, i.e. assuming that the vector {right arrow over (z)} is oriented vertically upwards. Equally, the terms ‘left’ and ‘right’ shall be understood relatively in relation to the vector {right arrow over (x)}, the left-hand side being the starting point of the vector {right arrow over (x)} and the right-hand side being the end point of the vector {right arrow over (x)}.
The structure 4 has an oblong-shaped main body 8 oriented in the direction of the vector {right arrow over (y)}. The body 8 is extended by a first cross arm 10 and a second cross arm 12. The cross arms 10 and 12 extend from the two respective ends of the body 8 in the direction and sense of the vector {right arrow over (x)}. Each of the arms 10, 12 is oblong shaped and is oriented parallel to the direction of the vector {right arrow over (x)}. The arms 10 and 12 are of the same length. The structure 4 also has a longitudinal arm 14. The arm 14 is connected on one side to the end of the arm 10 opposite the connection end to the body 8 and on the other side to the end of the arm 12 opposite the connection end to the body 8. The arms 14 extend between these ends in the direction of the vector {right arrow over (y)}.
As shown in
The structure 4 carries a plurality of warp threads indicated as a whole using reference sign 16. In the example shown, ten warp threads 16a, 16b, 16c, 16d, 16e, 16f, 16g, 16h, 16i and 16j are arranged in succession and in this order in the direction and the sense of the vector {right arrow over (x)}. Naturally, the number of threads shown here is in no way limiting.
With the help of the structure 4, and more specifically the arms 10 and 12, the warp threads 16 extend in the longitudinal direction of the structure 4 parallel to the vector {right arrow over (y)}. For example, the arm 10 can have a perforated plate (not shown), the warp threads 16 passing respectively through the perforations in the perforated plate held by the arm 10. On the other side, the arm 12 can have two rollers (not shown) between which the fabric made is passed. Alternatively, a single roller about which the fabric made is wound can be provided. Thus, the arms 10 and 12 hold the portion of the warp threads 16 facing the arms 10 and 12 in the direction of the vectors {right arrow over (x)} and {right arrow over (z)}.
The weaving machine 2 can also have a feed mechanism (not shown) for the fabric and therefore the warp threads 16. In a known manner, such a mechanism can include an electric motor (not shown) driving a roller causing the simultaneous movement of the fabric and therefore the warp threads 16 in the direction of the vector {right arrow over (y)}.
The structure 4 is also provided with a heddle mechanism 18 including an upper cross arm 20 and a lower cross arm 22 that face one another vertically. The arm 20 has a vertical portion (not referenced) extending from the upper surface of the body 8 in the direction and in the sense of the vector {right arrow over (z)}. The arm 22 has a vertical portion (not referenced) extending from a lower surface of the body 8 in the direction of the vector {right arrow over (z)} and in the sense opposite the vector {right arrow over (z)}. Each arm 20, 22 has a horizontal portion (not referenced) extending respectively from the upper or lower end of the vertical portion of said arm 20, 22 in the direction and in the sense of the vector {right arrow over (x)}.
The operating principle of the heddle mechanism 18 is shown schematically in
The heddle mechanism 18 can be used to selectively move at least some of the warp threads 16 such as to form several sheets of warp threads. More specifically, in the example embodiment shown, the mechanism 18 is designed to selectively move half of the heddles upwards and the other half of the heddles downwards. The heddle mechanism 18 thus divides the heddles 24 into two groups of heddles, a first group comprising the heddles 24b, 24d, 24f, 24h and 24j and a second group comprising the heddles 24a, 24c, 24e, 24g and 24i. The mechanism 18 thus forms two sheets, one lower and the other upper. The sheets correspond respectively to the threads associated with the first group and to the threads associated with the second group, the mechanism 18 then periodically alternating the position of the two sheets.
Again with reference to
With reference to
More specifically, the angle α can vary between a first extreme value α1 and a second extreme value α2. In the example shown, the angle α1 is substantially equal to 90°, the angle α2 being substantially equal to 40°.
In the example shown, the shaft 17 has an electric motor (not shown) for driving the section 31 in rotation about the direction of the vector {right arrow over (z)}. Other means may nonetheless be used to cause this rotation without thereby moving outside the scope of the invention. For example, in a variant, the rotation of the section 31 about the direction of the vector {right arrow over (z)} in relation to the structure 4 is caused manually by the operator.
Again with reference to
The actuating device 32 has a rack actuator (not shown) that is intended to cause the rod 33 to move in translation in relation to the pin 34. For this purpose, the rack actuator can include an electric motor for driving a pinion gear cooperating with a rack. For example, the electric motor has a casing rigidly connected to the movable portion of the pin 34, the pinion gear meshing with a rack that is part of the rod 33 and that extends in the longitudinal direction of said rod 33. The rack advantageously extends over the entire length of the rod 33 between the ends 35 and 37. Consequently, the rod 33 can move between a first end position in which the end 35 is close to the pin 34, as shown in
Thus, the pivoting section 31 and the rack actuator (not shown) can be used to move the rod 33 in rotation about the direction of the vector {right arrow over (z)} and in translation in the longitudinal direction of the rod 33, in relation to the structure 4.
The actuating device 32 also has hitching means. The hitching means are intended to enable the rod 33 to be rigidly connected to a support shuttle for the weft-thread feed spool. For this purpose, the end 35 of the rod 33 has a permanent magnet 36. As explained below, the permanent magnet 36 is designed to cooperate with a corresponding permanent magnet on the shuttle.
With reference to
With reference to
The shuttle 44 is oblong shaped, and the longitudinal direction of the shuttle 44 coincides substantially with the direction of the shaft 40. The shuttle 44 has two ends 45 and 47.
With reference to
In this case, the magnets 36 and 46 are dimensioned such that the force ε36-46 satisfies the following inequation:
ε36-46≥m·(g+amax),
in which:
m is the mass of the shuttle 44 supporting the spool 38 loaded with weft thread 43,
g is the acceleration of gravity, and
amax is the maximum acceleration undergone by the rod 33 during movement thereof in relation to the structure 4.
The machine 2 also has a disconnection device 48 that is used to exert an additional force on the shuttle 44 such as to break the rigid assembly formed by the rod 33 on one hand and by the shuttle 44 and the spool 38 on the other hand.
With reference to
In this case, the electromagnet 50 and the permanent magnet 54 are dimensioned such that the force ε50-54 is strictly greater than the force ε36-46, and preferably equal to or greater than the force ε36-46 multiplied by a factor of at least 1.5.
As explained below, the actuating device 32 moves the spool 38 in translation in the longitudinal direction of the rod 33 such as to arrange the weft thread 43 in that same longitudinal direction of the rod 33. Consequently, the laying direction of the weft thread 43 coincides with the longitudinal direction of the rod 33 and the weaving angle, which is the angle formed between the direction of the weft thread 43 laid and the direction of the warp threads 16, is the angle α.
With reference to
When the section 31 is rotated by the electric drive motor, the control device 58 can also have an input interface for a weaving angle αconsigne. As a function of the angle αconsigne, the device is 58 controls the rotation of the pin 34 such that the angle α is equal to the angle αconsigne. The input interface can also be used to enter other instruction parameters, such as an instruction for making a fabric with a plain weave or taffeta, a twill weave, a satin weave or an equivalent weave.
In the example shown, the heddle mechanism 18 is designed to split the heddles 24 into two groups of heddles. However, the number of heddle groups can be increased to make the fabric produced more flexible without thereby moving outside the scope of the invention. For example, the use of three or four groups of heddles makes it possible to achieve greater flexibility, without thereby significantly complicating the weaving method.
For example, in an arrangement in which the mechanism 18 splits the heddles 24 into four groups of heddles, a first group comprises the heddles 24a, 24e and 24i, a second group comprises the heddles 24b, 24f and 24j, a third group comprises the heddles 24c and 24g, and a fourth group comprises the heddles 24d and 24h. The heddle mechanism 18 is then appropriately arranged to distribute the groups of heddles into two sheets and to modify this distribution periodically. More specifically, the mechanism implements four successive steps. In each of the first, second, third and fourth steps respectively, the first, second, third or fourth group of heddles forms the first sheet, and the other three groups of heddles form the second sheet. The mechanism 18 is designed to repeat the succession of these four steps as long as the machine 2 is being used. Such an arrangement notably enables a fabric with a satin weave to be obtained. An arrangement in which the mechanism 18 divides the heddles 24 into three groups of heddles notably enables a fabric with a twill weave to be obtained.
Advantageously, the machine 2 is provided with a plurality of beaters similar to the beaters 64 and 66, the slats of which form different angles in relation to the longitudinal direction of said beaters. For example, the machine 2 has a beater in which the slats form a 90° angle in relation to the longitudinal direction of said beater, a beater with a corresponding angle of 85°, a beater with a corresponding angle of 80°, etc. As explained below, this plurality of beaters forms a tool to enable the operator to produce fabrics with variable weaving angles.
Again with reference to
In the example shown, a single shuttle 44 is provided with a guide device with an adjustable guide angle β. A plurality of shuttles having guide devices with different guide angles β can naturally be provided without thereby moving outside the scope of the invention, such that a shuttle having a guide device with a particular guide angle β is suited to each weaving angle. Such an alternative has the advantage of keeping the design of the shuttle 44 simple. Furthermore, since the shuttle is held in relation to the structure 4 using magnetic means, it is particularly easy to carry out the assembly, disassembly and replacement steps for the shuttles.
As mentioned previously, the shuttle 44 is held in relation to the structure 4 by three permanent magnets 36, 46 and 54 respectively provided on the rod 33 and at the ends 45 and 47 of the shuttle 44, and by an electromagnet 50 provided on the support 52. However, different magnetic means may be used without thereby moving outside the scope of the invention. In particular, at least one of the permanent magnets 36, 46 and 54 can be replaced by an electromagnet, in which case the electromagnet 50 can be replaced by a permanent magnet.
In other words, the assembly formed by the hitching means and the disconnection device 48 includes a single electromagnet and two or three permanent magnets. This enables the shuttle 44 to be moved without increasing the complexity of the weaving machine 2.
However, the arrangement in the example shown is advantageous where only one electromagnet needs to be powered, or where the electromagnet is easier to power if the electromagnet is mounted on the support 52 than if it were mounted on the shuttle 44, and to a lesser extent on the rod 33.
The weaving machine 2 can be used to implement the method according to the following non-limiting example embodiment of the invention. According to this example embodiment, the weaving method is intended to obtain a fabric with a weaving angle of 70°. However, the machine 2 can also be used to obtain a fabric having different parameters, notably forming any weaving angle of between 40° and 90°.
In this example embodiment, at the starting state of the method, the machine 2 is arranged according to the arrangement shown in
During a first step, an operator uses the input interface of the device 58 to enter the instruction parameters. More specifically, the operator uses the input interface to enter a specific weaving angle, if required. In the present example embodiment, the operator enters a weaving angle αconsigne=700 and a continuous weft-thread fabric.
During the second step, the device 58 controls the electric drive motor of the section 31 such that the angle α is equal to the angle αconsigne. At the same time, the rod 33 pivots about the direction of the vector {right arrow over (z)} to be positioned parallel to the direction of the weave, the end 35 being close to the pin 34. At this instant, the rod 33 is said to be arranged in the starting position.
In a third step, the operator selects a beater suited to the chosen angle αconsigne selected from the plurality of beaters provided with the machine 2. More specifically, the operator selects a slatted beater in which the slats form an angle with the longitudinal direction of the beater corresponding to the value of the angle αconsigne. The operator then places the beater Selected on the movable support 68 thereof.
In a fourth step, the heddle mechanism 18 selectively moves a portion of the warp threads 16 such as to form an upper sheet and a lower sheet. In other words, the heddles 24a, 24c, 24e, 24g and 24i are shifted downwards and the heddles 24b, 24d, 24f, 24h and 24j are shifted upwards. Consequently, the warp threads 16a, 16c, 16e, 16g and 16i are selectively moved downwards and the warp threads 16b, 16d, 16f, 16h and 16j are selectively moved upwards. In other words, the weft threads 16 are moved selectively such as to form the sheets 28 and 30, as shown in
In a fifth step, the device 58 controls the rack actuator such as to move the rod 33 towards the electromagnet 50. The rod 33 is thus moved leftwards (with reference to
During a subsequent sixth step, the device 58 powers the electromagnet 50 with electrical energy. The force ε50-54 then it appears and the rigid assembly formed by the rod 33 on one hand and the shuttle 44 on the other is disconnected. The shuttle 44 is then rigidly connected to the electromagnet 50.
During a seventh step, the device 58 controls the rack actuator such as to return the rod 33 disconnected from the shuttle 44 to the starting position. The rod 33 is then moved rightwards (with reference to
During a subsequent eighth step, the heddle mechanism 18 selectively moves some of the warp threads 16 to a different arrangement than in the fourth step. The heddles 24b, 24d, 24f, 24h and 24j are then shifted downwards and the heddles 24a, 24c, 24e, 24g and 24i are shifted upwards. The warp threads 16b, 16d, 16f, 16h and 16j are therefore selectively moved downwards and the warp threads 16a, 16c, 16e, 16g and 16i are moved upwards. At the end of the eighth step, the position of the sheets 28 and 30 is then inverted in relation to the position thereof at the end of the fourth step.
In a ninth step, the device 58 again controls the rack actuator such as to move the rod 33 towards the electromagnet 50. The ninth step ends when the end 35 comes into contact with the end 45 of the shuttle 44.
During a tenth step, the device 58 deactivates the electrical energy supply to the electromagnet 50. This causes the force ε50-54 to disappear, such that the shuttle 44 again forms a rigid assembly with the rod 33.
During an eleventh step, the device 58 controls the rack actuator such as to return the rod 33 to the starting position. The rod 33 is moved rightwards (with reference to
The method includes a twelfth step of beating the weft thread laid. During this step, the beater (not shown) mounted by the operator is moved in translation in the direction and the sense of the vector {right arrow over (y)}. The beater, initially positioned between the heddle mechanism 18 and the being 15, moves beyond the beam 15 such as to push and beat the weft thread laid to an end position (not shown) between the beam 15 and the arm 12.
These twelve steps can be repeated as many times as required to obtain a fabric long enough for the intended use.
Advantageously, the machine 2 can also have clamps (not shown) mounted on the structure 4, and more specifically respectively mounted on the body 8 and on the arms 14, or on the section 31. The clamps are intended to maintain the tension of the weft thread when a weft thread is being laid between the warp threads 16. More specifically, each clamp respectively holds a portion of the weft thread Located to the left of the warp thread 16a And a portion of the weft thread Located to the right of the warp thread 16j. This hold is advantageously applied after the weft thread has been laid and before the beater is moved.
Thus, the weaving machine 2 and the method described above can be used to produce a continuous weft thread fabric with a variable weaving angle other than 90°. Furthermore, the overall production rate remains the same as with a conventional industrial weaving machine. Furthermore, the weaving machine does not have a more complex design and the corresponding weaving method does not involve any steps that are particularly complex for the operator. Compared to a conventional industrial weaving machine, the invention also makes it possible to control the tension of the weft thread laid at a weaving angle other than 90°. This results in a better quality fabric.
In the example embodiment illustrated, the machine 2 makes it possible to obtain a fabric with a continuous weft thread. However, the weaving machine 2 can also be used to obtain a fabric with a discontinuous weft thread without there by moving outside the scope of the invention. To do so, a cutting member designed to cut the weft thread with each pass of the shuttle 44 need simply be provided.
A particularly beneficial application of such a weaving machine relates to the manufacture of tyres. Indeed, by enabling the production of warp threads with continuous weft threads at a weaving angle other than 90°, the fabric produced is particularly suited for use as tyre reinforcement. Indeed, on account of the continuity of the weft threads and the arrangement thereof at a specific weaving angle, the fabric enables an enhanced transmission of the forces in the tyre and therefore between the road and the vehicle. Furthermore, by better controlling the tension of the weft thread, the quality of the tyre that can be made using the fabric produced also increases.
To do so, the fabric obtained using such a weaving machine and such a weaving method can be enveloped in a rubber mixture. Reinforced sections can then be cut from the rubber mixture, and portions taken therefrom to form crown plies or other reinforced portions of a tyre. In particular, the fabric made using a weaving method according to the invention can be enveloped in a rubber mixture using a calendering method.
An example fabric providing particularly satisfactory results when enveloped in a rubber mixture to produce a tyre is a fabric with metal warp threads, preferably steel, and a continuous weft thread, obtained using the method according to the invention with a weaving angle of approximately 60°.
A fabric 84 according to an example embodiment of the invention is shown schematically in
With reference to
In practice, the distance between two warp threads 16 respectively located at the two opposite ends of the plurality of warp threads 16 is greater than shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 1662897 | Dec 2016 | FR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2017/083456 | 12/19/2017 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2018/114895 | 6/28/2018 | WO | A |
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| 20190382929 A1 | Dec 2019 | US |
