Abstract:
A method and system for manufacturing complex, three-dimensional textile structures is disclosed. These textile structures may be large and heavy and difficult to maneuver without damaging them. The method enables various types of joints to be constructed between textile panels plus the application of patches and details onto the surface of these panels. The method minimizes handling and damage to the textile material. The method also reduces the manpower required during the manufacturing process, thus minimizing manufacturing time and cost.

Description:
TECHNICAL FIELD 
       [0001]    The present technology relates generally to manufacturing techniques and, in particular, to systems and methods for manufacturing textile structures. 
       BACKGROUND 
       [0002]    Next-generation structures in many industries will increasingly utilize high-performance engineered textiles, fabrics, laminates, and composite materials. These textiles may include functional fibers or embedded sensors or other elements such as, for example, photovoltaic filaments. 
         [0003]    Manufacturing such structures, however, is challenging because of the unconventional handling requirements for these textiles. For example, the fabrication of airships with solar energy capturing textiles may require the welding together of large sections of textiles. Efficiently handling these large sections of textiles for welding, cutting, inspection, or other such manufacturing operations has been a technical problem for which a viable solution is now disclosed herein. 
       SUMMARY 
       [0004]    In general, the present invention provides a novel method and system for manufacturing textile structures. The invention uses pressurized air to cause the textile structure, or a subcomponent thereof, to hover. While the textile structure is hovering, the textile structure may be easily displaced, manoeuvred, rotated, or otherwise moved relative to one or more manufacturing machines that are used to perform manufacturing operations on the textile structure. 
         [0005]    Thus, an aspect of the present invention is a method of manufacturing a textile structure. This novel manufacturing method comprises steps, acts, or operations of causing a textile structure to hover by applying air pressure to an underside of the textile structure, horizontally displacing the textile structure relative to a manufacturing machine while the textile structure is hovering, and performing a manufacturing operation on the textile structure using the manufacturing machine. 
         [0006]    Another aspect of the present invention is a system for manufacturing a textile structure. This novel manufacturing system comprises an air pressure source for providing air pressure within a chamber having an upper surface that includes a plurality of air apertures for discharging air to cause a textile structure to hover above the upper surface, and a manufacturing machine that is substantially vertically aligned with the upper surface to enable a manufacturing operation to be performed on the textile structure. 
         [0007]    Other aspects of the present invention are described below in relation to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    Further features and advantages of the present technology will become apparent from the following detailed description, taken in combination with the appended drawings, in which: 
           [0009]      FIG. 1  is a schematic depiction of a system for manufacturing a textile structure in accordance with an embodiment of the present invention; 
           [0010]      FIG. 2  is a schematic depiction of a system for manufacturing a textile structure in accordance with another embodiment of the present invention; 
           [0011]      FIG. 3  is a schematic depiction of a system for manufacturing a textile structure in accordance with another embodiment of the present invention; 
           [0012]      FIG. 4  is a schematic depiction of a system for manufacturing a textile structure in accordance with another embodiment of the present invention; and 
           [0013]      FIG. 5  is a schematic depiction of a system for manufacturing a textile structure in accordance with another embodiment of the present invention. 
       
    
    
       [0014]    It will be noted that throughout the appended drawings, like features are identified by like reference numerals. 
       DETAILED DESCRIPTION 
       [0015]    As depicted by way of example in  FIG. 1 , the novel manufacturing method and system is based around a central raised work surface ( 1 ) around which one or more manufacturing machines ( 2 ) are arranged. In the embodiment illustrated in  FIG. 1 , the manufacturing machines ( 2 ) are disposed to substantially vertically align the textile structure with the operative elements of the manufacturing machines. This provides a comfortable working height for the workers and obviates the need to lift the bulk (mass) of the structure under construction ( 3 ) off the floor ( 8 ). In general, this new technology facilitates manufacturing of textile structures. 
         [0016]    For the purposes of this specification, “manufacturing machines” are meant to encompass welding machines (e.g. high-frequency (HF) welding machines, ultrasonic textile welding machines, laser welding machines, hot air welding, chemical welding, etc.), cutting machines, drilling machines, plotters, inspection machines, sewing machines, or any other machine tools, equipment, apparatus, tool or device used to join, cut, drill, manipulate, fold, finish, clean, spray, or otherwise work the textile material. 
         [0017]    For the purposes of this specification, a “textile” or “textile material” is intended to encompass any material or fabric with a woven substrate which may or may not be coated with a polymer to enhance its properties (e.g. to make it more easily welded, to provide a gas barrier, a weather barrier, etc.). The term “textile” or “textile material”, as used herein, is also intended to include more generally any flexible material whether woven, non-woven, and even an unreinforced film with no substrate. For example, “textiles” or “textile materials” may include any flexible plastic material such as polyamides, polyimides, polyethylene derivatives, polyvinylchloride (PVC), polyurethane films, polyester and polyurethane coated fabrics. A “textile structure”, as the expression is used herein, is therefore any structure made of (or incorporating) such a textile or textile material, and is meant to include any component, subcomponent, assembly, subassembly or part that is constructed or used to form a textile structure. 
         [0018]    Alternatively, in another embodiment such as the one depicted in  FIG. 2 , the manufacturing machines (e.g. welding machines) may be sunk into a trough or pit ( 4 ) around the perimeter of the factory floor ( 5 ) that acts as the work surface. This arrangement achieves the same objective of vertically aligning the textile structure with the one or more manufacturing machines. However, it should be understood that the manufacturing machines need not be disposed around the perimeter. For example, in an alternative configuration, the manufacturing machines may be disposed centrally with the work surfaces being disposed peripherally. 
         [0019]    As further shown in  FIG. 1 , in some embodiments, the manufacturing machines ( 2 ), for example welding machines, are suspended from overhead gantries ( 6 ) or suspended (or otherwise supported) from cantilevered cranes ( 7 ) so that the floor ( 8 ) underneath the machines ( 2 ) is clear and there is no danger of damaging the structure ( 3 ) when moving the machine(s). 
         [0020]    As depicted in the embodiment of  FIG. 3 , one or more operator work stations may also be suspended along with the welding machine so that the operator can avoid stepping, kneeling or otherwise putting unwanted pressure onto the structure or any of its component textile materials. The work station might include one or more seats ( 9 ), one or more standing platforms ( 10 ) and/or one or more harness systems ( 11 ) as appropriate to the operation(s) being conducted. 
         [0021]    The machines depicted for example in  FIG. 1  may move along the gantries, either manually or via a motor drive ( 12 ). In one particular embodiment, the motor drive may be synchronized to the desired welding speed. 
         [0022]    The cantilevered cranes, which are depicted for example in the figures, may move freely on casters, wheels, rollers, etc. or along a guide rail mounted for example on the floor ( 8 ), either manually or via a motor drive ( 13 ). In one particular embodiment, the motor drive may be synchronized to the desired welding speed. 
         [0023]    In one embodiment, a control system comprising sensors and a processor for executing a control algorithm that may be provided to control the displacement of the motor drives ( 12 ,  13 ). 
         [0024]    In embodiments of the present invention, the work surface ( 1 ) of the manufacturing system has a ventilated upper surface ( 14 ) with a chamber or chambers underneath ( 15 ). The chambers may be pressurized (with a pressure P) with a gas such as air from a fan system ( 16 ) or equivalent to create a stream of air ( 17 ) underneath the textile structure ( 3 ) under construction. This creates a cushion of air under the textile structure allowing it to ‘hover’ and thus to be easily moved (while the textile structure is hovering) into a desired position with minimal effort. For the purposes of this specification, to “hover” means to float or remain aloft in the air at a substantially constant vertical position or elevation relative to the ground or a work surface. When the textile structure hovers, there is a small gap or space between the bottom of the textile structure and the ground or work surface such that the textile structure does not contact the ground or work surface while hovering. While hovering, the lift force produced by the pressurized air is equal and opposite to the weight of the structure, thereby placing the structure is vertical equilibrium. The hovering of the textile structure minimizes the possibility of damage to the fabric. Alternatively, the chambers may be evacuated of air to create a vacuum (V) beneath the textile structure to stabilize its position, i.e. to immobilize the textile structure. For the purposes of the specification, it is understood that a vacuum includes a partial vacuum. One such exemplary arrangement is depicted for example in  FIG. 1 . An exhaust fan may be provided to draw air from the one or more air chambers. In one embodiment, an air system having a reversible fan provides either positive air pressure or a vacuum. The air system can be switched between a hover mode (for displacing the textile structure) and a vacuum mode (for immobilizing the textile structure). In another embodiment, the air system may include a fan for drawing air into the chamber and a separate exhaust fan to evacuate the chamber and to create a vacuum in the chamber. 
         [0025]    In some embodiments of the present invention, as depicted in  FIG. 4 , the system optionally includes one or more winches ( 18 ,  19 ), or pulleys or equivalent mechanisms. The one or more winches may be distributed or disposed at various locations in the system. For example, a first winch ( 18 ) may be disposed on the work surface. As another example, a second winch ( 19 ) may be disposed on an overhead gantry. Winches may be alternatively mounted to the ceiling, structural beams, posts, overhead structures, walls, or to other equipment or machinery, etc. The ends of the winch cables ( 20 ) can be connected to parts of the textile structure under construction via suitable connectors such as, for example, a clamp ( 21 ) and/or a vacuum cup ( 22 ). The winches ( 18 ,  19 ) may be remotely controlled individually or synchronously to maneuver the textile structure into a suitable position for welding or to assist with packing the envelope as shown by way of example in  FIG. 4 . In an alternative embodiment, the clamp ( 21 ) and vacuum cup ( 22 ) may be mounted on robotic manipulators or any other suitable mechanism(s) instead of being mounted to the winches. The winches, manipulators or other such lift mechanism(s) may thus be used to lift a portion of the textile structure to which the clamp or vacuum cup is affixed, as shown by way of example in  FIG. 4 . 
         [0026]    In yet other embodiments of the present invention, as depicted by way of example in  FIG. 5 , the system may include one or more air hoses to inflate (or at least partially inflate) the textile structure. For example, this might be very useful when constructing an airship having a textile structure, although it should be understood that inflation of textile structures might be used in many other applications outside of aerospace. 
         [0027]    In the embodiment depicted by way of example in  FIG. 5 , an air connection point in the form of an air hose coupling ( 23 ) is mounted to the upper surface of the air chamber to enable the connection of an air hose ( 24 ). The air hose may be used to inflate or deflate the textile structure using the chamber&#39;s air supply as shown by way of example in  FIG. 5 . For example, a textile structure for an airship may be inflated (or at least partially inflated) to facilitate welding, surface finishing, application of coatings, cleaning, inspection or other manufacturing operations. After the operations are complete, the airship or other product may optionally be deflated through the same air hose ( 24 ). Although only a single air hose coupling and a single air hose are depicted in  FIG. 5 , it should be understood that the system in another embodiment could have a plurality of air hose couplings and a plurality of air hoses for simultaneously inflating the textile structure. In a variant, the system may include a manifold for connecting a plurality of air hoses. 
         [0028]    As shown by way of example in  FIG. 5 , the system may include one or more suspension points ( 25 ) affixed to the overhead gantries (or, alternatively, to other movable or immovable mounting points) to enable an operator or worker to be suspended by a harness or any equivalent means above the textile structure. This provides the suspended worker with access to the upper surface of the textile structure without having to step on, or otherwise apply unwanted pressure to, the textile structure. 
         [0029]    In one embodiment, the system may comprise a means (air flow subsystem) to vary the air pressure. Variable air pressure may be used to support (hover) structures of different weight or to increase or decrease the hover elevation. Such a system may include a computerized control system to control air pressure based on the vertical position of the textile. For example, the control system may include a height or elevation sensor and a feedback control loop implemented in software executed by a processor the control system. This control system is thus able to control an elevation or vertical position of the textile structure. For example, an optical sensor may be used to measure an elevation of the structure over the work surface. The processor of the control system may then generate a control signal to the air flow subsystem to vary the pressure of the air, either by controlling an air compressor and/or by regulating an air supply valve. Controlling the air pressure enables the elevation over the work surface to be adjusted to ensure that the textile structure remains substantially vertically aligned with the welding machine or other manufacturing machine. Alternatively, the air collector boxes may include zones and valves so that air flows only when and where it is needed (e.g. for larger or smaller items). In another embodiment, the system may provide positive flow in some areas and negative flow in others so that part of the structure under construction may be hovered while, at the same time, vacuuming other parts of the structure to hold the structure in a fixed (stable) position. 
         [0030]    The novel method and system disclosed herein may be applied to a broad variety of manufacturing processes. Some examples of how this novel method and system may be used in different applications are described below to illustrate the versatility of this novel method and system. 
         [0031]    As a first example, this novel manufacturing method and system may be used for the fabrication of textile structures for the airship industry in which the textile structures (e.g. textiles made of polyesters and polyurethanes, etc) are impermeable to small gas molecules such as helium (He) or hydrogen (H 2 ). Similarly, the process may be used for the sailboat industry. 
         [0032]    As a second example, this novel method and system may be used for the fabrication of textiles for the solar-based transportation industry where solar cells or modules (or other electricity generating means) are integrated into the textile. 
         [0033]    As a third example, this novel method and system may be used for the fabrication of textiles for the solar-based infrastructure industry where solar cells or modules (or other electricity generating means) are integrated into a textile. These textiles require structural integrity to withstand winds and the elements (e.g. military or disaster-relief tents). For inflatable tents, the textiles may also need to withstand the stress and strain of pressurization and depressurization cycles. 
         [0034]    As a fourth example, this novel method and system may be used for the fabrication of textiles into which power generators and/or power storage elements are integrated. 
         [0035]    As a fifth example, this novel method and system may be used for the fabrication of textiles with sensing capabilities (e.g. leak sensing, pressure sensing, etc). 
         [0036]    As a sixth example, this novel method and system may be used for the fabrication of textiles with media capabilities such as flexible displays, banners, etc. 
         [0037]    As a seventh example, this novel method and system may be used for the fabrication of textiles with deicing capabilities for the transportation and the infrastructure industries. 
         [0038]    As an eighth example, this novel method and system may be used for the fabrication of textiles with self-cleaning capabilities for the transportation and the infrastructure industries. 
         [0039]    As a ninth example, this novel method and system may be used for the fabrication of textiles with self-healing capabilities for the transportation and the infrastructure industries. 
         [0040]    Other uses or applications of this novel technology will become apparent to those of skill in the art. Therefore, the examples presented above are not intended to restrict the uses of this technology. 
         [0041]    It should be appreciated that wherever human operators are shown as being involved in the manufacturing process these human operators can be replaced by robotics for a fully automated manufacturing process. 
         [0042]    It should also be appreciated that although the hovering is achieved using air, other gases e.g. nitrogen, may be used. In some embodiments, the air or other gas may be heated to increase lift. In other embodiments, self-contained portions or components of the textile structure may be fully or partially inflated with a lifting gas like hydrogen or helium. 
         [0043]    This new technology has been described in terms of specific implementations and configurations which are intended to be exemplary only. Persons of ordinary skill in the art will appreciate that many obvious variations, refinements and modifications may be made without departing from the inventive concepts presented in this application. The scope of the exclusive right sought by the Applicant(s) is therefore intended to be limited solely by the appended claims.