CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application 63/389,960, filed July 18, 2022, whose disclosure is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to production of fabrics and clothes, and particularly to methods and systems for controlling the interlacing of fiber arrays.

BACKGROUND OF THE INVENTION

Various techniques for interlacing fibers of cloths and fabrics have been published.

SUMMARY OF THE INVENTION

An embodiment of the present invention that is described herein provides a system for interlacing fibers, the system includes: a frame, which is configured to wind one or more first fibers about a plane of the frame; a needle, which is configured to: (a) be coupled with at least a second fiber, and (b) interlace the second fiber with the one or more first fibers; and a motor assembly, which is coupled to the needle and is configured to: (i) move the needle relative to the frame along a first axis for coupling between a section of the needle and at least the second fiber, and at the same time, (ii) vibrate at least the section of the needle relative to the frame along a second axis, different from the first axis.

In some embodiments, the frame is configured to be rotated about the first axis for winding the one or more first fibers. In other embodiments, the frame is configured to be moved, along the first axis, relative to a supplying source of the one or more first fibers for winding the one or more first fibers.

In some embodiments, the motor assembly is configured to move and vibrate the section in a pattern such that one or more first given fibers of the first fibers are located at a first side of the needle, and one or more second given fibers of the first fibers are located at a second side of the needle. In other embodiments, the motor assembly is configured to move the needle along the first axis: (i) in a first direction for coupling between the section and the second fiber, and subsequently, (ii) in a second direction opposite the first direction, for interlacing the second fiber with the one or more first fibers. In yet other embodiments, the system includes a processor, which is configured to control the motor assembly to determine the pattern by setting: (i) a first movement speed of the needle in the first direction, and (ii) a frequency and an amplitude of at least the section of the needle along the second axis.

In some embodiments, after coupling with the second fiber, the processor is configured to control the motor assembly to move the needle in a second movement speed in the second direction. In other embodiments, the processor is configured to control the motor assembly to determine an alternating pattern having alternating: (i) one or more first groups of the one or more first given fibers, and (ii) one or more second groups of the one or more second given fibers. In yet other embodiments, the motor assembly includes a piezoelectric crystal, which is configured to vibrate the at least section of the needle along the second axis.

There is additionally provided, in accordance with an embodiment of the present invention, a method for interlacing fibers, the method including winding one or more first fibers about a plane of a frame. A needle is moved relative to the frame along a first axis in a first direction for couphng between a section of a needle and at least a second fiber, and at the same time, at least the section of the needle is vibrated relative to the frame along a second axis, different from the first axis. The section of the needle and at least the second fiber are coupled, and the needle is moved relative to the frame along the first axis in a second direction opposite the first direction, for interlacing between at least the second fiber and the first fibers.

There is further provided, in accordance with an embodiment of the present invention, a system for interlacing fibers, the system includes: a frame, a needle, and a motor assembly. The frame is configured to wind one or more first fibers about a plane of the frame, the needle is movable and having (i) a first section configured to be rotated about a first axis, and (ii) a second section, which is bent relative to the first section, and is configured to be coupled with at least a second fiber, and to interlace the second fiber with the one or more first fibers, and the motor assembly is coupled to the first section of the needle and is configured to interlace the second fiber with the one or more first fibers by: (i) moving the needle relative to the frame along the first axis, and at the same time, (ii) rotating the needle about the first axis.

In some embodiments, the motor assembly is configured to move and rotate at least the second section in a pattern such that one or more first given fibers of the first fibers are located at a first side of the needle, and one or more second given fibers of the first fibers are located at a second side of the needle. In other embodiments, the motor assembly is configured to move the needle along the first axis: (i) in a first direction for coupling between the second section and the second fiber, and subsequently, (ii) in a second direction opposite the first direction, for interlacing the second fiber with the one or more first fibers. In some embodiments, the system includes a processor, which is configured to control the motor assembly to determine the pattern by setting: (i) a movement speed of the needle along the first axis, and (ii) a rotation frequency of the needle about the first axis. In other embodiments, the processor is configured to control the motor assembly to determine an alternating pattern having alternating: (i) one or more first groups of the one or more first given fibers, and (ii) one or more second groups of the one or more second given fibers.

There is additionally provided, in accordance with an embodiment of the present invention, a method for interlacing fibers, the method including winding one or more first fibers about a plane of a frame. A needle is moved relative to the frame along a first axis in a first direction, and at the same time, the needle is rotated about the first axis, and the needle includes (i) a first section coupled to a motor assembly, and (ii) a second section, which is bent relative to the first section. The second section of the needle and at least a second fiber are coupled, and the needle is moved relative to the frame along the first axis in a second direction, opposite the first direction, for interlacing between at least the second fiber and the one or more first fibers.

The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings in which:

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a schematic, pictorial illustration of a system for winding one or more fibers about a frame, in accordance with an embodiment of the present invention;

Fig. 2 is a schematic, pictorial illustration of a system for winding one or more fibers about a frame, in accordance with another embodiment of the present invention;

Fig. 3 is a schematic top view of an assembly for inserting a needle between the fibers of Fig. 1, in accordance with an embodiment of the present invention;

Fig. 4 is a schematic side view of an assembly for inserting a needle between the fibers of Fig. 1, in accordance with an embodiment of the present invention;

Figs. 5-8 are schematic side views of an assembly for inserting a needle between the fibers of Fig. 1, in accordance with embodiments of the present invention;

Fig. 9 is a schematic top view of an assembly for inserting a needle and interlacing additional fibers between the fibers of Fig. 1, in accordance with an embodiment of the present invention;

Fig. 10 is a schematic side view of an assembly for inserting a needle and interlacing additional fibers between the fibers of Fig. 1, in accordance with an embodiment of the present invention; Fig. 11 is a schematic side view of an interlacing between different types of arrays of fibers in an example crisscross configuration, in accordance with an embodiment of the present invention;

Fig. 12 is a diagram that schematically illustrates a pictorial illustration of a process sequence for interlacing fibers, in accordance with an embodiment of the present invention;

Fig. 13 is a diagram that schematically illustrates a sectional view of a process sequence for interlacing fibers, in accordance with an embodiment of the present invention; and

Figs. 14 and 15 are flow charts that schematically illustrate methods for interlacing fibers using the systems of Fig. 1-11, in accordance with embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

OVERVIEW

Various techniques for interlacing fibers of cloths and fabrics have been published, typically, the fiber interlacing is carried out manually.

Embodiments of the present invention that are described hereinbelow provide improved techniques for interlacing fibers and/or wires using an automatic interlacing (also referred to herein as weaving) process.

In some embodiments, a system for interlacing fibers comprises: a frame, which is configured to wind first fibers about a plane of the frame, the winding process is described in more detail below. The system comprises a needle, which is configured to: (a) be coupled with at least a second fiber (different from the first fibers), and (b) interlace the second fiber with the first fibers.

In some embodiments, the system comprises a motor assembly, which is coupled to the needle and is configured to: (i) move the needle relative to the frame along a first axis (which is typically parallel to the plane) for coupling between a section (e.g., the distal end) of the needle and at least the second fiber, and at the same time, (ii) vibrate at least the section of the needle relative to the frame along a second axis, different from the first axis and typically orthogonal to the first axis.

In some embodiments, in the winding process, the frame is configured to be rotated about the first axis. Moreover, the frame is further configured to be moved along the first axis, relative to a supplying source of the one or more first fibers for winding the one or more first fibers.

In some embodiments, the motor assembly is configured to move and vibrate the distal end of the needle in a pattern such that one or more first given fibers of the first fibers are located at a first side of the needle, and one or more "”'on fibers of the first fibers are located at a second side of the needle. Moreover, the motor assembly is configured to move the needle along the first axis: (i) in a first direction for coupling between the section and the second fiber, and subsequently, (ii) in a second direction opposite the first direction, for interlacing the second fiber with the one or more first fibers.

It is noted that in the context of the present disclosure and in the claims, the terms “interlacing” and “weaving” and grammatical variations thereof, are used interchangeably, and refer to an automatic weaving of an array of the one or more second fibers in a crisscross configuration, with the array of the first fibers.

In some embodiments, the system comprises a processor, which is configured to control the motor assembly to determine the pattern by setting: (i) a first movement speed of the needle in the first direction, and (ii) a frequency and an amplitude of at least the section of the needle along the second axis. It is noted that the amplitude is typically, but not necessarily, larger than the diameter of each of the first fibers, so as to enable the interlacing process.

In some embodiments, after coupling with the second fiber, the processor is configured to control the motor assembly to move the needle in a second movement speed in the second direction, so as to interlace the second fiber with the first fibers (e.g., in the aforementioned crisscross configuration.

In some embodiments, the processor is configured to control the motor assembly to determine an alternating pattern to enable the interlacing in the crisscross configuration. The alternating having alternating: (i) one or more first groups of the one or more first given fibers, and (ii) one or more second groups of the one or more second given fibers.

In some embodiments, the motor assembly comprises a piezoelectric crystal. In response to a signal received from the processor, the piezoelectric crystal is configured to vibrate at least the distal end of the needle along the second axis.

SYSTEM DESCRIPTION

Fig. 1 is a schematic, pictorial illustration of a system 11 for winding one or more fibers 44 about a frame 33, in accordance with an embodiment of the present invention.

In some embodiments, system 11 comprises an electrical motor 12 configured to rotate frame 33 about a predefined axis, in the present example, an X-axis of an XYZ coordinate system, so as to wind one or more fibers 44 about frame 33.

Note that fibers 44 are used for producing a fabric and/or an item of clothing. As will be described below, two or more array of the fibers (e.g., fibers 44 and other fibers) are arranged in a crisscross configuration of a mesh, for producing a layer of the fabric comprising a plurality of the layers.

In some embodiments, system 11 for producing fabrics and items of clothing comprises an extrusion assembly (EA) 22. In the present example, EA 22 is configured to receive granules of one or more substances, which are produced from recycled clothes or from any other source. EA 22 is configured to move the granules along a column, melt the granules and output the molten granules onto a movable substrate.

In some embodiments, system 11 comprises and a motion assembly 16, which is disposed on a table 10 and has at least two axes 15 and 17, is configured to move EA 22 along X-axis and Y-axis, respectively. System 11 further comprises additional components, such as but not limited to the motors (not shown) of axes 15 and 17, and a processor 99 configured for controlling motion assembly 16, motor 12, the rotation of frame 33, and any additional components of system 11.

In the example of Fig. 1, fibers 44 are arrange along the Y-axis and are parallel to one another, for example, because EA 22 is not moved while motor 12 rotates frame 33 about the X-axis.

Fig. 2 is a schematic, pictorial illustration of system 11 for winding one or more fibers 44 about frame 33, in accordance with another embodiment of the present invention.

In some embodiments, processor 99 is configured to control EA 22 to produce a second fiber 45 and to move EA 22 (e.g., along the X-axis) while producing second fiber 45 for controlling an angle 18 between a first fiber 44 and second fiber 45. Note that by moving EA 22 along the X-axis and/or the Y-axis (while producing the fibers), processor 99 is configured to control any suitable arrangement of the fibers (e.g., fibers 44 and 45) while being winded around frame 33.

Fig. 3 is a schematic top view of an assembly 20 for inserting a needle between fibers 44, in accordance with an embodiment of the present invention.

In some embodiments, assembly 20 comprises a needle 55 and a motor assembly, referred to herein as a motor 14, which is configured to move needle 55 in direction 19 (e.g., parallel to the X-axis), and at the same time, to vibrate at least a section of needle 55 in direction 21 (e.g., parallel to the Z-axis). It is noted that fibers 44 are arranged in an XY plane of the XYZ coordinate system, and in the present example, needle 55 is moved along the X-axis and be rotated along the Z-axis.

In some embodiments, assembly 20 is controlled by processor 99 (shown in Fig. 1 above) for determining the movement speed along ^{1 n} and the amplitude and frequency of the movement along direction 21. Embodiments of the present disclosure, and use cases related to the controlled movement in directions 19 and 21, are shown in Figs. 4-7 below.

Figs. 4-7 are schematic side views of assembly 20 operated for inserting and interlacing needle 55 between fibers 44 in several arrangements, in accordance with embodiments of the present invention.

In the context of the present disclosure and in the claims, the terms “interlacing” and “intertwining,” and grammatical variations thereof, are used interchangeably for describing the arrangement of arrays of fibers with one or more additional fibers using any suitable type of crisscross configuration.

Reference is now made to Fig. 4. In some embodiments, processor 99 is configured to control assembly 20 to interlace needle 55 between every adjacent pair of fibers 44. More specifically, needle 55 is moved above a fiber 44a along the Z-axis by moving needle 55 along the X-axis at a slow speed, e.g., about one meter per minute, and at the same time processor 99 controls the vibration in direction 21 to position a distal end 23 of needle 55 above fiber 44a along the Z-axis. Subsequently, processor 99 controls motor 14 of assembly 20 to continue the slow movement of needle 55 along direction 19, and at the same time, processor 99 controls motor 14 to control the vibration in direction 21 for positioning distal end 23 below fiber 44b along the Z-axis. The same process repeats for fibers 44c and 44d and the other fibers 44 winded around frame 33.

In some embodiments, motor 14 comprises a piezoelectric crystal (not shown), which is configured to vibrate needle 55 responsively to a signal received from processor 99 or from any other suitable signal generating component of system 11. In an embodiment, in response to a signal received from processor 99, motor 14 is configured to vibrate at least distal end 23 of needle 55 at selected one or more frequencies (described below), and one or more amplitudes. For example, in case the diameter of fibers 44 is about 0.2 mm, the vibration amplitude of the vibration of distal end 23 along the Z-axis may be between about 0.25 mm and 0.8 mm, or any other suitable amplitude. It is noted that the vibration amplitude may be altered while distal end 23 is being moved along the X-axis, as will be described in detail below.

In some embodiments, frame 33 is not rotated during the movement of needle 55. In other embodiments, frame 33 may be slightly rotated and vibrated about the X-axis and/or about the Z-axis for assisting the interlacing needle 55 between fibers 44.

In some embodiments, after interlacing needle 55 in a crisscross configuration between fibers 44, distal end 23 is coupled to a fiber 66 produced by EA 22 for pulling fiber 66 in a direction 25, as will be described in more dc'" ^{; i} 9 and 10 below. In some embodiments, fibers 44 and 66 may be produced by EA 22 using any suitable technique. Some non-limiting example implementations of techniques for producing such fibers are described in detail in U.S. Provisional Patent Application 63/317,984 to Maizels et al., whose disclosure is incorporated herein by reference.

Reference is now made to Fig. 5. In some embodiments, processor 99 is configured to control motor 14 of assembly 20 to alter the vibration frequency in direction 21 and/or to alter the speed in direction 19. In the example of Fig. 5, the altered speed and/or vibration frequency cause an asymmetric arrangement of fibers 44 above and below needle 55. For example, fibers 44a and 44b are positioned below needle 55 along the Z-axis, fibers 44c, 44d, 44e and 44f are arranged in the same configuration shown in Fig. 4 above, and fibers 44g and 44h are positioned above needle 55 along the Z-axis.

Reference is now made to Fig. 6. In some embodiments, processor 99 is configured to control motor 14 of assembly 20 to alter the speed in direction 19 while maintaining a constant vibration frequency in direction 21. In such embodiments, first and second pairs of fibers 44 are arranged above and below needle 55, respectively, and this structure is repeated along the X- axis. Note that in Fig. 6, the speed of needle 55 in direction 19 is about two meters per minute, larger than that in Fig. 4 above.

Reference is now made to Fig. 7. In some embodiments, processor 99 is configured to control motor 14 of assembly 20 to alter the speed in direction 19 while maintaining a constant vibration frequency in direction 21. In such embodiments, first and second threesomes of fibers 44 are arranged above and below needle 55, respectively, and this structure is repeated along the X-axis. Note that in Fig. 7, the speed of needle 55 in direction 19 is about three meters per minute, larger than that in Fig. 6 above.

In some embodiments, processor 99 is configured to control motor 14 to determine one or more patterns of interlacing between needle 55 and fibers 44. In the examples of Figs. 4-7 the patterns comprise alternating patterns, such that a first group of one or more fibers 44 are located at a first side of needle 55, and a second group of one or more fibers 44 are located at a second side of needle 55, opposite the first side. In the example of Fig. 4, each of the first group and the second group comprises a single fiber 44, in the example of Fig. 6, each of the first group and the second group comprises two fibers 44, in the example of Fig. 7, each of the first group and the second group comprises three fibers 44.

In some embodiments, the number of fibers 44 may be altered in at least one of the first and second groups. As shown in the example of Fig. 5, the first groups are located below needle 55 along the Z-axis. In such embodiments, or ^Q '' ^r ^st groups comprises two fibers 44 (e.g., fibers 44a and 44b), and each of the other groups among the first groups comprises a single fiber 44 (e.g., fiber 44d in a first group).

In some embodiments, the frequency of the vibration in direction 21 may be different in order to arrange the different patterns, e.g., a different number of fibers 44 above and below needle 55, as described above. Note that the frequency of Fig. 4 is typically higher than that of Fig. 6, which is higher than that of Fig. 7. For example, in Figs. 4, 6 and 7 the vibration frequencies in direction 21 are between about 0.5 KHz and 10 Khz, or any other suitable frequency. Note that processor 99 controls: (i) the frequency and amplitude of the vibration along the Z-axis, and (ii) the movement speed along the X-axis, so as to enable the arrangement of the needle relative to fibers 44 as shown in Figs 4-7. More specifically, in order to obtain the arrangement of Fig. 6, processor 99 is configured to control the speed along the X-axis to be faster (e.g., about twice) relative to that in the arrangement of Fig. 4.

In other embodiments, in case the speed along the X-axis is similar in the configurations of Figs. 4 and 6, processor 99 is configured to control the frequency in the arrangement of Fig. 6 to be about half of the frequency in the configuration of Fig. 4.

Fig. 8 is a schematic side view of assembly 20 operated for inserting and interlacing needle 55 between fibers 44, in accordance with another embodiment of the present invention.

In some embodiments, instead of applying the vibration along the Z-axis to distal end 23 (and optionally other sections) of needle 55 as shown in Figs. 4-7 above, distal end 23 of needle 55 has a section 24, which is bent relative to the longitudinal axis (e.g., parallel to the X-axis) of needle 55. In some embodiments, in addition to the movement in direction 19, motor 14 is configured to rotate needle 55 about the X-axis, so as to arrange groups of one or more fibers 44 above and below needle 55. In the example of Fig. 8, section 24 is inserted between fibers 44c and 44d, and while being moved along direction 19, needle 55 completes a rotation of about 180° about the X-axis for separating between fibers 44f and 44g. Using this combination of motion (in direction 19) and rotation (about the X-axis) fibers 44 are being arranged in groups of threesomes above and below needle 55.

Fig. 9 is a schematic top view of assembly 20 after inserting and interlacing needle 55 between fibers 44, in accordance with an embodiment of the present invention. Note that the techniques shown in Fig. 9 and in Fig. 10 below are applicable, mutatis mutandis, for all the configurations on needle 55 shown in Figs. 3-8 above. In some embodiments, distal end 23 is coupled to a distal end 27 of fiber 66. The coupling may be carried out using any suitable technique, such as but not limited to gluing, tying, welding, or using any other suitable technique.

Fig. 10 is a schematic side view of assembly 20 being operated for interlacing fiber 66 between fibers 44, in accordance with an embodiment of the present invention.

In some embodiments, after interlacing needle 55 between groups of one or more fibers 44 (as shown in Figs. 4-8 above) and coupling between distal ends 23 and 27 of needle 55 and fiber 66, respectively (as shown, for example, in Fig. 9 above), processor 99 is configured to control motor 14 of assembly 20 to move needle 55 in direction 25 for pulling and interlacing fiber 66 between fibers 44.

In the example of Fig. 10, needle 55 was interlaced between fibers 44 using the configuration shown in Fig. 4 above, and therefore, in response to the pulling of fiber 66 in direction 25, fiber 66 is interlaced between fibers 44 in the same configuration shown in Fig. 4 above.

Reference is now made back to Fig. 9. In some embodiments, system 11 may comprise one or more assemblies 20 arranged along the Y-axis and/or the Z-axis of the array of fibers 44 winded around frame 33. In such embodiments, a plurality of fibers 66 may be interlaced between any of the aforementioned groups of fibers 44. For example, a first group of assemblies 20 may be arranged, at a first selected distance from one another, along the Y -axis in a first XY plane of frame 33 located at a second position along the Z-axis.

In some embodiments, the first group of assemblies 20 is configured for interlacing a first respective group of fibers 66 using the configuration shown in Figs. 4 and 10 above. Similarly, a second group of assemblies 20 may be arranged, at a second selected distance from one another (similar to or different from the first distance of the first group of assemblies 20), along the Y-axis in a second XY plane of frame 33, which is located at a second position along the Z-axis, different from the first position of the first group of assemblies 20.

In some embodiments, the second group of assemblies 20 is configured for interlacing a second group of fibers 66, respectively, using the configuration shown in Fig. 6 above.

In other words, arrays of assemblies 20 may be arranged in any suitable configuration for interlacing fibers 66 with fibers 44 using one or more suitable interlacing configuration(s).

In the embodiments described in the above four paragraphs, a plurality of fibers 66 may be interlaced with fibers 44 at the same time.

In some embodiments, fibers 44 and 66 may have the same materials and equal properties (subject to process variations in th" •"••'"duction process). In other embodiments, at least one of fibers 66 may have at least one difference relative to at least one of fibers 44. The difference may be in the materials, structure, mechanical properties, physical properties, or any other suitable difference. For example, fibers 44 and 66 may have a different color and/or a different thickness between one another.

Fig. 11 is a schematic side view of an interlacing between an array of fibers 44 and fibers 66a and 66b in an example crisscross configuration, in accordance with an embodiment of the present invention.

In some embodiments, fibers 66a and 66b have a different thickness from one another, and a different thickness and color compared to fibers 44.

In some embodiments, fiber 66a is interlaced with fibers 44 such that fiber 66a is separating between every adjacent fibers 44. This configuration is shown, for example, in Fig. 10 above.

In some embodiments, fiber 66b, which is thicker than fiber 66a, is interlaced with fibers 44 such that fiber 66b is separating between every adjacent pair 46 of fibers 44. More specifically, fiber 66b separates between a pair 46a and a pair 46b of fibers 44, and also between pair 46b and a pair 46c of fibers 44. This configuration is shown, for example, in Fig. 6 above.

In the configuration of Fig. 11, different types of fibers 66 are interlaced with different arrays of fibers 44, and are also arranged, within frame 33, in different layers of the arrays of fibers 44. Note that the multi-layered structure may be obtained using a suitable structure of frame 33, or by coupling between two or more frames having fibers 44 and 66 interlaced using any suitable configuration. In the example of Fig. 11, the multi-layered structure is obtained by placing a frame 33a over a frame 33b, and coupling between the arrays of interlaced fibers using any suitable technique, such as but not limited to gluing, welding, or winding of additional fibers (not shown), e.g., about fibers 66a and 66b along the Z-axis.

In other embodiments, any other arrangement of any other (similar or different) types of fibers may be carried out within frame 33 or between a plurality of frames 33 and/or within each frame 33 of the plurality of frames 33.

Fig. 12 is a diagram that schematically illustrates a pictorial illustration of a process sequence for interlacing fibers 44 and 66 using a system 80, in accordance with another embodiment of the present invention.

In some embodiments, system 80 comprises: (i) assembly 20, which is described, for example, in Fig. 3 above, (ii) an anchor 30 configured to fixate a section 78, which is the end of fiber 66, and (iii) an assembly 88, which is configured to perform the interlacing of fiber 66 with fibers 44. Assembly 88 is described in detail In some embodiments, system 80 comprises motorized axes 36 and 38 configured to move assembly 88 along the Z-axis and X-axis, respectively. In the present example, axis 38 is moved along axis 36, and assembly 88 is moved along axis 38. In some embodiments, by controlling the motion in axes 36 and 38, processor 99 is configured to control the movement and the location of each component of assembly 88 in the XYZ coordinate system of system 80. Note that the motion along the X-axis is typically parallel to direction 19 in which needle 55 is moved, as described in Figs. 3-8 above.

In some embodiments, assembly 88 comprises a first bar, referred to herein as a bar 32, whose longitudinal axis is disposed in an orientation parallel to axis 36 and orthogonal to axis 38. Assembly 88 further comprises a second bar, referred to herein as a bar 34, whose longitudinal axis is disposed in an orientation parallel to the Y-axis and orthogonal to the longitudinal axis of bar 32. In such embodiments, bars 32 and 34 are coupled together and are arranged an L-shape. Note that bar 34 is extended below axis 38 along the Z-axis.

In other embodiments, axis 38 is fixated to axis 36, and bar 32 is configured to move assembly 88 along the Z-axis, as shown in steps 1, 2, and 3 of Fig. 12.

In some embodiments, assembly 88 comprises a closed loop (CL) 77 formed at the edge of bar 34 and has an inner diameter larger than the outer diameter of fiber 66. Moreover, the surface of CL 77 is shaped such that fiber 66 may be threaded through CL 77, and when required, assembly 88 and CL 77 are configured to move a section of fiber 66 and to locally manipulate the shape of at least the section of fiber 66 that is threaded through CL 77.

In the present example, bar 34 comprises a flexible material, such as but not limited to an alloy of nickel and titanium (also referred to herein as nitinol), or stainless steel. Moreover, in order to obtain the required flexibility, bar 34 may be shaped as any suitable type of spring, or may have any other suitable shape for enabling the flexibility described above.

In such embodiments, in response to applying force to bar 34 along a direction 82 parallel to the Z-axis, the shape of assembly 88 may be altered. For example, in response to pulling CL 77 down (i.e., in direction 82) along the Z-axis, the orientation of the longitudinal axis of bar 34 may be aligned with that of bar 32 along the Z-axis, and the shape of assembly 88 may be altered from an L shape to an I shape whose orientation is parallel to the Z-axis. Moreover, the angle between bars 32 and 34 in the YZ plane may be any angle between about 0° and 180°, depending on the direction and amplitude of the force applied to bar 34 and/or CL 77.

Reference is now made to step 1 of Fig. 12. In some embodiments, fiber 66 is threaded through CL 77 and section 78 of fiber 66 is coupled to anchor 30. Note that section 78 at the end of fiber 66 remains coupled to anchor 30 along the entire interlacing process, as shown for example in steps 1-3 of Fig. 12.

In some embodiments, processor 99 is configured to: (i) control assembly 20 to move needle 55 in direction 19, and at the same time, (ii) control assembly 88 to alternately move along directions 82 and 83 for performing the interlacing between fiber 66 and the array of fibers 44.

Reference is now made to step 2 of Fig. 12. In some embodiments, processor 99 controls: (i) assembly 88 to move in direction 82, and (ii) assembly 20 to move in direction 19, such that needle 55 is positioned between fibers 44 and bar 34 and CL 77. In other words, needle 55 is positioned above bar 34 and CL 77 along the Z-axis.

Moreover, in the example of step 2, needle 55 is moved in direction 19 so that distal end 23 of needle 55 is positioned between fibers 44b and 44c.

Subsequently, assembly 88 is moved in direction 83 and, in response to making physical contact with needle 55 (which is stiffer than bar 34), bar 34 and CL 77 are bending toward direction 82 until CL 77 bypasses needle 55 and is moved in direction 83 together with the other parts of assembly 88. Note that bypassing needle 55 is taking place due to the flexibility of bar 34 of assembly 88.

Reference is now made to step 3 of Fig. 12. In some embodiments, in response to the movement of assembly 88 in direction 83 and the bypassing of bar 34 and CL 77 over needle 55, a section 86 of fiber 66 is winded around needle 55 between fibers 44a and 44b. Moreover, while winding section 86 about needle 55, processor 99 controls assembly 20 to further move needle in direction 19 so that distal end 23 of needle 55 is positioned between fibers 44c and 44d.

In some embodiments, processor 99 is configured to control assemblies 20 and 88 to repeat steps 2 and 3, so as to form bindings of additional sections of fiber 66 around needle 55, each binding is formed between a pair of fibers 44. In the context of the present disclosure and in the claims, the terms “binding” and “winding” and grammatical variations thereof are used interchangeably and refer to loops of sections of fiber 66 formed (between every pair of fibers 44) about needle 55. Note that during steps 2 and 3, EA 22 is configured to continue the production of fiber 66, so as to provide system 80 with a supply of additional sections of fiber 66 that will be winded al loops about needle 55.

In some embodiments, after forming the bindings between every pair of fibers 44, processor 99 is configured to control motor 14 to retract needle away from the array of fibers 44, so as to complete the intertwining bet wee ” ^r;k — ■ and 44 in a crisscross configuration. In other embodiments, in addition to or instead of having bar 34 and CL 77 made from flexible materials and/or structures, system 80 may comprise an additional axis (not shown) configured to move assembly in directions 84 and 85 (e.g., parallel to the Y-axis of the XYZ coordinate system), so as to carry out steps 2 and 3 for producing the loops of the sections of fiber 66 about needle 55.

Fig. 13 is a diagram that schematically illustrates a sectional view of a process sequence for interlacing fibers 44 and 66, in accordance with an embodiment of the present invention. Fig. 13 shows the formation of the loops about needle 55 and between each pair of fibers 44 in the binding process described in Fig. 12 above and using the configuration of the system shown in Fig. 12 above.

At a step 1 of Fig. 13, assembly 88 is positioned between fibers 44a and 44b, and CL 77 is positioned below needle 55 for positioning section 86 between fibers 44a and 44b. Moreover, CL 77 is moved along fiber 66 at least in direction 19, and optionally, also along direction 82.

At a step 2 of Fig. 13, needle 55 is moved in direction 19, and CL 77 is moved in directions 19 and 83 (using the techniques described in Fig. 12 above) for producing the first binding about needle 55.

At a step 3 of Fig. 13, needle 55 is further moved in direction 19, and CL 77 is moved along fiber 66: (i) in directions 19 and 83 over fiber 44c, and subsequently, (ii) in directions 19 and 82 for starting the production of the second binding about needle 55.

In some embodiments, processor 99 is configured to repeat the sequence of steps 1-3 for obtaining the winding of additional sections of fiber 66 about needle 55 between every pair of fibers 44.

In some embodiments, after the formation of the last loop is concluded, EA 22 may stop the formation of fiber 66 and a remaining section of fiber 66 is coupled to the last fiber of the array, e.g., fiber 44d in the example of step 3. Subsequently, processor 99 controls assembly 20 to move needle 55 in direction 25 for retracting needle 55 out of the array of fibers 44, and tightens the bindings of fiber 66 about fibers 44, so as to conclude the interlacing between fiber 66 and the array of fibers 44.

Fig. 14 is a flow chart that schematically illustrates a method for interlacing fibers using system 11, in accordance with an embodiment of the present invention.

The method begins at a winding step 100 with processor 99 controlling motion assembly 16 to wind fibers 44 about a plane of frame 33, as described in detail in Figs. 1 and 2 above.

At a first needle movement step 102, processor 99 controls assembly 20 to move needle 55 relative to frame 33 along the X axis in 9 f _or coupling between distal end 23 (which is a section) of needle 55 and fiber 66, and at the same time, vibrate at least distal end 23 of needle 55 relative to frame 33 along the Y axis, in direction 21, as described in detail in Figs. 3 and 4 above.

At a coupling step 104, distal end 23 is coupled to fiber 66, as described in detail, for example, in Fig. 4 above.

At a second needle movement step 106 that concludes the method, processor 99 controls assembly 20 to move needle 55 relative to frame 33 along the X axis in direction 25, opposite direction 19, for interlacing between the fiber 66 and fibers 44, as described in detail, for example, in Figs. 10 and 11 above.

Fig. 15 is a flow chart that schematically illustrates a method for interlacing fibers using system 11, in accordance with another embodiment of the present invention.

The method begins at a winding step 200 with processor 99 controlling motion assembly 16 to wind fibers 44 about a plane of frame 33, as described in detail in Figs. 1 and 2 above.

At a first needle movement step 202, processor 99 controls assembly 20 to move needle 55 relative to frame 33 along the X axis in direction 19 for coupling between distal end 23 (which is a section) of needle 55 and fiber 66, and at the same time, rotate needle 55 relative to frame 33 along the X axis, as described in detail in Fig. 8 above. In some embodiments, needle 55 comprises two sections, (i) the first section is coupled to motor 14, and (ii) the second section, referred to as section 24, is bent relative to the first section, as described in detail in Fig. 8 above.

At a coupling step 204, section 24 is coupled to fiber 66, as described in detail, for example, in Fig. 9 above.

At a second needle movement step 206 that concludes the method, processor 99 controls assembly 20 to move needle 55 relative to frame 33 along the X axis in direction 25, opposite direction 19, for interlacing between the fiber 66 and fibers 44, as described in detail, for example, in Figs. 10 and 11 above.

It will be appreciated that the embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art. Documents incorporated by reference in the present patent application are to be considered an integral part of the application except that to the extent any terms are defined in these incorporated documents in a manner that conflicts with the definitions made explicitly or implicitly in the present specification, only the definitions in the present specification should be considered.