The present invention relates to a carpet, in particular a wall to wall carpet, having a shadow effect and further relates to a method for weaving such a carpet fabric having a shadow effect.
For providing a carpet having a structural pattern or a colour pattern on its front side, i.e. the side that can be seen when the carpet is positioned on a floor, it is known to either use warp threads of different colour for providing a pattern or to use structural weave elements such as, for example, cut piles, pile loops or ribs or combinations thereof for providing a structural pattern on the front side of the carpet. Even a combination of such weaving structures with differently coloured pile warp threads for providing the cut piles, the pile loops or the ribs is known.
It is the object of the present invention to provide a carpet having a shadow effect and a method for weaving a carpet fabric having a shadow effect by means of which a visually recognizable pattern can be provided at a carpet front side in an easy manner.
According to a first aspect of the present invention, this object is achieved by a carpet having a shadow effect, comprising a backing fabric having weft threads and tension warp threads, further comprising pile warp threads interlaced with the weft threads of the backing fabric and forming pile elements, the weft threads being provided in groups of weft threads repeatedly appearing in a warp direction, each group of weft threads providing a relative positioning of the weft threads thereof relative to at least one tension warp thread, a weft thread of a group being either positioned on a pile side relative to a tension warp thread or on a back side relative to this tension warp thread in a respective relative positioning, a first group of weft threads having a first relative positioning of the weft threads thereof and a second group having a second relative positioning of the weft threads thereof different from the first relative positioning, wherein the first relative positioning and the second relative positioning provide a substantially mirror-symmetrical arrangement with respect to each other relative to a plane of symmetry extending in the weft direction, and/or wherein in each relative positioning of first relative positioning and second relative positioning a weft thread positioned at a first group end region in the warp direction and a weft thread positioned at a second group end region in the warp direction have a different relative positioning with respect to at least one tension warp thread, which means that in the first relative positioning and the second positioning weft threads positioned at a first group end region in the warp direction and weft threads positioned at a second group end region in the warp direction have a different relative positioning with respect to at least one tension warp thread.
With providing such groups of weft threads in a carpet, due to an interaction of the pile warp threads which are visible at the front side of the carpet with these weft threads, a particular orientation of the pile elements constituted by the pile warp threads can be obtained and can be varied across the front side of the carpet. Due to such a variation of the orientation, i.e. inclination of the pile elements constituted by the pile warp threads, such a carpet has a varying light reflection capability across the front side such that there appears a pattern which is visually recognizable and which may also vary when viewing such a carpet from different directions and under different angles. Such a carpet having a shadow effect structure can either be woven with coloured yarn or can be woven with uncoloured yarn and later on can be coloured individually, for example, in a colour bath, according to a customer's desire. In this case, for example, polyamide material or polyester material could be used for the pile warp threads. After applying a colour to such a carpet, the pattern provided by the shadow effect can be clearly seen on the front side of the carpet. This reduces the delivery times and the need for a stock of yarns in different colours or for carpets in different colours.
In the context of the present invention such a group of weft threads is constituted by a plurality of weft threads positioned adjacent to each other in the warp direction. One of these weft threads is positioned at a first group end region and another one is positioned at a second group end region in the warp direction. Each group constitutes an entity of weft threads provided in the respective relative positioning and repeatedly appearing in the warp direction. While of course between two such groups of weft threads there may be weft threads which are not associated to one of these two groups, the weaving structure of a carpet, as far as the weft threads are concerned, may be constituted exclusively by repeatedly appearing groups of weft threads positioned adjacent to each other and therefore following each other in the warp direction.
For more clearly defining the above-referenced plane of symmetry, it can be stated that this plane not only extends in the weft direction but additionally is perpendicular with respect to a plane containing the weft direction and the warp direction.
Such carpets having a shadow effect are provided with more plain variations at their front side and, therefore, can be combined with modern interiors. In particular, such carpets can also be used for wall-to-wall applications.
For generating a particular pattern on the front side of a carpet by adjusting the inclination of the pile elements, for example, pile legs or pile loops, it is proposed that at least one first group is arranged immediately adjacent to a first group in the warp direction, and/or at least one second group is provided immediately adjacent to a second group in the warp direction, and/or that at least one first group is provided immediately adjacent to a second group in the warp direction.
For increasing the variety of pile element positionings for obtaining a desired pattern, it is further proposed that a third group has a third relative positioning of the weft threads thereof which is different from the first relative positioning and the second relative positioning, at least one third group being positioned between two first groups and/or between two second groups and/or between a first group and a second group.
For discriminating such a third group of weft threads from the first and the second groups of weft threads, it is proposed that the weft threads of the third group are arranged substantially mirror-symmetrical with respect to each other relative to a symmetry plane extending in the weft direction and being positioned in a central region of the third group in the warp direction, and/or a weft thread positioned at a first group end region of a third group in the warp direction and a weft thread positioned at a second group end region of the same third group in the warp direction have the same relative positioning with respect to at least one tension warp thread. Again the above-referenced plane of symmetry can more clearly be defined as a plane not only extending in the weft direction but also being substantially perpendicular with respect to a plane containing the weft direction and the warp direction.
According to another very advantageous aspect of the present invention, in the first group of weft threads and/or the second group of weft threads and/or the third group of weft threads a weft thread positioned at a first group end region in the warp direction and/or a weft thread positioned at a second group end region in the warp direction is thinner than at least one weft thread positioned therebetween in the warp direction. According to this aspect, the or at least one weft thread positioned in a centre region of a respective group of weft threads is thicker than at least one of the weft threads positioned at the two group end regions, which leads to an enhanced shadow effect. For example, such a thicker weft thread may have a thickness that is in the range of 110% to 150%, preferably 150% to 200%, more preferably more than 200% of the thickness of such a thinner weft thread positioned at a group end region. This, for example, may refer to the diameter of a substantially circular cross-section of such weft threads.
According to a further aspect of the invention, it is proposed that a plurality of warp thread systems extending in the warp direction are provided side by side, a row of pile elements extending in the warp direction being provided by each warp thread system.
For providing a sufficient stability in the backing fabric of the carpet according to the present invention, it is proposed that at least one warp thread system, preferably a plurality of warp thread systems, further preferably each warp thread system, comprises at least one tension warp thread.
Further, in at least one row of pile elements there may be at least one change in the type of the pile warp threads used for providing the pile elements. Those pile warp threads not used for forming pile elements can be bound into the backing fabric. By changing the pile warp threads used for forming pile elements, it is possible to provide a colour change, for example by using differently coloured warp threads or by using differently structured pile warp threads or pile warp threads made of different materials which when coming into contact with a colour after the carpet has been woven provide different colouring effects.
According to a further aspect, at least one warp thread system, preferably a plurality of warp thread systems, further preferably each warp thread system may comprise one tension warp thread and the at least one weft thread, i.e. the thicker weft thread, positioned between the weft threads positioned at the group end regions is positioned at a pile side relative to the tension warp thread.
The stability and the volume of the backing fabric can be further increased if at least one warp thread system, preferably a plurality of warp thread systems, further preferably each warp thread system, comprises two tension warp threads, preferably offset with respect to each other in a direction from the pile side to the back side, and/or if tension warp threads of different warp thread systems are offset with respect to each other in a direction from the pile side to the back side.
For ensuring that the two tension warp threads of a warp thread system remain positioned offset with respect to each other, it is proposed that two tension warp threads are separated in the direction from the pile side to the back side by at least one weft thread, preferably of a first group of weft threads and/or a second group of weft threads.
According to a further preferred aspect of the invention, it is proposed that each first group of weft threads and/or each second group of weft threads and/or each third group of weft threads comprises at least one weft thread positioned at the pile side of the two tension warp threads and at least one weft thread positioned at the back side of the two tension warp threads. This leads to a further increase of the volume of the backing fabric. Such a relative positioning of the weft threads can also be used in warp thread systems having only a single tension warp thread.
According to a further aspect, each first group of weft threads and/or each second group of weft threads may comprise at least one weft thread positioned between the two tension warp threads.
The strength of the backing fabric and the defined positioning of the pile warp threads interlaced in the backing fabric can be increased if at least one warp thread system, preferably a plurality of warp thread systems, further preferably each warp thread system, comprises at least one binding warp thread.
According to a further advantageous aspect of the invention, a first group and a second group and preferably a third group may comprise three weft threads, respectively, and/or a first group and a second group and preferably a third group may comprise the same number of weft threads. According to a very advantageous aspect of the invention, all the groups, i.e. all first groups, second groups, and preferably third groups may comprise three weft threads and/or the same number of weft threads.
For increasing the quality of the pattern by providing a defined positioning of the pile elements which can be seen at the front side of the carpet, it is proposed that a pile element, preferably two pile elements, are provided in at least one region where two groups are adjacent to each other. Such pile elements preferably are provided by the same pile warp thread system and therefore are members of the same row of pile elements constituted by such a warp thread system. Further pile elements may be provided substantially only in a region where two groups are adjacent to each other.
By providing the above-referenced groups of weft threads and interlacing the pile warp threads with these weft threads in a defined manner, the shadow effect and, therefore, a pattern visible at the front side of the carpet is generated due to the inclination or non-inclination of pile elements. Therefore, according to a further aspect of the invention, it is proposed that in a region where a first group and a further first group are adjacent to each other at least one pile leg or a pile loop providing a pile element is inclined in the warp direction in a first orientation, and in a region where a second group and a further second group are adjacent to each other at least one pile leg or a pile loop providing a pile element is inclined in the warp direction in a second orientation opposite to the first orientation, and/or in a region where a first group is adjacent to a second group or in a region where a third group is adjacent to a third group at least one pile leg or a pile loop providing a pile element is substantially not inclined in the warp direction, and/or in a region where a third group is adjacent to a first group or a second group at least one pile leg or pile loop providing a pile element is inclined in the warp direction or is substantially not inclined.
For increasing the variability of the pattern provided on a carpet, it is proposed that, between at least two adjacent groups of weft threads, a binding element different from the first group of weft threads, the second group of weft threads, and the third group of weft threads is provided, said binding element comprising at least one weft thread, preferably a plurality of weft threads offset with respect to each other in the warp direction and/or the direction from the pile side to the back side. This means that it is not necessary that, throughout an entire carpet, the above-referenced groups of weft threads must be positioned immediately side by side. Instead, between two such groups or in particular regions of the carpet, additional binding elements having one or a plurality of weft threads and possibly comprising pile warp threads interlaced with such weft threads can be provided.
For enhancing the stability and the durability of the carpet of the present invention, in particular in environments of high humidity, it is proposed that at least one weft thread, preferably all the weft threads of at least one group of weft threads, comprise fibrillated yarn and/or are made of polypropylene material.
For providing a stable contact between the carpet of the present invention and a floor supporting such a carpet, it is proposed that at the back side a ground contact material, preferably latex material, is arranged preferably engaging into the backing fabric.
According to a further aspect of the present invention, the above object is achieved by a method for weaving at least one carpet fabric having a shadow effect, in particular according to one of the preceding claims, wherein in association to at least one dent, preferably to a plurality of dents, further preferably to each dent, of a weaving machine a warp thread system for providing a row of pile elements extending in a warp direction is provided, the warp thread system comprising at least one pile warp thread, preferably at least two pile warp threads, and in association to each carpet fabric to be woven comprises at least one tension warp thread and at least one binding warp thread for providing a backing fabric together with weft threads, wherein groups of weft threads repeatedly appearing in each fabric are provided in such a manner that a first group of weft threads has a first relative positioning of the weft threads thereof relative to a tension warp thread and a second group has a second relative positioning of the weft threads thereof relative to a tension warp thread different from the first relative positioning, wherein the first relative positioning and the second relative positioning are substantially mirror-symmetrical with respect to each other relative to a symmetry plane extending in the weft direction, and/or in each relative positioning of first relative positioning and second relative positioning a weft thread positioned at a first group end region in the warp direction and weft thread positioned at a second group end region in the warp direction have a different relative positioning with respect to at least one tension warp thread, wherein in a relative positioning a respective weft thread of a group either is positioned at a pile side of a tension warp thread or at a back side of this tension warp thread, wherein two pile elements of the same pile warp thread system are provided in at least one region where two groups G are adjacent to each other.
According to a particularly advantageous aspect of the present invention, two carpet fabrics connected with each other by pile warp threads and separated from each other by cutting the pile warp threads may be woven, and/or at least one warp thread system in association to at least one carpet fabric may comprise two tension warp threads preferably offset with respect to each other in a direction from a pile side to a back side, and/or tension warp threads of different warp thread systems may be offset with respect to each other in a direction from the pile side to the back side. This can be obtained by positioning a particular weft thread on a pile side relative to a tension warp thread, for example the only tension warp thread of one warp thread system and positioning the same weft thread on the back side relative to a tension warp thread, for example the only tension warp thread of an immediately adjacent warp thread system.
Alternatively or additionally, the weft threads may be inserted by means of a single weft insertion means, preferably gripper mechanism, per each carpet fabric to be woven in a predetermined weft insertion plane.
At least a part of the tension warp threads, preferably each tension warp thread, may be moved by means of a Jacquard machine for forming a shed. By forming a shed for inserting weft threads by moving at least a part of the tension warp threads, preferably each tension warp thread, by means of a Jacquard machine, it is possible to reduce the number of necessary weft insertion means for obtaining different positionings of weft threads relative to at least one tension warp thread, while ensuring a high variability in the positioning of the tension warp threads relative to the weft threads. Further, when using a Jacquard machine for moving tension warp threads, there exist more patterning possibilities as compared to moving the tension warp threads, for example, by a heddle frame drive.
A contact between a carpet to be woven with such a method according to the present invention and the floor supporting the carpet can be enhanced if a floor contact material, preferably latex material, is provided at a back side of at least one fabric preferably engaging into the backing fabric.
It is to be noted that the method of the present invention can be used for providing each one of the above-referenced structural features of the carpet of the present invention, either alone or in combination with one or a plurality of the other structural features referred to.
In the following, the present invention will be explained with reference to drawings in which:
As can be seen from
In each fabric St1, St2, there are provided groups G1, G2, and G3 of weft threads S. Further, the fabric St1, and therefore also the fabric St2, comprises two tension warp threads S1, S2 offset with respect to each other from a pile side SP to a back side SB. It is to be noted that the pile side SP constitutes the front side of a carpet which can be seen when the carpet is positioned on a floor. The back side SB is the side of the carpet which will be in contact with the floor.
Each fabric St1, St2 further comprises, preferably in association to each warp thread system, a binding warp thread B such that, in association to at least one warp thread system, a backing fabric BF of a respective fabric St1, St2 comprises the two tension warp threads S1, S2, the weft threads S and the binding warp thread B.
In this context, it is to be noted that such a warp thread system as shown in
Due to the fact that the warp thread system shown in
In the various groups G1, G2, G3 of weft threads shown in
The arrangement of the weft threads S of the second groups G2 is substantially mirror-symmetrical with respect to a plane of symmetry Sy1 that is shown in
In the third groups G3, the arrangement of the weft threads S is substantially mirror-symmetrical relative to a plane of symmetry Sy2, which is also shown as a plane extending in the weft direction and being perpendicular with respect to the warp direction. This means that, for example, the two weft threads S positioned at the two group end regions E1, E2 are positioned at the back side SB of both tension warp threads S1, S2, while the weft thread positioned in the centre of the third groups G3 is either positioned between the two tension warp threads S1, S2 or is positioned at the pile side SP of the two tension warp threads S1, S2. This means that there can exist two different kinds of third groups G3.
The pile warp threads P1, P1, P2, P2 which are used for generating pile legs PS as pile elements in the fabrics St1, St2 are alternately interlaced with weft threads S associated to the top fabric St1 and with weft threads S associated to the bottom fabric St2. The weaving structure used is a so-called 3/6W-weave wherein, in each group, the pile warp thread coming from the other fabric is interlaced with a weft thread positioned at one group end region E1, E2 on the back side SB, then is led around the weft thread positioned in the centre of this group at the pile side SP thereof, and finally is interlaced with the weft thread positioned at the other group end region E2, E1 at the back side SB thereof. This leads to a structure in which, in each region where two groups G1, G1, or G1, G2, or G1, G3, or G2, G3 are immediately adjacent to each other, pile points PP are constituted by two pile legs PS after cutting the pile warp threads P1, P1, P2, P2.
The two pile warp threads P1, P1 or P2, P2 which are used simultaneously for forming pile points PP are interlaced with the backing fabrics BF of the two fabrics St1, St2 such that, in these two fabrics St1, St2, a substantially mirror-symmetrical arrangement of the pile warp threads and the pile legs constituted by them is obtained.
Depending on the kind of groups which are positioned immediately adjacent to each other, these pile legs PS will either be inclined or not inclined in the warp direction. For example, in the region where, in
By combining the respective groups G1, G2, and G3 in a predefined sequence in the warp direction, it is possible to control the inclination of the pile legs PS in particular regions of the fabrics St1, St2 and to thereby generate a structural pattern that can be seen at the pile side SP, i.e. the front side of a carpet. This pattern will appear irrespective of the colour of the pile warp threads used for providing these pile legs PS. Of course, the use of different colours can emphasize the pattern or lead to an additional pattern that is superimposed to the pattern provided by the inclination of the pile legs PS.
As can be seen in
As can be seen in
A weaving structure shown in
By moving the tension warp threads by means of a Jacquard machine, it is possible to obtain a rather high variability in the positioning of the weft threads without the necessity of inserting these weft threads at different weft insertion planes. Further, the Jacquard machine can additionally be used to move the pile warp threads either for forming pile elements or for providing them bound into the backing fabrics. If such a variation in the binding structure of the pile warp threads is not necessary, these pile warp threads can also be moved by heddle frames, as is the case with the binding warp threads.
For increasing the volume and the stability of the backing fabrics BF and for providing enhanced durability of the fabrics St1, St2 even in environments of high humidity, the weft threads S are preferably made of fibrillated yarns and are further preferably made of polypropylene material. The yarn used for providing the pile warp threads may be coloured or uncoloured. If uncoloured pile warp threads are used, then after weaving the fabrics St1, St2 and the carpets constituted by these fabrics St1, St2 with a particular pattern provided by the shadow effect of the inclined pile elements, such a carpet can be coloured according to a customer's wish such that a customized carpet having the shadow effect pattern provided by the inclined pile legs can be obtained.
It is to be noted that in
In
Each warp thread system comprises two tension warp threads S1, S2 as well as a single binding warp thread B in association to each fabric St1, St2. Further, the warp thread systems shown in
The weaving structure shown in
Following the two second groups G2, there is a transition from the 3/6W-weave to the 1/3V-weave. The two pile warp threads P2 stop forming pile elements and are interlaced around weft threads positioned between the two tension warp threads S1, S2 of the top fabric St1 and at the back side of the two tension warp threads S1, S2 of the bottom fabric St2 and then extend within the backing fabrics BF. In this region where the two pile warp threads P2, P2 are not used for forming pile points, the pile warp thread P1 which, in the left part of
In the pile warp thread system shown in
As can be seen in
It is to be noted that, in such a combination of two different weaving structures, for example, one of the two pile warp threads P2, P2 can be used for forming pile elements in the 1/3V-weave area, while one or both of the pile warp threads P1, P3 can be used for forming pile elements in the 3/6W-weave area. The pile warp threads P1, P2, P2, P3 can be of different colour and/or of different structure or material. Of course, all these pile warp threads can have the same colour and/or can be constituted of the same material. Further, it is to be noted that, in accordance with the desired pattern of a carpet, the areas where each of these different weaving structures is used can be selected without any restriction. Of course, other weaving structures than the 1/3V-weave can be combined with a weaving structure comprising the various groups of weft threads and providing the shadow effect. Additionally, such other weaving structures can be used for providing binding elements which are present between two of the groups G1 and/or G2 of the 3/6W-weave. For example, such a binding element may comprise only one weft thread in association to each of the fabrics St1, St2 or may comprise a plurality of weft threads which may be located at any position relative to the tension warp threads S1, S2 of the respective fabrics St1, St2.
Another alternative weaving structure is shown in
One major difference between the weaving structure shown in
In the left part of
It can be seen in
The warp thread systems shown in
Following the region where the 3/8W-weave is generated, i.e. the region comprising the two first groups G1 and the two second groups G2 on the left side of
Due to the fact that the pile loops PL are present in the regions where two groups G1, G2 or G1, G3 are adjacent to each other, the pile loops PL will be inclined depending on the kind of the two adjacent groups. In the region where two first groups G1 are adjacent to each other, the pile loops PL will be inclined to the left side in
When using such a thicker weft thread S in the centre region of a respective group G1, G2, G3, an additional influence on the inclination of the pile elements provided in the regions where the respective groups G1, G2, G3 are adjacent to each other can be obtained such that these pile elements PP have an increased inclination. This effect can further be enhanced when positioning these thicker weft threads S at the pile side SP of the respective tension warp thread S1.
Such thicker weft threads S positioned in the centre region of a respective group G1, G2, G3 may have a thickness that is in the range of 110% to 150%, preferably 150% to 200%, more preferably more than 200% of the thickness of the weft thread or weft threads S positioned at a respective group end region E1, E2. When considering such a thickness, this, for example, can refer to the diameter of the respective threads which, for example, may have a substantially circular cross-section at least in regions where no lateral load is applied to such threads.
It is to be noted that of course the two weft threads S positioned at the group end regions E1, E2 can, but must not have the same thickness. One of these two weft threads may be thicker than the other one and may even have the same thickness as the weft thread positioned in the centre region of a respective group G1, G2, G3. It is further to be noted that such a structure can even be used if at least one of the groups comprises more than three weft threads. In this situation, at least one of the weft threads positioned between the two weft threads positioned at the group end regions E1, E2, preferably all of these weft threads may be thicker than at least one of the weft threads positioned at the group end regions. Further, it is to be noted that such a weaving structure using thicker weft threads may be used in each different type of group G1, G2, G3 or, for example, only may be used in one or some of the different types of groups. Preferably each group of a particular type of group having at least one such a thicker weft thread in the centre region thereof is provided in this way, while it is not excluded that some groups of a particular type of group can be provided for example with weft threads having the same thickness or having a thicker weft thread at at least one group end region.
From the above description, it becomes clear that, when producing a carpet having a shadow effect weaving structure, there is a high variability in combining this shadow effect weaving structure with other weaving structures. In addition, the shadow effect weaving structure may not only be used for forming pile legs in a carpet, but can also be used for providing a carpet or areas in a carpet with pile loops.
The structures shown can be varied in different aspects. For example, it is possible to use more than one binding warp thread in the warp thread systems and in association to each fabric to be woven, so that even with one and the same pile warp thread system it will be possible to fix each one of the weft threads to the backing fabric. For example, two binding warp threads could be used in each or at least a part of the pile warp thread systems and in association to each fabric to be woven.
Number | Date | Country | Kind |
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13150582 | Jan 2013 | EP | regional |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2013/073271 | 11/7/2013 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2014/108228 | 7/17/2014 | WO | A |
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20160201235 | Debaes | Jul 2016 | A1 |
Number | Date | Country |
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103814162 | May 2014 | CN |
319324 | Mar 1920 | DE |
4303273 | Dec 1993 | DE |
1081260 | Mar 2001 | EP |
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Number | Date | Country | |
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20150354106 A1 | Dec 2015 | US |