Patent Application
20190010636
The present invention relates to a fabric, for example, a carpet, having a shadow effect. The invention further relates to a method of weaving a fabric, for example, a carpet, having a shadow effect.
From WO 2014/108228 A1 it is known that for providing a shadow effect at the pile side of a fabric, for example, a carpet, the piles provided by pile warp yarns are to be interlaced with weft yarns of a backing fabric such as to extend inclined relative to a direction that is perpendicular with respect to a plane defined by the warp direction and the weft direction. Depending on the direction of inclination of the piles and the viewing angle the surface of a fabric appears to be either a little bit darker or brighter.
It is an object of the present invention to provide a fabric, in particular a carpet, having a shadow effect and a method of weaving a fabric, in particular a carpet, having a shadow effect in which there is no need for moving tension warp yarns by means of a jacquard machine.
According to a first aspect of the present invention, this object is achieved by a fabric, in particular a carpet, having a shadow effect, comprising:
Due to providing the weft yarns between which piles extend out of the backing fabric at the pile side offset with respect to each other in the direction that is perpendicular with respect to a plane defined by the warp direction and the weft direction, a clear shadow effect can be obtained without the need for moving the tension warp yarns by means of a jacquard machine due to a quite simple and preferably constant ground weave of the backing fabric throughout at least a major portion of the fabric. For forming the sheds, the tension warp yarns may be moved by the same means as used for moving the other yarns of the backing fabric.
It is to be noted that, in the sense of the present application the expression “the majority of” means at least 50% of a particular structural element is provided in a particular manner.
In the fabric of the present invention, at least one pile may comprise two pile legs, one of the pile legs extending out of the backing fabric between the end weft yarn and the intermediate weft yarn and the other pile leg extending out of the backing fabric between the end weft yarn and an end weft yarn of an immediately adjacent weft receiving opening. In an alternative arrangement, at least one pile may comprise a single pile leg extending out of the backing fabric between the end weft yarn and the intermediate weft yarn or at least one pile may comprise a single pile leg extending out of the backing fabric between the end weft yarn and an end weft yarn of an immediately adjacent weft receiving opening.
For providing different shadow effects on the surface of a fabric, in association with at least one weft receiving opening, a pile may be provided by interlacing a pile warp yarn with an end weft yarn of this weft receiving opening positioned immediately adjacent to the crossing of the binding warp yarns defining this weft receiving opening in a first orientation of the warp direction and, in association with at least one other weft receiving opening, a pile may be provided by interlacing a pile warp yarn with an end weft yarn of this weft receiving opening positioned immediately adjacent to the crossing of the binding warp yarns defining this weft receiving opening in a second orientation of the warp direction, and/or in association with at least one weft receiving opening, preferably the majority of the weft receiving openings (O), most preferably each weft receiving opening, only one pile may be provided. Such a single pile may have one or two pile legs.
With such an arrangement, the piles will have different inclinations with respect to the surface of the fabric. In such a weaving structure, the selection of the direction of inclination of a respective pile is made by selecting an end weft yarn and the position of an end weft yarn within a weft receiving opening, respectively, for interlacing with a pile warp yarn. Therefore, there is no need for introducing a change of the ground weave of the backing fabric for allowing the changing of the direction of inclination of the piles. Depending on the desired pattern of the fabric the necessary direction of inclination of the piles in different areas of the fabric, is determined and correspondingly the positions of the end weft yarns within the weft receiving openings either at the one end or the other end in the warp direction are selected for interlacing with the pile warp yarns.
For providing a more emphasized shadow effect by increasing the offset of the weft yarns between which a pile extends out of the backing fabric, it is proposed that pile warp yarns not used for forming piles are bound into the backing fabric such as to extend substantially in the warp direction as dead pile warp yarns, and that at least one, preferably each intermediate weft yarn of at least one weft receiving opening is separated from both end weft yarns of this weft receiving opening by at least one tension warp yarn and at least one, preferably all the dead pile warp yarns extending in the area of this weft receiving opening.
In an alternative arrangement, pile warp yarns not used for forming piles may be bound into the backing fabric such as to extend substantially in the warp direction as dead pile warp yarns, and at least one, preferably each intermediate weft yarn of at least one weft receiving opening may be separated from a first one of the two end weft yarns of this weft receiving opening only by at least one tension warp yarn and may be separated from the second one of the two end weft yarns of this weft receiving opening by at least one tension warp yarn and at least one, preferably all the dead pile warp yarns extending in the area of this weft receiving opening. For using the increased offset of the weft yarns between which a pile extends out of the backing fabric in this arrangement, preferably in association with this weft receiving opening, a pile is formed by interlacing a pile warp yarn with the second one of the two end weft yarns of this weft receiving opening. The first one of the two end weft yarns of this weft receiving opening may be arranged on the pile side relative to the dead pile warp yarns extending in the area of this weft receiving opening and the second one of the two end weft yarns of this weft receiving opening may be arranged on the back side relative to the dead pile warp yarns extending in the area of this weft receiving opening.
For providing a fabric with a high density of piles, it is proposed that through at least one weft receiving opening, preferably the majority of the weft receiving openings, most preferably each weft receiving opening, at least three weft yarns, preferably exactly three weft yarns, extend. These three weft yarns may comprise two weft yarns providing the two end weft yarns and one intermediate weft yarn extending substantially in the weft direction. This means that only three weft yarns, what means exactly three weft yarns, extending through such weft receiving openings are needed for providing one pile. However, there may be weft receiving openings through which more than three weft yarns extend.
In the fabric of the present invention, a plurality of warp yarn systems may be provided following each other in the weft direction, at least one warp yarn system, preferably the majority of warp yarn systems, most preferably each warp yarn system, comprising two binding warp yarns crossing each other, at least one tension warp yarn, and at least one, preferably a plurality of pile warp yarns, wherein in the pile warp yarn systems piles are provided by the pile warp yarns of a respective pile warp yarn system by interlacing these pile warp yarns with weft yarns extending through the weft receiving openings provided by the binding warp yarns of the same pile warp yarn system, preferably such that, by means of the pile warp yarns of each one of the warp yarn systems, one row of piles substantially extending in the warp direction is provided. In such an arrangement, binding warp yarns extending in the warp direction in close proximity to each other in the weft direction are used for forming weft receiving openings and the pile warp yarns are interlaced with weft yarns extending through such weft receiving openings, while at the same time warp yarns of such a warp yarn system are used as weft separating warp yarns generating the offset of the intermediate weft yarns with respect to the end weft yarns. This leads to a defined positioning of the weft yarns in the direction perpendicular with respect to the plane defined by the weft direction and the warp direction, and leads to a defined positioning of the weft yarns in the warp direction in the region of each weft receiving opening. Such a defined positioning of the weft yarns in turn leads to a defined positioning of the piles extending out of the backing fabric and therefore leads to a clear shadow effect on the surface of such a fabric.
For ensuring a sufficient offset of those weft yarns which are positioned immediately adjacent to the two crossings defining a respective weft receiving opening, which weft yarns, for example, may be the two end weft yarns provided in a respective weft receiving opening, relative to the at least one intermediate weft yarn in at least one weft receiving opening, preferably the majority of these weft receiving openings, most preferably each weft receiving opening, the two weft yarns positioned immediately adjacent to the two crossings of the binding warp yarns defining this weft receiving opening are not separated by a tension warp yarn.
According to a further advantageous aspect of the present invention, throughout the major portion of the fabric, preferably throughout the entire fabric, the ground weave of the backing fabric provided by the binding warp yarns, the tension warp yarns, and the weft yarns is the same. This means that, in this portion of the fabric or in the entire fabric, the relative positioning of the weft yarns extending through respective weft receiving openings in particular with respect to the tension warp yarns is the same. Further the crossings of the binding warp yarns defining the weft receiving openings in the two orientations of the warp direction may be located at the same position in the warp direction.
According to a further aspect of the present invention, the object is achieved by a method of weaving a fabric, in particular a carpet, having a shadow effect, preferably a fabric according to the present invention, wherein for weaving a backing fabric binding warp yarns are provided crossing each other for providing weft receiving openings, such that each weft receiving opening is defined in the warp direction by two crossings of binding warp yarns, wherein tension warp yarns are provided extending substantially in the warp direction and in association with at least one weft receiving opening, preferably the majority of weft receiving openings, most preferably each weft receiving opening, weft yarns are provided extending through this weft receiving opening substantially in the weft direction, such that the weft yarns positioned immediately adjacent to the two crossings defining this weft receiving opening in the warp direction are provided as end weft yarns positioned at a back side relative to at least one weft separating warp yarn, and at least one intermediate weft yarn positioned substantially between the two end weft yarns in the warp direction is positioned at a pile side relative to the at least one weft separating warp yarn, wherein, in association with this weft receiving opening, a pile is generated by interlacing a pile warp yarn with one of the end weft yarns of this weft receiving opening such as to extend out of the backing fabric at the pile side between this end weft yarn and an intermediate weft yarn of this weft receiving opening.
When carrying out this method, pile warp yarns not used for forming piles may be bound into the backing fabric such as to extend substantially in the warp direction as dead pile warp yarns, and at least one, preferably each intermediate weft yarn of at least one weft receiving opening may be separated from both end weft yarns of this weft receiving opening by at least one tension warp yarn and at least one, preferably all the dead pile yarns extending in the area of this weft receiving opening.
Alternatively pile warp yarns not used for forming piles may be bound into the backing fabric such as to extend substantially in the warp direction as dead pile warp yarns, and at least one, preferably each intermediate weft yarn of at least one weft receiving opening may be separated from a first one of the two end weft yarns of this weft receiving opening only by at least one tension warp yarn and may be separated from the second one of the two end weft yarns of this weft receiving opening by at least one tension warp yarn and at least one, preferably all of the dead pile yarns extending in the area of this weft receiving opening. In association with this weft receiving opening, a pile may be formed by interlacing a pile warp yarn with the second one of the two end weft yarns of this weft receiving opening, and/or preferably wherein the first one of the two end weft yarns of this weft receiving opening is arranged on the pile side relative to the dead pile warp yarns extending in the area of this weft receiving opening and the second one of the two end weft yarns of this weft receiving opening is arranged on the back side relative to the dead pile warp yarns extending in the area of this weft receiving opening.
In association with each fabric to be woven, a plurality of warp yarn systems may be provided following each other in the weft direction, at least one warp yarn system, preferably the majority of warp yarn systems, most preferably each warp yarn system, comprising two binding warp yarns crossing each other, at least one tension warp yarn, and at least one, preferably a plurality of pile warp yarns, wherein in the pile warp yarn systems piles are provided by the pile warp yarns of a respective pile warp yarn system by interlacing these pile warp yarns with weft yarns extending through the weft receiving openings provided by the binding warp yarns of the same pile warp yarn system, preferably such that, by means of the pile warp yarns of each one of the warp yarn systems, one row of piles substantially extending in the warp direction is provided. In association with at least one, preferably each reed dent of a weaving machine, at least one warp yarn system may be provided. By providing a defined association of the warp yarn systems with the reed dents, a defined positioning of the weft yarns provided such as to extend through respective weft receiving openings generated by the crossing binding warp yarns of the warp yarn systems is obtained.
For increasing the output of a weaving machine, the method may be a face-to-face weaving method for simultaneously weaving two fabrics.
For providing the same number of pile rows in each one of the two fabrics to be woven, at least one, preferably each warp yarn system may comprise the warp yarns for both fabrics to be woven.
In the method of the present invention, in association with at least one warp yarn system, the crossings of the binding warp yarns of one of the two fabrics to be woven may be offset relative to the crossings of the binding warp yarns of the other one of the fabrics to be woven in the warp direction. In this way, the same direction of inclination of the piles provided in the two fabrics can be obtained. Further in at least one of the fabrics the crossings of the binding warp yarns defining the weft receiving openings in the two orientations of the warp direction are located at the same position in the warp direction, which may also be the case if, with the method of the present invention, only a single fabric is to be woven.
The present invention will now be explained with respect to the drawings in which:
Each one of the fabrics F1, F2 is constituted by a plurality of warp yarn systems comprising binding warp yarns B1, B2 and tension warp yarns T for providing the ground weave of respective backing fabrics BF as well as pile warp yarns PY1, PY2, PY3, PY4 for providing piles P extending out of the backing fabrics BF on a pile side PS. Each warp yarn system may comprise all the warp yarns for providing a ground weave of the two backing fabrics BF for both fabrics F1, F2 and all the pile warp yarns PY1, PY2, PY3, PY4 interlaced with the weft yarns E1, I, E2 for generating piles P or bound into the backing fabrics BF such as to extend substantially in the warp direction WA as dead pile warp yarns.
When carrying out the face-to-face weaving method of the present invention, one warp yarn system may be associated with each reed dent of a weaving machine.
It is to be noted that, in the sense of the present invention the cooperation of pile warp yarns with weft yarns extending through weft receiving openings defined by binding warp yarns, while other pile warp yarns and tension warp yarns extend within a respective backing fabric refers to warp yarns extending in close proximity to each other in the weft direction, preferably refers to warp yarns of one and the same warp yarn system.
In the weaving structure shown in
In the weaving structure of
In a weft receiving opening O in which a change of the pile forming pile warp yarn occurs, especially if both pile-forming pile warp yarns are bound into the same fabric when not forming piles, both end weft yarns E1, E2 may be positioned on the back side BS relative to all the warp yarns bound into the backing fabric BF, such that all these warp yarns are used as weft separating warp yarns. This can, for example, be seen in the weft receiving opening O of the top fabric F1, where a change from the pile warp yarn PY1 to the pile warp yarn PY2 occurs.
In some of the weft receiving openings O, the end weft yarns E1 positioned adjacent to the crossings C1 defining these weft receiving openings O in the first orientation OW1 are separated from the associated intermediate weft yarns I by means of the tension warp yarn T only and therefore are positioned on the pile side PS with respect to the dead pile warp yarns, while the end weft yarns E2 positioned adjacent to the crossings C2 defining these weft receiving openings O in the second orientation OW2 are separated from the associated intermediate weft yarns I by means of the tension warp yarn T and the dead pile warp yarns and therefore are positioned on the back side BS with respect to the dead pile warp yarns. However, in all the weft receiving openings O, or at least in the major portion of the weft receiving openings O, both end weft yarns E1, E2 are separated from the intermediate weft yarn I by the tension warp yarn T of a respective warp yarn system.
For forming piles P, the pile-forming pile warp yarns are interlaced with one of the two end weft yarns E1, E2 received in the weft receiving openings O. For example, pile warp yarn PY1 is interlaced with the end weft yarns E1 received in the weft receiving openings O on the back side of the tension warp yarn T and the dead pile warp yarns, while pile warp yarn PY2 is interlaced with the end weft yarns E2 received in the weft receiving openings O on the back side of the tension warp yarn T and the dead pile warp yarns, such that, in each weft receiving opening O, a pile-forming pile warp yarn is interlaced with an end weft yarn E1 or E2 positioned at the back side of the tension warp yarn T and all the dead pile warp yarns bound into the backing fabrics BF acting as the weft separating warp yarns. This leads to a structure in which the piles P generated by pile warp yarn PY1 extend out of the backing fabric BF of each one of the two fabrics F1, F2 between the end weft yarn E1 with which they are interlaced and the intermediate weft yarn I of the same weft receiving opening O, and extend out of the backing fabric between the end weft yarns E1 with which they are interlaced and the immediately adjacent end weft yarn E2 of the weft receiving opening O following in the first orientation OW1 of the warp direction, if such a pile comprises two pile legs PL1, PL2, such that V-piles are provided. If a pile P comprises only one pile leg PLs, which is the case at locations where a pile warp yarn starts or ends forming piles P, this single pile leg PLs extends out of the backing fabric BF between the end weft yarn E1 with which it is interlaced and the immediately adjacent end weft yarn E2 of the weft receiving opening O following in the first orientation OW1 of the warp direction WA or the intermediate weft yarn I of the weft receiving opening O through which the end weft yarn E1 extends.
Due to the fact that the intermediate weft yarns I are separated from each one of the end weft yarns E1, E2 by at least one weft separating yarn, i.e. the tension warp yarns T and the dead pile warp yarns or the tension warp yarns T only, in each case the piles P extend out of a respective one of the backing fabrics BF between two weft yarns I, E2 positioned adjacent to the weft yarn E1 with which a pile-forming pile warp yarn, for example, PY1, is interlaced. As can be seen in the top fabric F1 of
This shadow effect depends on whether a respective pile-forming pile warp yarn is interlaced with an end weft yarn E1 or is interlaced with an end weft yarn E2 of a respective weft receiving opening O. As can be seen in
As stated above, due to the forces applied to the weft yarns by the binding warp yarns and/or applied to the weft yarns during the weaving process, the sequence of the weft yarns in the warp direction and/or the distance of immediately adjacent weft yarns from each other may deviate from the ones shown in the drawings. The sequence of the weft yarns in the drawings corresponds to the sequence with which the weft yarns are introduced during the weaving process by weft insertion means. For example, for each one of the weft receiving openings, an end weft yarn, and intermediate weft yarn, and a further end weft yarn may be introduced one after the other for each one of the two fabrics. Due to the above stated forces applied to the weft yarns in the warp direction, in particular applied to the weft yarns not used for interlacing pile warp yarns, these weft yarns may become shifted in the warp direction, such that, for example, an intermediate weft yarn is closer to a crossing of two binding warp yarns than the one end weft yarn not used for interlacing a pile warp yarn (in a particular warp yarn system) which, when introducing this weft yarn, was closer to this crossing than the intermediate weft yarn. This can lead to a situation in which, in some of the weft receiving openings, in association with some of the warp yarn systems the sequence of the weft yarns in the warp direction is such that a weft yarn used for interlacing a pile warp yarn and being positioned immediately adjacent to a crossing of the two binding warp yarns of a respective warp yarn system is followed by the other end weft yarn not used for interlacing a pile warp yarn and then the intermediate weft yarn, i.e. the weft yarn which is separated from the end weft yarns by means of at least one weft separating warp yarn, preferably comprising at least the tension warp yarn(s) of a respective warp yarn system. Further there may be situation, in which two weft yarns not used for interlacing pile warp yarns, for example, comprising an intermediate weft yarn and an end weft yarn, due to the forces applied thereto, are positioned substantially one above the other in the direction D. However, it is to be expected that, in the major portion of the weft receiving openings, the sequence of the weft yarns corresponds to the sequence with which the weft yarns are introduced into the backing fabrics during the weaving process
In an alternative weaving structure shown in
For providing a symmetrical structure in both fabrics F1, F2, the crossings C1, C2 of the top fabric F1 are offset with respect to the crossings C1, C2 of the bottom fabric F2 in the warp direction. This leads to a corresponding offset of the weft receiving openings O and the weft yarns received in these weft receiving openings O, in particular the end weft yarns E1, E2 with which the pile-forming pile warp yarns are interlaced. When looking at the first pile P generated by means of the pile warp yarn PY1 in the bottom fabric F2, i.e. the pile P positioned on the left most side of
While the crossings C1, C2 of the two fabrics F1, F2 preferably are shifted with respect to each other in the warp direction WA, for example, by one weft yarn, i.e. one weaving cycle, the crossings C1, C2 of different warp yarn systems following each other in the weft direction within each one of the two fabrics F1, F2 preferably are positioned at the same location in the warp direction WA. This leads to lines of crossings C1 and lines of crossings C2 within each one of the two fabrics F1, F2 extending substantially in the weft direction.
By providing the weaving structure shown in
What becomes clear from the above explanation of the embodiments shown in
It is to be noted that in a fabric according to the present invention, more than one intermediate weft yarn may be used in the various weft receiving openings. In each case, in line with the principles of the present invention, a pile or a pile leg of a pile, respectively, will extend out of the backing fabric on the pile side between the weft yarn with which it is interlaced and an intermediate weft yarn of the same weft receiving opening. Further there may be additional weft yarns positioned on the back side relative to one or a plurality of weft separating warp yarns, which additional weft yarns may be positioned between the two end weft yarns of a respective weft receiving opening. In addition to interlacing the pile warp yarns with one of the end weft yarns, the pile warp yarns may be interlaced with such an additional weft yarn, such as to be interlaced with two adjacent weft yarns of the same weft receiving opening, one of these weft yarns being an end weft yarn. Further, when weaving such a structure as shown in the drawings, additional steps known to the man skilled in the art will have to be carried out. For example, when weaving these structures in a face-to-face weaving process, one of the last measures will be the cutting of the piles connecting the two fabrics with each other, such that the two separated fabrics will be obtained.
A further embodiment of a fabric and a method of weaving fabric, respectively, is shown in
In the transition zones Z of this embodiment, there is provided a weft receiving opening O in which both end weft yarns E1, E2 are used for interlacing the pile forming pile warp yarn PY1. Both end weft yarns E1, E2 of these weft receiving openings O are on the back side BS relative to the associated tension warp yarns T and relative to the dead pile warp yarns bound into the respective fabrics F1, F2 (four in the top fabric F1 and three in the bottom fabric F2). In this a weaving structure, in each one of the two fabrics F1, F2, in association with the respective weft receiving openings O, two piles P, each pile P comprising two pile legs PL1, PL2 are provided. This leads to an increased pile density in the area of this transition zones Z and avoids the occurrence of a pile gap in these transition zones Z.
As shown in association with the top fabric F1, the immediately adjacent end weft yarn E2 of at least one weft receiving opening O positioned immediately adjacent to the weft receiving opening O of the transition zone Z and not used for interlacing with a pile-forming pile warp yarn may be positioned at the back side BS relative to the tension warp yarn T and the dead pile warp yarn PY2 bound into this fabric, such as to be on the same level as the immediately adjacent end weft yarn E1 of the transition zone Z. However, as shown on the right side of the top fabric F1 and as shown on both sides of the transition zone Z of the bottom fabric F2, the immediately adjacent end weft yarn of at least one immediately adjacent weft receiving opening O may be positioned on the pile side PS relative to the dead pile warp yarns and on the back side BS relative to the tension warp yarns T, such that only the tension warp yarns T are used as weft separating warp yarns between this immediately adjacent end weft yarn and the intermediate weft yarn of the weft receiving opening O and in these areas.
| Number | Date | Country | Kind |
|---|---|---|---|
| 16151396.5 | Jan 2016 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2017/050170 | 1/5/2017 | WO | 00 |
