Reference numerals are used in this detailed description which refer to the attached drawings, wherein
FIG. 1 shows a fabric structure according to the invention having tied-in non-figure forming pile warp yarns, and which is woven according to the face-to-face weaving method;
FIG. 2 shows a fabric structure according to the invention with floating non-figure forming pile warp yarns on the pile side which are regularly tied up over a second weft yarn which is on the back, and which is woven according to the face-to-face weaving method;
FIG. 3 shows a fabric structure according to the invention with floating non-figure forming pile warp yarns on the pile side which are regularly tied up over a second weft yarn which is on the pile side, and which is woven according to the face-to-face weaving method;
FIG. 4 shows a fabric structure according to the invention wherein some of the pile warp yarns are tied up over a second weft yarn on the back of the fabric, and which is woven on a weaving machine with two weft-insertion means and according to the face-to-face weaving method;
FIG. 5 shows a fabric structure according to the invention wherein some of the pile warp yarns are tied up over a second weft yarn on the back of the fabric, and which is woven on a weaving machine with three weft-insertion means according to the face-to-face weaving method;
FIGS. 6
a and 6b show two adjacent pile warp yarn systems of a fabric structure according to the invention which are woven according to a 1+1/2 V-weave by means of a weaving machine with three weft-insertion means wherein two pile warp yarn systems are situated in the same reed dent;
FIGS. 7
a and 7b show two adjacent pile warp yarn systems of a fabric structure woven in accordance with a particular method according to the invention by means of a weaving machine with three weft-insertion means, wherein two pile warp yarn systems are situated in the same reed dent.
With one method for weaving of a fabric (1, 2) according to the invention, wherein the fabric (1, 2), mainly on the back, has the appearance of a hand-knotted fabric, a ground fabric (100, 200) is made from ground warp yarns, comprising one or more binding warp yarns (101, 201), second weft yarns (4a, 4b, 4′, 4″) which are tied up in the ground fabric (100, 200), and one or more tension warp yarns (102, 202), as is illustrated in FIGS. 1 to 9. Furthermore, the fabric (1, 2) comprises first weft yarns (3) which are on the back outside the ground fabric and non-figure forming and/or figure forming pile warp yarns (6, 7), the figure forming pile warp yarns (6) forming figure forming pile burls (6a, 6b), with at least one set of two successive figure forming pile burls (6a, 6b) in the warp direction alternately being tied up over a first weft yarn (3) which is on the back of the fabric (1, 2) outside the ground fabric (100, 200), and over a second weft yarn (4a, 4b, 4′, 4″) which is tied up in the ground fabric (100, 200). The weft yarns (3, 4) are in this case preferably laid in at least two layers.
The fabrics (1, 2), as illustrated in FIGS. 1 to 7, are woven according to the face-to-face weaving method. However, these fabrics (1, 2) may also be woven according to the single-side weaving method.
As can be seen in FIGS. 1 to 9, preferably each set of two successive pile burls (6a, 6b) in the warp direction is alternately formed over a first weft yarn (3) and over a second weft yarn (4a, 4b, 4′, 4″), and using the same pile warp yarns (6). The second weft yarns which are tied up in the ground fabric (100, 200) by weave and tension warp yarns (101, 201, 102, 202) can be divided into
- first second weft yarns (4a) on the pile side of the ground fabric (100, 200);
- second second weft yarns (4b) on the back of the ground fabric (100, 200).
With the fabrics illustrated in FIGS. 1 to 5, the second weft yarns (4a, 4b, 4′, 4″) are tied up by two binding warp yarns (101, 201) and one tension warp yarn (102, 202) per warp yarn system while with the fabrics illustrated in FIGS. 6a, 6b, 7a and 7b, the second weft yarns (4a, 4b, 4′, 4″) are tied up by one binding warp yarn (101, 201) and one tension warp yarn (102, 202) per warp yarn system. A tension warp yarn (102, 202) is situated between the first second weft yarns (4a) on the pile side and the second second weft yarns (4b) on the back.
Preferably, the second weft yarns over which the pile burls (6a, 6b) are tied up are first second weft yarns (4a) on the pile side of the ground fabric (100, 200) (see FIGS. 1 to 3). Nevertheless, the second weft yarns over which pile burls (6a, 6b) are tied up may also be second second weft yarns (4b) on the back of the ground fabric (100, 200).
As illustrated in FIGS. 1, 4 and 5, the non-figure forming pile warp yarns (7) can be tied up as dead pile between the first second weft yarns (4a) on the pile side of the ground fabric (100, 200) and second second weft yarns (4b) on the back of the ground fabric (100, 200). As can be seen in FIGS. 1 and 4, the non-figure forming pile warp yarns (7) are preferably between the tension warp yarn (102, 202) and the first second weft yarns (4a) on the pile side of the ground fabric (100, 200).
As illustrated in FIGS. 2 and 3, the non-figure forming pile warp yarns (7) may float on the pile side, and only occasionally be tied up over a second weft yarn (4a, 4b, 4′, 4″). In FIG. 2, this second weft yarn is a second second weft yarn (4b) on the back of the ground fabric (100, 200), while in FIG. 3, this second weft yarn is a first weft yarn (4a) on the pile side of the ground fabric (100, 200). The non-figure forming pile warp yarns (7) can successively be tied in as dead pile and float over first second weft yarns (4a) on the pile side in a zone where no pile is formed, in order to form figure in the ground fabric (100, 200) at the surface of the ground fabric (100, 200) (not illustrated in the figures).
As illustrated in FIGS. 1 to 5, the yarns used for the first weft yarns (3) are preferably thicker than those used for the second weft yarns (4a, 4b, 4′, 4″). Preferably, the second weft yarns (4′) around which pile warp yarn (6) is tied up are thicker yarns than the second weft yarns (4″) around which no pile warp yarn (6) is tied up.
With the method according to the invention, during the insertion of weft yarns (3, 4a, 4b, 4′, 4″), two weft-insertion means (3, 4a, 4b, 4′, 4″) can be inserted simultaneously at different weft-insertion levels, as is illustrated in FIGS. 1 to 4. However, as is shown in FIGS. 5 to 9, it is also possible to insert at least three weft-insertion means (3, 4a, 4b, 4′, 4″) simultaneously during the insertion of weft yarns (3, 4a, 4b, 4′, 4″).
Fabric structures according to the invention can be produced using a 1/2V pile weave (see FIGS. 1, 2 and 4), with one pile burl (6a, 6b) being provided in each fabric (1, 2) for every 2 weft yarns (3, 4a, 4b, 4′, 4″) inserted per fabric.
Furthermore, as shown in FIG. 3, the use of the 1/2V fabric structure on a two-rapier weaving machine in combination with, for example, a ground weave in repeat 8, makes it impossible to insert one second weft yarn (5a) on the pile side of the fabric per series of 4 weft yarns (3, 4a, 4b, 4′, 4″) per fabric, so that a 1+1/2V fabric structure (fabric structure with continuous alteration between 1/1V and 1/2V in each fabric per 2 machine cycles) is produced, as can be seen in FIG. 3.
The fabric structure illustrated in FIG. 5 is achieved using a weaving device with three weft-insertion means with a ground weave in repeat 8, with 2 second weft yarns (5a, 5b) not being inserted over 4 weft-insertion cycles, i.e. a first second weft yarn (5b) which, if it were inserted, would be on the back of the fabric (1, 2), and a second second weft yarn (5a) which would be on the pile side of the fabric (1, 2). In this manner, a 2/3+1/1V pile weave is produced.
Even if a second weft yarn (5b), which would be on the back of the fabric, were again to be used as second non-inserted second weft yarn, a 2/3+1/1V pile weave is achieved (not illustrated in the figures), with the section 1/1 tying up V-pile weave over a first second weft yarn (5a) on the pile side of the fabric, thus making a higher fabric density and a better quality of the back of the carpet possible as the weft yarns on the pile side and the back are sufficiently far apart for the resulting plurality of layers of weft yarns (3, 4a, 4b, 4′, 4″) to be pressed together in a more compact way.
The fabrics (1, 2), as illustrated in FIGS. 1 to 5, are shown in weave repeat 8, but it is obvious that other weave repeats can also be used. Thus, for example, all multiples of 4 can be selected as weave repeat.
As is illustrated in FIGS. 6a and 6b, with the abovementioned 2/3+1/1V pile weave, the weft yarn (5a) which is situated on the pile side between the pile burl (6a, 6b) can be omitted in the 2/3V section, freeing up some space in the fabric (1, 2), as has already been indicated above, which may be used to increase the fabric density, and producing a 1+1/2 V-weave by means of the three-rapier weaving technique resulting in the advantages which have already been described above (advantage already indicated in the introductory text of the description).
Furthermore, during weaving of the fabrics (1, 2), as illustrated in FIGS. 6a and 6b, and as is the case with the method described in EP 1 347 086, two warp yarn systems can be in the same reed dent, and in each warp yarn system only one binding warp yarn (101) per fabric (1, 2) can be present, with the two binding warp yarns (101) of the same fabric (1, 2) tying up all second weft yarns (4a, 4b) from the two different warp yarn systems in the ground fabric. The second second weft yarns (4b) which are on the back of the ground fabric with respect to the tension warp yarn (102, 202) and are not tied up by a binding warp yarn (101, 201) in their warp yarn system are in this case not visible on the back of the fabric (1, 2) since they are hidden under the pile warp yarns (6, 7) which are pressed closely together and tie up on the back around the first weft yarns (3). This method produces very dense fabrics (1, 2), the backs of which have an appearance which is similar to that of hand-knotted carpets, with each point on the back having two corresponding pile burls (6a, 6b) on the pile side.
In order to solve the abovementioned problem regarding tension of the binding warp yarns (101, 201) used in the method for weaving fabrics (1, 2) as illustrated in FIGS. 6a and 6b, the formation in at least one pile warp yarn system of at least one set of two successive figure forming pile burls (6a, 6b) in the warp direction by alternately tying these up over a first weft yarn (3) which is on the back of the fabric (1, 2) outside the ground fabric (100, 200) and over a second weft yarn (4a, 4b, 4′, 4″) which is tied up in the ground fabric (100, 200), as illustrated in FIGS. 7a and 7b, is preceded or followed by two successive pile burls (6a, 6b) within the same fabric (1, 2) which are only tied up over first weft yarns (3), while the same succession of pile burls (6a, 6b) occurs in an adjacent pile warp yarn systems, with a second weft yarn (4a, 4b, 4′, 4″) which is tied up in these pile warp yarn systems by a pile warp yarn (6) being tied up by only one pile warp yarn (6) in these pile warp yarn systems.
As can be seen in FIGS. 7a and 7b, with FIG. 7a showing a first pile warp yarn system and FIG. 7b showing a second adjacent pile warp yarn system, a first second weft yarn (4a) is tied up in the top and the bottom fabric, respectively, by a pile warp yarn (6) in the second pile warp yarn system during a first and a second machine cycle (301, 302), while during the same machine cycles (301, 302) the second weft yarns (4a) are not tied up by a pile warp yarn (6) in the first pile warp yarn system. However, during the following third and fourth machine cycles (303, 304), a first second weft yarn (4a) is tied up in the top and bottom fabric, respectively, by a pile warp yarn (6) in the first pile warp yarn system, while during the same machine cycles (303, 304) the second weft yarns (4a) are not tied up by a pile warp yarn (6) in the second pile warp yarn system.
In this case, a pile burl (6a, 6b) is no longer formed in each pile warp yarn system during each machine cycle in one of the two fabrics (1, 2), but still 6 pile burls are formed during 8 machine cycles which is still quite a high figure for a fabric (1, 2) of this quality at high pile warp yarn system densities.
Also when working according to the methods using two pile warp yarn systems per reed dent, as illustrated in FIGS. 6a, 6b, 7a and 7b, some colours of the pile warp yarns (6, 7) may differ between the two pile warp yarn systems. As a result, when selecting one of these colours for pile-forming, only a halve density is achieved in the weft direction compared to the pile-forming by pile warp yarns (6, 7) which are present in each of the pile warp yarn systems. This halving in pile density can substantially be compensated for by working according to the invention in those areas in the fabric, so that a double density is produced in said areas in the warp direction, as a result of which the density in the fabric corresponds to the density of the pile warp yarns (6, 7) which are present in each of the pile warp yarn systems and which are only tied up over first weft yarns (3).
Furthermore, it is preferable if the figure forming pile burls (6a) start forming figure at colour transitions and end figure forming by tying up over first weft yarns (3). This then means that between the end of the figure-forming by the one pile warp yarn (6) and the start of the figure-forming by the other pile warp yarn (6), no pile warp yarns (6) are tied up in a figure-forming way over the intermediate second weft yarns (4a, 4b, 4′, 4″).
This results in a limited loss of figure forming pile burls (6a), but does offer a more accurately defined pattern on the pile side, because mixing contours are thus avoided.
Furthermore, one advantage of the invention as described here is the fact that with using one and the same fabric design pattern fabrics of different densities can be produced for the same pattern by means of different processing:
- single density if the pile warp yarns (6) are tied up only over the first weft yarns (3);
- double density if the pile warp yarns (6) in between are in each case also tied up over a second weft yarn (4a, 4b, 4′, 4″);
- one and a half density if, as described, if two adjacent pile warp yarn systems are made different
- but also numerous other varying densities in between.
With the method according to the invention, the pile warp yarns (6) which are tied up over a first weft yarn (3) are lifted to a position which, relative to the position of the weaver, is located behind the rapiers which insert the weft yarns (3), this position being chosen in such a manner that, at the bottom rapiers, these pile warp yarns (6) are positioned just below these bottom rapiers, and perform a guiding function for these bottom rapiers during their movement through the shed.
Such positioning may be effected by
- using a weaving frame having a number of healds which are provided with heald eyes, a cord, wire or bar extending through several or all heald eyes of this weaving frame in the weft direction, and this weaving frame being lifted for the insertion of the first weft yarns in such a manner that the a cord, wire or bar takes the figure forming pile warp yarns (6) which are situated below the bottom rapiers to just below these rapiers;
- dimensioning at least one weaving frame for driving the binding warp yarns in the top fabric in such a manner that, when these binding warp yarns are in their highest position above the top rapier, a cord, wire, bar or beam which extends in the weft direction and is connected to this weaving frame, lifts the pile warp yarns (6, 7) which are in the bottom position along in order to position them just below the bottom rapier;
- using at least one weaving frame which is driven by a servomotor, the vertical movement of the weaving frame being controllable and programmable, as a result of which this weaving frame with binding warp yarns (101, 201) which is situated above the top rapier at the point in time when the bottom rapier has to be supported, is lifted slightly higher than is required for shed-forming of the binding warp yarns (101, 201), so that the bottom beam of the weaving frame lifts the pile warp yarns (6) which are in the bottom position along in order to position them just below the bottom rapier;
- using a reciprocating weaving frame or a reciprocating table which is provided at the top with a surface which positions said pile warp yarns (6) just below the bottom rapiers;
- using a fixed table which always positions said pile warp yarns (6) just below the bottom rapier, said fixed table being in this case preferably positioned as closely as possible to the rapiers in order to keep the zone wherein the pile warp yarns (6) and binding warp yarns (101, 201) meet as short as possible in positions where there are also binding warp yarns (101, 201) below the bottom rapier.
The method according to the invention can in particular be used for carpets, but other applications are also possible.
Patent Application
20080053557
