U.S. patent application number 09/774596 was filed with the patent office on 2001-08-02 for method for manufacturing a pile fabric with a high frame count.
Invention is credited to Dewispelaere, Andre, Smissaert, Ludo.
Application Number | 20010010236 09/774596 |
Document ID | / |
Family ID | 3896394 |
Filed Date | 2001-08-02 |
United States Patent
Application |
20010010236 |
Kind Code |
A1 |
Dewispelaere, Andre ; et
al. |
August 2, 2001 |
Method for manufacturing a pile fabric with a high frame count
Abstract
Method for face-to-face weaving pile fabrics whereby warp yarns
(1)-(15) of a series of warp yarn systems are interwoven with weft
yarns (16), (17), (18) in order to weave a top (19) and a bottom
backing fabric (20), whereby pile warp yarns (11)-(15) are
alternately passed around a weft yarn (16), (18) of the top backing
fabric (19) and the bottom backing fabric (20) so that they form
pile, whereby per warp yarn system at least two non-pile-forming
pile warp yarns (11)-(15) are inwoven in one and the same backing
fabric (19), (20) and according to this invention are divided per
warp yarn system into at least two groups each with at least one
pile warp yarn, so that the weft yarns (11, 13), (12); (14), (15)
of different groups extend respectively at a different level in the
backing fabric, and whereby finally the pile-forming pile warp
yarns are cut through between the two backing fabrics so that two
fabrics are obtained. A pile fabric whose non-pile-forming pile
warp yarns (11)-(15) are per warp yarn system inwoven in the
backing fabric (19), (20) in two layers located one above the
other. Especially with pile fabrics with high frame count because
of this it is avoided that with a color transition in weft
direction the pile loops are spread apart from each other by
interjacent inwoven pile warp yarns.
Inventors: |
Dewispelaere, Andre;
(Kortrijk/Marke, BE) ; Smissaert, Ludo;
(Assebroek, BE) |
Correspondence
Address: |
James C. Wray
Suite 300
1493 Chain Bridge Road
McLean
VA
22101
US
|
Family ID: |
3896394 |
Appl. No.: |
09/774596 |
Filed: |
February 1, 2001 |
Current U.S.
Class: |
139/391 |
Current CPC
Class: |
D03D 27/10 20130101 |
Class at
Publication: |
139/391 |
International
Class: |
D03D 027/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 2, 2000 |
BE |
2000/0087 |
Claims
1. Method for face-to-face weaving pile fabrics whereby warp yarns
(1)-(15) of a series of warp yarn systems are interwoven with weft
yarns (16), (17), (18) so that a top (19) and a bottom backing
fabric (20) are formed, whereby pile warp yarns (11)-(15) are
alternately passed around a weft yarn (16) of the top backing
fabric (19) and around a weft yarn (18) of the bottom backing
fabric (20) so that they form pile, while per warp yarn system at
least two non-pile-forming pile warp yarns (11), (12), (13; (14),
(15) are inwoven in one and the same backing fabric (19); (20), and
whereby the pile-forming pile warp yarns (11)-(15) are split
between the two backing fabrics so that two fabrics are obtained,
characterized in that the aforesaid non-pile-forming pile warp
yarns (11)-(15) are divided per warp yarn system into at least two
groups each with at least one pile warp yarn (11, 13), (12); (14),
(15), and that the pile warp yarns of the different groups extend
respectively at a different level in the same backing fabric (19),
(20).
2. Method for face-to-face weaving pile fabrics according to claim
1 characterized in that the pile warp yarns (11, 13) , (12); (14) ,
(15) of different groups inwoven in the same backing fabric are
separated from each other by weft yarns (17) of the backing
fabric.
3. Method for face-to-face weaving pile fabrics according to claim
1 or 2 characterized in that each group (11, 13), (12); (14), (15)
comprises at least two pile warp yarns.
4. Method for face-to-face weaving pile fabrics according to any of
the preceding claims characterized in that in each warp yarn system
per group of pile warp yarns (11, 13), (12); (14), (15) a tension
warp yarn (7), (8), (9), (10) is inwoven adjacent to these pile
warp yarns.
5. Method for face-to-face weaving pile fabrics according to any of
the preceding claims characterized in that in each backing fabric
(19), (20) weft yarns (16), (17), (18) are inwoven at three
different levels, namely a pile side level, a middle level and a
back level, and that in each backing fabric per warp yarn system a
first (12), (14) and a second group of pile warp yarns (11, 13),
(15) are inwoven, respectively running along the pile side and
along the backside of the weft yarns (17) of the middle level.
6. Method for face-to-face weaving pile fabrics according to claim
5 characterized in that the pile warp yarns (12), (14) of the first
group run between the weft yarns (16), (18) of the pile side level
and the weft yarns (17) of the middle level, and that the pile warp
yarns (11, 13), (15) of the second group run between the weft yarns
(17) of the middle level and the weft yarns (16), (18) of the back
level.
7. Method for face-to-face weaving pile fabrics according to claim
5 or 6 characterized in that the pile warp yarns (12), (14) of the
first group are undulatingly inwoven, whereby they alternately run
along the pile side in relation to a weft yarn (16), (18) of the
pile side level and between a weft yarn (16), (18) of the pile side
level and a weft yarn (17) of the middle level.
8. Method for face-to-face weaving pile fabrics according to one of
the claims 5 through 7 characterized in that in each backing fabric
(19), (20) alternately two weft yarns (16, 17), (17, 18) one above
the other and one single weft yarn (16); (18) are inwoven, that the
two weft yarns inwoven one above the other are inwoven in the
backing fabric (19), (20) respectively at the middle level and at
the back level, and that the single weft yarns (16), (18) are
inwoven in the backing fabric at the pile side level.
9. Method for face-to-face weaving pile fabrics according to any of
the preceding claims characterized in that the non-pile-forming
pile warp yarns (11)-(15) are inwoven divided per warp yarn system
between the top (19) and the bottom backing fabric (20).
10. Method for face-to-face weaving pile fabrics according to any
of the preceding claims characterized in that it is utilized on a
weaving machine with weft insertion means that are provided for
inserting three weft yarns (16), (17), (18) between warp yarns per
weft insertion cycle.
11. Method for face-to-face weaving pile fabrics according to one
of the claims 8 through 10 characterized in that in each backing
fabric (19), (20) a first (1), (4), a second (2), (5) and a third
binding warp yarn (3), (6) is provided per warp yarn system, so
that the first (1), (4) and the second binding warp yarn (2), (5)
cross each other repeatedly and an opening is formed in each case
between every two successive intersections, through which two weft
yarns (16), (17); (17), (18) extend one above the other, and so
that the third binding warp yarn (3), (6) runs alternately along
the pile side in relation to a weft yarn (16), (18) of the pile
side level and along the back in relation to a weft yarn (17) of
the middle level.
12. A pile fabric, comprising a backing fabric (19), (20) woven out
of weft yarns (16), (17), (18) and warp yarns (1)-(15), a number of
pile yarn loops passed around weft yarns of the backing fabric and
pile warp yarns (11)-(15) inwoven in the backing fabric
characterized in that the inwoven pile warp yarns are inwoven
divided between at least two layers located one above the other in
the backing fabric (19), (20).
13. A pile fabric according to claim 12 characterized in that the
pile warp yarns (11)-(15) of different layers are separated from
each other by interjacent weft yarns (17).
14. A pile fabric according to claim 12 or 13 characterized in that
the inwoven pile warp yarns (11)-(15) are divided per warp yarn
system between the aforesaid layers and that in each warp yarn
system a tension warp yarn (7), (8), (9), (10) is married to each
layer of pile warp yarns.
Description
[0001] This invention relates to a method for face-to-face weaving
pile fabrics whereby warp yarns of a series of warp yarn systems
are interwoven with weft yarns so that a top and a bottom backing
fabric are formed, whereby pile warp yarns are alternately passed
around a weft yarn of the top backing fabric and around a weft yarn
of the bottom backing fabric so that they form pile, while per warp
yarn system at least two non-pile-forming pile warp yarns are
inwoven in one and the same backing fabric, and whereby the
pile-forming pile warp yarns are split between the two backing
fabrics so that two fabrics are obtained.
[0002] This invention also relates to a pile fabric comprising a
backing fabric woven out of weft yarns and warp yarns, a number of
pile yarn loops passed around weft yarns of the backing fabric and
pile warp yarns inwoven in the backing fabric, and more especially
such a pile fabric that is woven according to the method according
to this invention.
[0003] The above described known method can be implemented on a
known weaving machine which is provided for inserting one or
several weft yarns between warp yarns in the course of successive
weft insertion cycles. These warp yarns are for that purpose
positioned in relation to the weft insertion levels by means of a
shed-forming device.
[0004] The warp yarns are provided in a series of warp yarn systems
located next to one another, and the warp yarns of each warp yarn
system are pulled through a respective space between reed dents.
Per warp yarn system several pile warp yarns are provided, for
example in order to allow differently colored pile warp yarns
alternately to form pile and be inwoven in accordance with a
predetermined pattern, so that the differently colored pile loops
of the fabric form the pattern.
[0005] The demand for pile fabrics with a wide color variation is
increasing and the development of such fabrics is becoming evermore
easy by the use of CAD systems and electronic jacquard machines.
For this purpose per warp yarn system a large number of differently
colored pile warp yarns must be provided. If the number of pile
warp yarns per warp yarn system, also called "the number of pile
frames per reed space", is high (for example 6 or higher) they are
called pile fabrics with high frame count. In each warp yarn system
there are a number of pile warp yarns that form no pile and are
burried in one of the backing fabrics. It is usual to divide these
non-pile-forming pile warp yarns between the top and the bottom
backing fabric for their inweaving. As long as the number of pile
warp yarns per fabric to be inwoven remains limited, pile fabrics
of a high quality can be woven in the known manner.
[0006] But with pile fabrics with high frame count, drawback
effects occur with color transitions in weft direction. If namely
in two warp adjacent yarn systems with several different pile warp
yarns provided next to one another in a specific sequence a pile
warp yarn of different frame has to form pile, it is possible that
a large number of inwoven pile warp yarns extend between the two
pile-forming pile warp yarns running next to one another and push
apart the pile loops formed by these pile warp yarns. Because of
this with a number of color transitions in weft direction a line
becomes visible extending in warp direction. Such a fabric is
clearly of a lesser quality.
[0007] In order to remedy for this drawback a number of measures
have been put forward in the Belgian patent application no.
9700712. These measures reduce the drawback effects with color
transitions in weft direction but appear in general, and especially
with fabrics where a frame count of 8 or more is used per warp yarn
system, insufficient for obtaining fabrics of a perfect
quality.
[0008] The purpose of this invention is on the one hand to provide
a face-to-face weaving method that enables pile fabric weaving of a
perfect quality, and this not only where the frame count per reed
space is relatively low (at least two), but also where this frame
count is particularly high (e.g. 12, 14 or more), and on the other
hand to provide a pile fabric with such properties that the quality
thereof is independent of the frame count per reed space, in
contrary to the known pile fabrics.
[0009] These objectives are achieved according to this invention by
means of a method with the characteristics mentioned in the first
paragraph of this specification, whereby the aforesaid
non-pile-forming pile warp yarns are divided per warp yarn system
into at least two groups each with at least one pile warp yarn, and
whereby the pile warp yarns of the different groups extend
respectively at a different level in the same backing fabric, and
by providing a pile fabric comprising a backing fabric woven out of
weft yarns and warp yarns, a number of pile yarn loops passed
around weft yarns of the backing fabric and pile warp yarns inwoven
in the backing fabric, of which the inwoven pile warp yarns divided
between at least two layers located one above the other are inwoven
in the backing fabric.
[0010] Because of the fact that the inwoven pile warp yarns are
divided per warp yarn system between two layers located one above
the other a series of inwoven pile warp yarns between two pile loop
rows no longer occupy such a large width as with fabrics that are
woven according to the known weaving methods. Because of this the
pile loops are not spread apart and the drawback effect of line
formation is prevented, in pile fabrics with high frame count.
[0011] According to a preferred method according to this invention
the pile warp yarns of different groups inwoven in the same backing
fabric are separated from each other by weft yarns of the backing
fabric.
[0012] This method according to the invention is preferably so
implemented that each group comprises at least two pile warp
yarns.
[0013] It is furthermore also preferable in each warp yarn system
per group of pile warp yarns to inweave a tension warp yarn
adjacent to these pile warp yarns.
[0014] According to a particularly efficient method in each backing
fabric weft yarns are inwoven at three different levels, namely a
pile side level, a middle level and a back level, and in each
backing fabric per warp yarn system a first and a second group of
pile warp yarns are inwoven, respectively running along the pile
side and along the backside of the middle level weft yarns.
[0015] This method can also be so applied that the pile warp yarns
of the first group run between the weft yarns of the pile side
level and the weft yarns of the middle level, while pile warp yarns
of the second group run between the weft yarns of the middle level
and the weft yarns of the back level.
[0016] The pile warp yarns of the first group can also be
undulatingly inwoven, whereby in each warp yarn system they
alternately run along the pile side in relation to a weft yarn of
the pile side level and between a weft yarn of the pile side level
and a weft yarn of the middle level.
[0017] The most preferred is the method according to this invention
whereby in each backing fabric alternately two weft yarns one above
the other and one single weft yarn are inwoven, whereby the two
weft yarns inwoven one above the other are inwoven in the backing
fabric respectively at the middle level and at the back level, and
whereby the single weft yarns are inwoven in the backing fabric at
the pile side level.
[0018] The non-pile-forming pile warp yarns are moreover preferably
also inwoven divided per warp yarn system between the top and the
bottom backing fabric.
[0019] This method has the greatest productivity if it is utilized
on a weaving machine with weft insertion means that are provided
for inserting simultaneous three weft yarns between warp yarns per
weft insertion cycle.
[0020] According to another particular property of the method
according to this invention in each backing fabric a first, a
second and a third binding warp yarn is provided per warp yarn
system, so that the first and the second binding warp yarn cross
each other repeatedly and an opening is formed in each case between
every two successive intersections, through which two weft yarns
extend one above the other, and so that the third binding warp yarn
runs alternately along the pile side in relation to a weft yarn of
the pile side level and along the back in relation to a weft yarn
of the middle level.
[0021] A pile fabric, comprising a backing fabric woven out of weft
yarns and warp yarns, a number pile yarn loops passed around weft
yarns of the backing fabric and pile warp yarns inwoven in the
backing fabric, of which the inwoven pile warp yarns are inwoven
divided between at least two layers located one above the other in
the backing fabric, is another object of this invention. The
quality of such a fabric is perfect, even if the warp yarn systems
comprise a large number of pile warp yarns. In pile fabrics with
high frame count and with color transitions in weft direction no
trouble lines are formed any longer.
[0022] With such a pile fabric the pile warp yarns of different
layers can be separated from each other by interjacent weft yarns,
and the inwoven pile warp yarns can be divided per warp yarn system
between the aforesaid layers while in each warp yarn system a
tension warp yarn is married to each layer of pile warp yarns.
[0023] Furthermore each pile fabric that is manufactured according
to the method according to this invention is of course also a pile
fabric according to this invention.
[0024] The characteristics and advantages of this invention are
further explained on the basis of the following detailed
specification of a possible method according to this invention and
of the fabric manufactured according to this method. This
specification is only given by way of example and can consequently
in no way be interpreted as a restriction on the scope of the
protection claimed for this invention in the claims of this patent
application.
[0025] In this specification reference is made to the drawing
attached hereto,
[0026] FIG. 1, which represents a schematic cross-section in warp
direction of a face-to-face fabric, in the course of the weaving
thereof on a face-to-face weaving machine according to a method
according to this invention.
[0027] On a known three-rapier face-to-face weaving machine
provided with a four-position open-shed jacquard machine a series
of warp yarn systems is provided next to one another. Each warp
yarn system comprises six binding warp yarns (1), (2), (3), (4),
(5), (6), four tension warp yarns (7), (8), (9), (10), and five
pile warp yarns (11), (12), (13), (14), (15) of different
colors.
[0028] The rapiers of the weaving machine are operated in order in
the course of successive weft insertion cycles in each case to
insert a top weft yarn (16), a middle weft yarn (17) and a bottom
weft yarn (18) one above the other between the warp yarns
(1)-(15).
[0029] Prior to each weft insertion the pile warp yarns are brought
by the jacquard machine and the backing warp yarns by a cam disks
or dobby to the correct height in relation to the weft insertion
levels in order to obtain two backing fabrics (19), (20) through
the interweaving of weft yarns (16), (17), (18) with binding warp
yarns (1), (2), (3); (4), (5), (6) and tension warp yarns (7) ,
(8); (9), (10) and in order to enable the pile warp yarns (11)-(15)
to form pile in specific places and to inweave in the fabric in
other places so that through the different colors of the pile loops
a specific pattern is formed according to a predetermined pattern
design.
[0030] In the course of a first operating cycle the warp yarns
(1)-(15) of the various warp yarn systems are so positioned that
the top (16) and the middle weft yarn (17) are inwoven one above
the other in the top backing fabric (19) by binding warp yarns (1),
(2), (3) while the bottom weft yarn (18) is inwoven in the bottom
backing fabric (20) by binding warp yarns (4), (5), (6). In the
course of a second operating cycle the warp yarns are so positioned
that only the top weft yarn (16) is inwoven in the top backing
fabric (19) by the binding warp yarns (1), (2), (3), while the
middle (17) and the bottom weft yarn (18) are inwoven one above the
other in the bottom backing fabric (20) by the binding warp yarns
(4), (5), (6).
[0031] These first and second operating cycles are utilized
alternately so that two backing fabrics (19), (20) are woven in
which alternately (in warp direction) two weft yarns (16), (17);
(17), (18) one above the other and one single weft yarn (16); (18)
are inwoven by binding warp yarns (1)-(3); (4)-(6).
[0032] In each backing fabric (19), (20) the weft yarns (16), (17),
(18) are inwoven at three different levels: a back level, a middle
level and a pile side level.
[0033] In each backing fabric (19), (20) two tension warp yarns
(7), (8); (9), (10) are inwoven per warp yarn system. One tension
warp yarn (7), (10) extends between the weft yarns (16), (17);
(17), (18) inwoven one above the other, while the other tension
warp yarn (8), (9) extends between the weft yarns (16), (18) of the
pile side level and the weft yarns (17) of the middle level.
[0034] The pile warp yarns (11), (12), (13), (14), (15) are in the
course of the successive operating cycles positioned in order
either to form pile or to be inwoven in one of the backing fabrics
(19), (20), so that the various pile-forming pile warp yarns of the
fabric form pile loops which through the mutual color differences
make a figure or a specific pattern visible in the fabric.
[0035] If the pile warp yarns do not form pile they are inwoven in
the backing fabrics (19), (20). Two pile warp yarns (14), (15) are
inwoven in the bottom backing fabric (20) if they do not form pile.
The three other pile warp yarns (11), (12), (13) are inwoven in the
top backing fabric (19) if they do not form pile.
[0036] In each backing fabric (19), (20) the inwoven pile warp
yarns are divided between two layers located one above the other.
The pile warp yarns of one layer extend between the weft yarns
(16), (17); (17), (18) inwoven one above the other, while the pile
warp yarns of the other layer are undulatingly inwoven and run
alternately above and below a weft yarn (16), (18) of the pile side
level. In each warp yarn system the inwoven pile warp yarns of one
layer are therefore married to a tension warp yarn (7), (10).
[0037] Per warp yarn system three binding warp yarns (1), (2), (3);
(4), (5), (6) are provided for each backing fabric (19), (20). For
each backing fabric a first (1), (4) and a second binding warp yarn
(2), (5) are so positioned in each operating cycle that they cross
each other repeatedly, whereby in each case an opening is formed
between two successive intersections, and that the successive weft
yarns (16), (17); (17), (18) provided one above the other extend
through these openings. For each backing fabric (19), (20) a third
binding warp yarn (3), (6) is furthermore also so positioned that
it runs alternately along the pile side in relation to a weft yarn
(16), (18) of the pile side level and along the back in relation to
a weft yarn (17) of the middle level.
[0038] The above described method has been specified for only five
pile warp yarns per warp yarn system. This invention is especially,
though not exclusively, applicable to manufacturing pile fabrics
with a greater number of pile warp yarns or frame count. Thus
according to this method a 14 frame count pile fabric can for
example be woven, whereby in each backing fabric and per warp yarn
system a first layer with four inwoven pile warp yarns and a second
layer with three inwoven pile warp yarns is formed. The layer with
four pile warp yarns preferably extends between the weft yarns
(16), (17); (17), (18) inserted one above the other. The pile
fabric can also be woven with four (instead of six) binding warp
yarns per warp yarn system, so that in each backing fabric two
binding warp yarns cross each other repeatedly and so that in the
successive openings between their intersections in each case two
weft yarns (16), (17); (17), (18) inwoven one above the other, as
well as one single weft yarn (16); (18) extend.
[0039] The pile fabric can also be woven with single, double or
quadruple weft insertion means, whereby use is either made or not
made of disengagement of one or several weft insertion means or
whereby weft cancellation is utilized.
[0040] The known means for avoiding double-acting pile warp yarns
or mixed contours can of course also be applicated with this
weave.
* * * * *