Textiles: weaving – Fabrics – Pile
Reexamination Certificate
1999-07-07
2001-01-16
Calvert, John J. (Department: 3741)
Textiles: weaving
Fabrics
Pile
C139S391000, C139S037000, C139S435100, C139S38300A
Reexamination Certificate
active
06173746
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to a method for manufacturing fabrics with a rib structure, in particular false boucl{acute over (e)} fabrics, whereby on a weaving machine, by inserting weft threads in successive sheds between warp threads of a series of warp thread systems, a fabric is formed with sets of at least two weft threads running one above the other, whereby in each warp thread system two pattern warp threads opposite each other, respectively along the upper side and the lower side of the fabric, form a number of ribs whereby these pattern warp threads alternately along their respective fabric side are rib-formingly passed around over one or several sets of weft threads and are interlaced in the fabric.
This invention also relates to fabrics with a rib structure which are manufactured according to such a method, in particular false boucl{acute over (e)} fabrics, comprising a number of sets of at least two weft threads running one above the other which are inwoven by warp threads of a series of warp thread systems, of which two pattern warp threads opposite each other, respectively along the upper side and the lower side of the fabric, form a number of ribs whereby these pattern warp threads alternately along their respective fabric side are rib-formingly passed around over one or several sets of weft threads and are interlaced in the fabric.
A fabric with a rib structure which approximates the appearance of a loop pile fabric or boucl{acute over (e)} fabric, is called a false boucl{acute over (e)} fabric.
In this specification and in the claims of this patent application the terms “lower side” and “upper side” of a fabric are only used to indicate the two different sides of the fabric. The aforesaid terms must be interpreted in the sense of “the one side” and “the other side”. The literal meaning of the terms “upper side” and “lower side” may therefore not give rise to any restriction on this invention.
According to a known weaving method for manufacturing a false boucl{acute over (e)} fabric, which has the above mentioned characteristics, tension warp threads are inwoven stretched in the fabrics and in each weft insertion cycle on the weaving machine two weft threads are simultaneously inserted one above the other. In successive insertion cycles the two weft threads are in relation to the tension warp threads alternately inserted along the upper side and along the lower side of the fabric.
In warp thread systems located next to each other a first and a second pattern warp thread of a different color are provided in order to be able to make a design or a pattern visible with the two colors along the upper side of the fabric.
The first pattern warp thread is alternately rib-formingly passed over the two weft threads along the upper side of the fabric and interlaced between the two weft threads along the lower side of the fabric, in order to achieve a rib structure on the upper side of the fabric and to form the design or the pattern. The second pattern warp thread is interlaced opposite the first pattern warp thread, alternately between the two weft threads along the upper side of the fabric and passed around over the two weft threads along the lower side of the fabric. The color of the second pattern warp thread is then not visible on the upper side, but it is on the lower side of the fabric. The second pattern warp thread forms a rib structure on the lower side of the fabric. With these known fabrics the weft threads are inwoven by the pattern warp threads. With each insertion cycle a rib line is produced (alternately along the upper side and along the lower side of the fabric).
Both the upper side and the lower side of this known fabric have a rib structure. On the lower side of the fabric a type of negative (with swapped colors) is obtained of the two-colored design which is visible on the upper side of the fabric.
A disadvantage of this method is that the fabrics thus produced cannot closely approximate the appearance of the real loop pile fabrics or boucl{acute over (e)} fabrics. Furthermore the designs or patterns provided on these fabrics only have two different colors.
SUMMARY OF THE INVENTION
The purpose of this invention is to provide a method for manufacturing a fabric with a rib structure on both sides, with which the appearance of the real loop pile fabrics is far more closely approximated, and with which at the same time the possibility also exists of forming designs or patterns with more than two colors in the fabric.
This objective is achieved according to this invention, with a method having the characteristics mentioned in the first paragraph of this specification, by providing at least one additional pattern warp thread in each warp thread system and inweaving it between weft threads of the sets over which other pattern warp threads are rib-formingly passed around.
Because of the fact that the additional pattern warp threads are between the weft threads of the aforesaid systems, they hold these weft threads at a greater distance from each other in the fabric. Because of this a greater rib height is provided, so that the rib structure becomes clearer and the fabric more closely approximates a loop pile fabric.
Furthermore with each additional pattern warp thread an additional color can be added to the fabric.
The pattern warp threads of each warp thread system preferably have a different appearance, in particular a different color, while each pattern warp thread is so provided that it has on at least one fabric side one or several visible parts corresponding to a design or pattern to be formed.
Thus a fabric is obtained with a design or a pattern whose appearance on the one hand is more varied (e.g. has greater wealth of colors), and on the other hand more closely approximates the appearance of a loop pile fabric, in comparison to existing fabrics which have a rib structure on both sides.
By utilizing the method according to this invention tension warp threads are preferably also provided in the fabric, while the sets of weft threads over which pattern warp threads along the upper side of the fabric are passed around and the sets of weft threads over which pattern warp threads along the lower side of the fabric are passed around are respectively above and below the tension warp threads.
Because of this ribs are obtained with a maximum height, so that an excellent approximation to the appearance of a loop pile fabric is obtained.
Moreover successive sets of weft threads of the fabric are preferably also provided alternately above and below the tension warp threads.
Because of this a rib is formed alternately along the upper side of the fabric and along the lower side of the fabric.
According to a very preferred method according to this invention on the weaving machine in successive insertion cycles in each case one set of weft threads is inserted.
This makes it possible in each case to form one rib per insertion cycle.
A greatly preferred fabric according to this invention is obtained if each set of weft threads consists of two weft threads running one above the other.
When weaving according to the double rapier weaving method the tension warp threads after each weft insertion cycle must be brought from a position below both rapiers to a position above both rapiers, and vice versa.
This lifting is considerable and results in a great strain of the warp threads and the weaving frames drive.
This can be remedied by manufacturing the fabric on a weaving machine with three weft insertion means (with respective insertion levels), and in the successive weft insertion cycles by not inserting a weft thread alternately in the bottom insertion level and in the top insertion level.
With this method the tension warp threads only have to be moved upward and downward over one rapier height.
Another aspect of this invention is a fabric manufactured according to the method of this invention.
Apart from the characteristics mentioned in the second paragraph of this specification a fabric according to this invention also comprises more particularly i
Debaes Johnny
Smissaert Ludo
Vandoorne Nico
Calvert John J.
Creighton Wray James
Muromoto Jr. Robert H.
N.V. Michael Van de Wiele
Narasimhan Meera P.
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