Textiles: weaving – Fabrics – Pile
Reexamination Certificate
1999-12-21
2001-08-14
Calvert, John J. (Department: 3741)
Textiles: weaving
Fabrics
Pile
C139S021000, C139S037000, C139S116500, C139S404000, C139S405000
Reexamination Certificate
active
06273148
ABSTRACT:
This invention relates to a method for weaving pile fabrics, whereby weft threads are brought between warp threads of a series of warp thread systems so that two backing fabrics are woven located one above the other, and whereby in a number of warp thread systems dead pile warp threads and tension warp threads are inwoven in the backing fabrics, and at least one pile warp thread is pile-loop-formingly passed around a weft thread alternately in the top and the bottom backing fabric, so that in each backing fabric respective pile loops are formed around first and second weft threads which run respectively along the back and along the pile side of a tension warp thread, and whereby the pile-forming pile warp threads are cut through between the backing fabrics.
This invention also relates to pile fabrics which are woven according to such a method.
Carpet weaving on a face-to-face weaving machine according to the above described weaving method is known.
In each warp thread system for each backing fabric a tension warp thread and two binding warp threads are provided. The backing fabrics are so woven that in each warp thread system alternately along the back and along the pile side of the tension warp thread a respective weft thread is inwoven by the two binding warp threads. These binding warp threads cross each other repeatedly so that in each case between two successive crossings they enclose a weft thread running along the back of the tension warp thread and a weft thread running along the pile side of the tension warp thread.
Per warp thread system a number of pile warp threads are provided. In order to form pile a pile warp thread is passed around a weft thread alternately in the top and the bottom backing fabric. This occurs according to a one-shot weave so that in each pile fabric a respective pile loop is formed around each weft thread. The successive pile loops are therefore alternately formed around a weft thread running along the back of the tension warp thread and around a weft thread running along the pile side of the tension warp thread.
In this specification and in the claims attached hereto a weft thread running along the back of the tension warp thread, around which a pile loop is formed, is called “a first weft thread”, and a weft thread running along the pile side of the tension warp thread, around which a pile loop is formed, is called “a second weft thread”.
The non-pile-forming pile warp threads or parts of pile warp threads, referred to by the term “dead pile warp threads” in that which follows, are inwoven in these backing fabrics divided between the top and the bottom backing fabric. These dead pile warp threads therefore come to lie next to the tension warp threads, between the successive weft threads.
The pile-forming pile warp threads are finally cut through between the two backing fabrics so that two separate pile fabrics are obtained.
This weaving method can be utilized on a single rapier weaving machine and on a double rapier weaving machine. In the latter case in the course of the successive weft insertion cycles alternately the top and the bottom weft insertion means is disengaged.
This weaving method and the fabrics manufactured according to this weaving method however have the following disadvantages:
The second weft threads running along the pile side have the tendency to push the inwoven dead pile warp threads through to the back of the carpet. Because of this the colors of the inwoven dead pile warp threads are visible on the back of the pile fabric. A consequence of this is that a pattern design formed in the pile fabric is less clearly visible on the back. A pile fabric is because of this considered as a fabric of less high quality.
It is also customary to improve the pile loop fastness of these pile fabrics by applying a latex layer on the back. The latex layer does not penetrate to the pile loops which have been formed around the second weft threads running along the pile side. Because of this a good pile loop fastness cannot be achieved for these pile loops.
The purpose of this invention is to provide such a method according to which pile fabrics can be woven without the above described disadvantages.
This purpose is achieved according to this invention with a method for weaving pile fabrics with the characteristics mentioned in the first paragraph of this specification, whereby the dead pile warp threads, running along the pile side of the second weft threads, are inwoven.
With a pile fabric woven according to this method the first and the second weft threads run along the back of the dead pile warp threads, through which these pile warp threads are not pushed through to the back of the fabric. The pattern design can because of this be discerned very clearly and perfectly on the back of the fabric. Furthermore the pile loops formed around the second weft threads now lie almost against the tension warp thread, so that a latex layer applied on the back of the pile fabric can penetrate much better to these pile loops. The pile loop fastness of these pile loops is because of this considerably improved.
With the method according to this invention third weft threads are preferably inwoven in each backing fabric, which run along the pile side of the dead pile warp threads. The dead pile warp threads are thus inwoven between the second and the third weft threads.
According to a preferred method according to this invention each third weft thread is provided between the tufts of a respective pile loop. Furthermore in each backing fabric a pile loop can be formed alternately around a first and around a second weft thread.
The method is preferably so implemented that each backing fabric comprises successive groups of weft threads, which comprise a first, a second, and a third weft thread.
If furthermore a respective pile loop is formed around the first and around the second weft thread of each group a pile fabric is obtained with a maximum pile density.
Very preferred pile fabrics are obtained if per warp thread system for each backing fabric two binding warp threads are provided so that these binding warp threads cross each other repeatedly, and so that a group of weft threads extends in each opening between two successive crossings of these binding warp threads.
For example successive series of six weft threads can be inserted on a weaving machine, whereby each series comprises a first, a second and a third weft thread of the top backing fabric, and a first, a second and a third weft thread of the bottom backing fabric, and whereby per weft insertion cycle in each case one weft thread is inserted.
The positions of a pile-forming pile warp thread in relation to the successive weft threads can with this method in each case be repeated after the insertion of a series of six weft threads, therefore after six weft insertion cycles. The pile-forming pile warp threads therefore have a repeat of 6 weft insertion cycles.
If the binding warp threads in each backing fabric run alternately above and below a group of weft threads, then their positions in relation to the successive weft threads are repeated after the insertion of two series of weft threads or after 12 weft insertion cycles. The binding warp threads therefore have a repeat of 12 weft insertion cycles. The weaving machine must in this case be provided with weaving frames with an operating repeat of 12 weft insertion cycles.
This method can be utilized on a weaving machine with one weft insertion means, such as e.g. a single rapier weaving machine.
By so inserting a series of weft threads successively a third weft thread is preferably inserted in the top backing fabric, a first weft thread in the top backing fabric, a second weft thread in the bottom fabric, a second weft thread in the top backing fabric, a first weft thread in the bottom backing fabric, and a third weft thread in the bottom backing fabric.
The method according to this invention can however be performed faster and therefore more economically if the six weft threads of a series on a weaving machine are inserted in the course of les
Debaes Johnny
Smissaert Ludo
Calvert John J.
Creighton Wray James
Muromoto Jr. Robert H.
N.V. Michel Van de Wiele
Narasimhan Meera P.
LandOfFree
Method for face-to-face weaving pile fabrics does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Method for face-to-face weaving pile fabrics, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Method for face-to-face weaving pile fabrics will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2442324