Textiles: weaving – Fabrics – Pile
Reexamination Certificate
1999-11-08
2001-06-19
Calvert, John J. (Department: 3741)
Textiles: weaving
Fabrics
Pile
C139S403000, C139S406000, C139S408000
Reexamination Certificate
active
06247506
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to a method for manufacturing a fabric with a rib structure, in particular a false bouclé fabric, whereby weft threads are brought in successive sheds between warp threads so that a fabric is formed with pattern warp threads which run alternately below and above one or several weft threads so that they form ribs.
This invention also relates to a fabric with a rib structure, in particular a false bouclé fabric, comprising weft threads and warp threads, of which pattern warp threads run alternately below and above one or several weft threads so that they form ribs.
A fabric with a rib structure which approximates the appearance of a loop pile fabric or bouclé fabric, is called a false bouclé fabric.
According to a known weaving method for manufacturing a false bouclé 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 colour are provided in order to be able to make a design or a pattern visible with the two colours 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 colour 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 colours) is obtained of the two-coloured design which is visible on the upper side of the fabric.
A disadvantage of this method is the high consumption of pattern warp yarn. The thus manufactured fabrics are relatively expensive because of this.
The purpose of this invention is to provide a method with which fabrics with a rib structure can be manufactured, with a lower pattern warp yarn consumption.
SUMMARY OF THE INVENTION
This purpose is achieved according to this invention by utilising a method with the characteristics mentioned in the first paragraph of this specification by proceeding so that a backing fabric is woven out of binding warp threads and weft threads, while the pattern warp threads are alternately interlaced in the backing fabric and are rib-formingly passed around at least one weft thread running outside the backing fabric.
In the preceding paragraph and in the first claim of this patent application corresponding thereto the expression “a weft thread running outside the backing fabric” is used in the sense of a weft thread which, at least in the location where the pattern warp thread is rib-formingly passed around this weft thread, runs outside the backing fabric. Other parts of such a weft thread can therefore be inwoven in the backing fabric.
Because of the fact that the pattern warp threads only have to form ribs on one fabric side (the rib side), the pattern warp yarn consumption is considerably reduced.
A fabric manufactured according to this method only has a rib structure on one side. This is not a disadvantage since for most applications of fabrics with a rib structure it is not required that the fabric has a rib structure on both sides.
According to this invention tension warp threads are preferably provided in the backing fabric, while the fabric is so woven that the weft threads running outside the backing fabric are part of a set of at least two weft threads running one above the other, while of each set of weft threads at least two weft threads run along the rib side of the fabric in relation to the tension warp threads.
Because of this a fabric with a very clear rib structure is obtained. The appearance of a fabric manufactured in that manner very closely approximates the appearance of a loop pile fabric.
In order to accentuate the rib structure even more, thicker threads can be taken for the weft threads running outside the backing fabric than for the weft threads inwoven in the backing fabric. By providing thinner weft threads in the backing fabric a more stable backing fabric is furthermore also obtained and the pattern warp yarn consumption is still further reduced.
The fabric is so woven according to a preferred method that, in the finished fabric, between two successive sets of weft threads a weft thread is provided inwoven in the backing fabric. This weft thread can then be utilised for interlacing the rib-forming pattern warp threads in the backing fabric.
It is moreover greatly preferred during successive weft insertion cycles of weft insertion means on a weaving machine to insert one weft thread and two weft threads respectively.
This method can for example be applied on a double rapier weaving machine, whereby the rapier device operating on the top insertion level alternately inserts a weft thread and inserts no weft thread during successive weft insertion cycles. In order to cancel the insertion of a weft thread either the presenting mechanism which is provided for presenting a weft thread to the top weft insertion mechanism can be disengaged, or the top weft insertion mechanism can be disengaged.
Preferably two binding warp threads and one tension warp thread are provided per reed tooth.
According to a very advantageous method the fabric is so woven that the weft threads running outside the backing fabric are part of a set of at least two weft threads running one above the other, and that a non-rib-forming pattern warp thread, running between weft threads of the aforesaid sets of weft threads running one above the other, is inwoven in the backing fabric. Because of this a very good rib effect is obtained.
The rib-forming pattern warp threads can also be interlaced under a weft thread inwoven along the back of the backing fabric. These pattern warp threads can because of this be well embedded in a synthetic material layer to be provided on the back of the fabric for that purpose. Preferably a latex layer is provided on the back of the fabric.
The non-rib-forming pattern warp threads can also be well embedded in a synthetic material layer on the back of the fabric if these pattern warp threads are inwoven in the backing fabric running alternately above a weft thread of the backing fabric and under a weft thread inwoven along the back of the backing fabric.
The pattern warp yarn consumption can be still further reduced if with the method according to this invention the rib-forming pattern warp threads are interlaced under a weft thread inwoven along the rib side of the backing fabric, and/or if non-rib-forming pattern warp threads are inwoven stretched in the backing fabric.
As appears from the foregoing the known fabrics with a rib structure have the disadvantage that they are relatively expensive, and this comes particularly because of the fact that their production requires a considerable amount of warp yarn.
This disadvantage is very effectively remedied according to this invention by providing a fabric with the characteristics mentioned in the second paragraph of this specific
Debaes Johnny
Smissaert Ludo
Vandoorne Nico
Calvert John J.
Creighton Wray James
Muromoto Jr. Robert H.
N.V. Michel Van de Wiele
Narasimhan Meera P.
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