Textiles: weaving – Fabrics – Pile
Reexamination Certificate
1999-12-21
2001-09-18
Calvert, John J. (Department: 3741)
Textiles: weaving
Fabrics
Pile
C139S021000, C139S037000, C139S435100, C139S398000, C028S206000, C028S206000
Reexamination Certificate
active
06289941
ABSTRACT:
This invention relates to a method for manufacturing fabrics with a rib structure, whereby on a weaving machine in successive weft insertion cycles in each case a top and a bottom weft thread are inserted between warp threads of a series of warp thread systems so that, a fabric is woven in which warp threads are alternately interlaced in the fabric and are rib-formingly passed around over a weft thread.
This invention also relates to a fabric with rib structure manufactured according to this method.
A fabric with a rib structure which approximates the appearance of a loop pile fabric or bouclé fabric, is called a false bouclé fabric.
This invention relates in particular to a method for weaving a false bouclé fabric, and a false bouclé fabric that has been woven according to this weaving method.
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 fabric 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 top of the fabric and along the back of the fabric.
Two pattern warp threads with a different colour are provided in order to be able to make a design or a pattern visible with the two colours along the top of the fabric.
A first pattern warp thread is alternately brought above the two weft threads along the top of the fabric and interlaced between the two weft threads along the back of the fabric, in order to implement a rib structure on the top of the fabric and to form the design or the pattern.
A second pattern warp thread is alternately interlaced between the two weft threads along the top of the fabric and brought under the two weft threads along the back of the fabric. The colour of the second pattern warp thread is then visible on the back of the fabric. The second pattern warp thread forms a rib structure on the back of the fabric. With these fabrics the weft threads are inwoven by the pattern warp threads.
With each insertion cycle a rib line is produced (alternately along the top and along the back of the fabric). On the back of the fabric a type of negative (with swapped colours) is obtained of the two-coloured design which is visible on the top of the fabric.
Manufacturing fabrics with a rib structure on a weaving machine can be effected according to this known method but with an average productivity.
The purpose of this invention is to provide a method for weaving a fabric with a rib structure, which can be utilised on a weaving machine which is provided for inserting two weft threads per weft insertion cycle, and with which a considerably higher productivity can be achieved than with the known method.
This objective is achieved according to this invention with a method having the characteristics mentioned in the first paragraph of this specification, by providing binding warp threads and pattern warp threads in each warp thread system, so that top and bottom weft threads are inwoven by a respective set of binding warp threads whereby two backing fabrics are woven, and so that respective pattern warp threads are alternately interlaced in a respective backing fabric and are rib-formingly passed around over a top or bottom weft thread running between the backing fabrics which is not inwoven by binding warp threads, so that two fabrics with a rib structure are woven one above the other.
According to the method according to this invention on a weaving machine two fabrics can be woven simultaneously. The application of this method instead of the known method therefore doubles the productivity. This method can be utilised on a weaving machine which is provided for inserting two weft threads per weft insertion cycle, such as for example a double rapier weaving machine.
According to a greatly preferred method according to this invention the weft threads are inserted in successive series of three weft insertion cycles, whereby of the weft threads inserted in each series in each case two top weft threads are inwoven in the top backing fabric and two bottom weft threads are inwoven in the bottom backing fabric, while around the two other weft threads a respective rib is formed by a pattern warp thread interlaced in the top backing fabric and by a pattern warp thread interlaced in the bottom backing fabric.
This method can be so utilised that the pattern warp threads interlaced in the top backing fabric are rib-formingly passed around over a bottom weft thread while the pattern warp threads interlaced in the bottom backing fabric are rib-formingly passed around over a top weft thread.
With a fabric manufactured according to this method the ribs are formed above two weft threads running one above the other. In such a fabric the rib height is rather great, through which a very clear rib structure is obtained.
The rib-forming pattern warp threads must with this method be capable in each weft insertion cycle of being brought “above” and “below” the two insertion levels of the weaving machine. In order to inweave non-rib-forming (parts of) pattern warp threads in a backing fabric these pattern warp threads must furthermore also be capable of being brought into a position “between” the insertion levels. The utilisation of this method therefore requires a three-position open-shed jacquard machine.
This method is for example so utilized that the pattern warp thread interlaced in the top backing fabric forms a rib around the bottom weft thread which is inserted during the second weft insertion cycle of each series and the pattern warp thread interlaced in the bottom backing fabric forms a rib around the top weft thread which is inserted during the third weft insertion cycle of each series.
In order to remedy the disadvantage that the above described method requires a three-position open-shed jacquard machine, the method according to this invention is so implemented that the pattern warp threads interlaced in the top backing fabric are rib-formingly passed around over a top weft thread, while the pattern warp threads interlaced in the bottom backing fabric are rib-formingly passed around over a bottom weft thread.
On the one hand both the formation of ribs with the pattern warp threads interlaced in the top backing fabric and the inweaving of non-rib-forming (dead) pattern warp threads in the top backing fabric can be performed with the positions “above” and “between” the insertion levels.
On the other hand both the formation of ribs with the pattern warp threads interlaced in the bottom backing fabric and the inweaving of non-rib-forming (dead) pattern warp threads in the bottom backing fabric can be performed with the positions “between” and “below” the insertion levels.
This method can therefore be implemented utilising a two-position open-shed jacquard machine. The jacquard machine must furthermore only perform half the total lifting.
According to this method the weft threads are, as mentioned above, preferably inserted in successive series of three weft insertion cycles, so that the pattern warp thread interlaced in the top backing fabric forms a rib around the top weft thread which is inserted during the third weft insertion cycle of each series, and so that the pattern warp thread interlaced in the bottom backing fabric forms a rib around the bottom weft thread which is inserted during the third weft insertion cycle of each series.
With the method according to this invention the height of the ribs in the fabric can be increased by taking thicker threads for the weft threads which support ribs than for the other weft threads. Because of this the loop effect of the rib structure is increased and a good approximation to the appearance of a loop pile fabric or a bouclé fabric is obtained.
The non-rib-forming pattern warp threads or parts of pattern warp threads (called the dead pattern warp threads in that which follows) are preferably inwoven in a backing fabric.
Acco
Calvert John J.
Creighton Wray James
Muromoto Jr. Robert H.
N.V. Michel Van de Wiele
Narasimhan Meera P.
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