Textiles: weaving – Special-type looms – Multiple-shed
Reexamination Certificate
1998-09-02
2001-02-06
Falik, Andy (Department: 3741)
Textiles: weaving
Special-type looms
Multiple-shed
C139S398000
Reexamination Certificate
active
06182708
ABSTRACT:
BACKGROUND OF THE INVENTION
The invention relates to carpet fabrics and more especially the weaving of face-to-face carpets whereby figures are formed in an upper fabric and a lower fabric by weaving in different pile warp threads alternately as non-working dead pile in the upper or lower fabric, and allowing them to run as figure-forming pile from the upper fabric to the lower fabric and vice versa.
Such carpet fabrics and weaving techniques for manufacturing them are in themselves known.
With face-to-face weaving the dead pile warp threads are woven into the upper and lower fabric, whereas the working pile warp or pile warps form a connection between the upper and lower piece which are then cut through by the cutting device in order to form a velvet carpet. With certain types of carpets (e.g. Chinese) it is desired that the contours of the figures according to a pattern acquire a kind of carving. This effect is achieved by not forming working pile in those places according to the pattern and therefore weaving in all pile warp threads. This is a popular design effect.
Now it occurs with face-to-face woven carpets that carving effects appear in places where this was not desired according to the pattern: namely with certain color transitions in weft direction. When such a color transition in weft direction is to follow a straight line in warp direction then an empty or open stripe is obtained in the carpet. This detracts from the quality of the carpet when a full velvet carpet is desired with an even and tight pile surface.
SUMMARY OF THE INVENTION
According to the invention this problem is resolved by making corrections to the carpet.
With the method for weaving face-to-face carpets whereby figures are formed in an upper fabric and a lower fabric by weaving in different pile warp threads alternately as non-working dead pile in the upper or lower fabric, and allowing them to run as figure-forming pile from the upper fabric to the lower fabric and vice versa, for that purpose, according to the invention, with a transition in weft direction from a pile warp thread out of the lower fabric as figure-forming pile to a pile warp thread out of the upper fabric as figure-forming pile, a double pile is woven in.
It should moreover be noted that the concepts lower fabric and upper fabric are related to a definition whereby a first series of successive pile threads (or pile warp threads) per reed opening belong to the lower fabric and the second series to the upper fabric and that the invention specifically relates to the weaving of face-to-face carpets whereby the number of pile warp threads per reed opening amount to 5 or more, in particular 5, 6, 7, 8, 10 or more.
According to a further characteristic of the invention a double pile is woven in each time when with a transition in weft direction in the lower fabric and in the upper fabric four or more pile warp threads are woven-in in a reed opening. In other words, for example in the case of a 6-pile-warp-thread fabric, in each case with a transition from pile warp thread
1
to pile warp thread
4
or more, from pile warp thread
2
to pile warp thread
5
or more, and from pile warp thread
3
to pile warp thread
6
, etc.
According to a first embodiment of the invention a double pile is thus woven in with such successive transitions which lie in a straight line in the warp direction.
According to another embodiment of the invention a double pile is woven in with each such transition.
According to the invention with such a transition either the following figure-forming pile warp thread can then be inwoven in the first reed opening together with the previous figure-forming pile warp thread, or the previous figure-forming pile warp thread is inwoven in the second reed opening together with the following figure-forming pile warp thread.
The invention further provides a carpet fabric with improved properties, consisting of a face-to-face carpet cut apart with in an upper fabric and a lower fabric figures formed of different pile warp threads which are alternately inwoven as non-working dead pile in the upper or lower fabric, and protrude as figure-forming pile from the carpet fabric, in which with a color transition from one pile warp thread as figure-forming pile to another pile warp thread as figure-forming pile a double pile is woven in.
According to a preferred characteristic this is namely the case each time when four or more dead pile warp threads are inwoven in an opening.
Moreover according to one embodiment of the invention the double pile is inwoven with successive color transitions which lie in a straight line in the warp direction, and according to another embodiment of the invention with each color transition.
The invention is further explained hereafter with respect to a 6-pile-warp-thread weaving system and with reference to the attached schematic drawings.
With carpets woven in 5, 7, 8 and 10 pile warp threads or more the conclusions remain the same.
The problem which lies at the basis of the invention consists therein that with the transitions from the pile threads in weft direction pile openings are caused there through the position of the inwoven pile threads. Factors which can influence these pile openings:
1) the number of pile warp threads per reed opening: 5, 6, 7, 8, 10
2) use of a double tight warp in the reed opening, through which the pile threads have even less freedom of movement
3) thickness and type of the pile yarns
This problem occurs each time when in weft direction in the pattern a transition from pile thread or pile warp thread
1
to pile thread or pile warp thread
6
is determined. This does not occur when conversely there is a transition from pile warp thread
6
to pile warp thread
1
. The phenomenon is also found with transitions 1-4, 1-5, 1-6, 2-5, 2-6, 3-6.
When in a reed tooth i pile warp thread
1
is working pile and in reed tooth i+1 pile warp thread
6
is working pile, then between both pile naps in the lower fabric lie
5
inwoven pile warps (2 for tooth i, and 3 for tooth i+1) for a 6-pile-warp-thread carpet. A similar arrangement is found for the upper fabric. This large number of interjacent, inwoven pile warp threads push the adjacent pile naps away from each other through which an undesired carving arises. This quality detracting effect becomes that much worse the more the number of pile warp threads in the carpet increases. Now there is a general trend to 6 pile warp threads. A trend to 8 and 10, yes even 12 pile warp threads may be expected as a result of the increasing demand for multicolored designs and the ease of development and production that has arisen through the use of CAD systems and electronic jacquard machines.
In order to remedy this problem the invention provides the above described solution. For that purpose according to the pulling through of the pile warp threads in the reed teeth the pile warp thread transitions in weft direction, which are the cause of the adverse effect, will first be determined. With an adverse pile warp thread transition in tooth i to tooth i+1 both pile warp thread
1
and pile warp thread
6
will be selected as working pile in the tooth i, in other words a double pile nap will be woven in tooth i: the existent pile warp thread and the new pile warp thread together. In tooth i+1 the previous pile warp thread and the new pile warp thread can also be allowed to work together.
This is further illustrated on the basis of the attached drawings as follows.
REFERENCES:
patent: 3519032 (1970-07-01), Sabbe
patent: 5398730 (1995-03-01), Derudder et al.
patent: 5404917 (1995-04-01), Gheysen
patent: 5655573 (1997-08-01), Gheysen et al.
patent: 1007294 (1995-05-01), None
Ludo Smissaert, Addendum Weave Catalogue 1994, Catalogue, Sep. 21, 1994, pp. 1-19, Michel Van De Wiele, Belgium.
Creighton Wray James
Falik Andy
N.V. Michel Van de Wiele
Narasimhan Meera P.
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