Fabric, in particular carpet, and method of weaving a fabric
11028507 ยท 2021-06-08
Assignee
Inventors
Cpc classification
International classification
Abstract
A fabric (e.g., carpet having a shadow effect) includes a backing fabric having binding warp yarns repeatedly crossing each other for providing weft receiving openings, tension warp yarns substantially extending in a warp direction, and weft yarns substantially extending in a weft direction through the weft receiving openings, pile warp yarns interlaced with weft yarns for providing piles extending out of the backing fabric, wherein, at least one weft yarn is positioned immediately adjacent to one of the crossings of the binding warp yarns provides an end weft yarn positioned at a back side relative to at least one weft separating warp yarn extending in the backing fabric substantially in the warp direction, and at least one intermediate weft yarn positioned adjacent to such an end weft yarn in the warp direction is positioned at the pile side.
Claims
1. Fabric having a shadow effect, comprising: a backing fabric having binding warp yarns repeatedly crossing each other for providing weft receiving openings, tension warp yarns substantially extending in a warp direction, and weft yarns substantially extending in a weft direction through the weft receiving openings, pile warp yarns interlaced with weft yarns of the backing fabric for providing piles extending out of the backing fabric at a pile side, wherein, in at least one weft receiving opening, at least one weft yarn positioned immediately adjacent to one of the crossings of the binding warp yarns defining this weft receiving opening in the warp direction provides an end weft yarn positioned at a back side relative to at least one weft separating warp yarn extending in the backing fabric substantially in the warp direction, and at least one intermediate weft yarn positioned adjacent to such an end weft yarn in the warp direction is positioned at the pile side relative to the at least one weft separating warp yarn, wherein, for providing a pile, in association with this weft receiving opening, a pile warp yarn is interlaced with an end weft yarn of this weft receiving opening such as to extend out of the backing fabric between this end weft yarn and an intermediate weft yarn of this weft receiving opening.
2. The fabric according to claim 1, wherein at least one pile comprises two pile legs, one of the pile legs extending out of the backing fabric between the end weft yarn and the intermediate weft yarn and the other pile leg extending out of the backing fabric between the end weft yarn and an end weft yarn of an immediately adjacent weft receiving opening, and/or wherein at least one pile comprises a single pile leg extending out of the backing fabric between the end weft yarn and the intermediate weft yarn, and/or wherein at least one pile comprises a single pile leg extending out of the backing fabric between the end weft yarn and an end weft yarn of an immediately adjacent weft receiving opening.
3. The fabric according to claim 1, wherein in association with at least one weft receiving opening a pile is provided by interlacing a pile warp yarn with an end weft yarn of this weft receiving opening positioned immediately adjacent to the crossing of the binding warp yarns defining this weft receiving opening in a first orientation of the warp direction and, in association with at least one other weft receiving opening, a pile is provided by interlacing a pile warp yarn with an end weft yarn of this weft receiving opening positioned immediately adjacent to the crossing of the binding warp yarns defining this weft receiving opening in a second orientation of the warp direction, and/or wherein in association with at least one weft receiving opening only one pile is provided.
4. The fabric according to claim 1, wherein pile warp yarns not used for forming piles are bound into the backing fabric such as to extend substantially in the warp direction as dead pile warp yarns, and wherein at least one intermediate weft yarn of at least one weft receiving opening is separated from both end weft yarns of this weft receiving opening by at least one tension warp yarn and at least one of the dead pile warp yarns extending in the area of this weft receiving opening.
5. The fabric according to claim 1, wherein pile warp yarns not used for forming piles are bound into the backing fabric such as to extend substantially in the warp direction as dead pile warp yarns, and wherein at least one of at least one weft receiving opening is separated from a first one of the two end weft yarns of this weft receiving opening only by at least one tension warp yarn and is separated from the second one of the two end weft yarns of this weft receiving opening by at least one tension warp yarn and at least one of the dead pile warp yarns extending in the area of this weft receiving opening.
6. The fabric according to claim 5, wherein, in association with this weft receiving opening, a pile is formed by interlacing a pile warp yarn with the second one of the two end weft yarns of this weft receiving opening, and/or wherein the first one of the two end weft yarns of this weft receiving opening is arranged on the pile side relative to the dead pile warp yarns extending in the area of this weft receiving opening and the second one of the two end weft yarns of this weft receiving opening is arranged on the back side relative to the dead pile warp yarns extending in the area of this weft receiving opening.
7. The fabric according to claim 1, wherein through at least one weft receiving opening two weft yarns providing the two end weft yarns and one intermediate weft yarn extend substantially in the weft direction, and/or wherein through at least one weft receiving opening three weft yarns extend.
8. The fabric according to claim 1, wherein a plurality of warp yarn systems are provided following each other in the weft direction, at least one warp yarn system comprising two binding warp yarns crossing each other, at least one tension warp yarn, and at least one pile warp yarn, wherein, in the pile warp yarn systems, piles are provided by the pile warp yarns of a respective pile warp yarn system by interlacing these pile warp yarns with weft yarns extending through the weft receiving openings provided by the binding warp yarns of the same pile warp yarn system.
9. The fabric according to claim 1, wherein, in at least one weft receiving opening the two weft yarns positioned immediately adjacent to the two crossings of the binding warp yarns defining this weft receiving opening are not separated by a tension warp yarn.
10. The fabric according to claim 1, wherein, throughout the major portion of the fabric the ground weave of the backing fabric provided by the binding warp yarns, the tension warp yarns, and the weft yarns is the same, and/or the crossings of the binding warp yarns defining the weft receiving openings in the two orientations of the warp direction are located at the same position in the warp direction.
11. The fabric according to claim 1, wherein the fabric is a carpet.
12. Method of weaving a fabric, wherein, for weaving a backing fabric, binding warp yarns are provided crossing each other for providing weft receiving openings, such that each weft receiving opening is defined in the warp direction by two crossings of binding warp yarns, wherein tension warp yarns are provided extending substantially in the warp direction and in association with at least one weft receiving opening, weft yarns are provided extending through this weft receiving opening substantially in the weft direction, such that the weft yarns positioned immediately adjacent to the two crossings defining this weft receiving opening in the warp direction are provided as end weft yarns positioned at a back side relative to at least one weft separating warp yarn and at least one intermediate weft yarn positioned substantially between the two end weft yarns in the warp direction is positioned at a pile side relative to the at least one weft separating warp yarn, wherein, in association with this weft receiving opening, a pile is generated by interlacing a pile warp yarn with one of the end weft yarns of this weft receiving opening such as to extend out of the backing fabric at the pile side between this end weft yarn and an intermediate weft yarn of this weft receiving opening.
13. The method according to claim 12, wherein pile warp yarns not used for forming piles are bound into the backing fabric such as to extend substantially in the warp direction as dead pile warp yarns, and wherein at least one intermediate weft yarn of at least one weft receiving opening is separated from both end weft yarns of this weft receiving opening by at least one tension warp yarn and at least one of the dead pile yarns extending in the area of this weft receiving opening.
14. The method according to claim 12, wherein pile warp yarns not used for forming piles are bound into the backing fabric such as to extend substantially in the warp direction as dead pile warp yarns, and wherein at least one intermediate weft yarn of at least one weft receiving opening is separated from a first one of the two end weft yarns of this weft receiving opening only by at least one tension warp yarn and is separated from the second one of the two end weft yarns of this weft receiving opening by at least one tension warp yarn and at least one of the dead pile yarns extending in the area of this weft receiving opening.
15. The method according to claim 12, wherein, in association with each fabric to be woven, a plurality of warp yarn systems is provided following each other in the weft direction, at least one warp yarn system comprising two binding warp yarns crossing each other, at least one tension warp yarn, and at least one of the pile warp yarns, wherein, in the pile warp yarn systems, piles are provided by the pile warp yarns of a respective pile warp yarn system by interlacing these pile warp yarns with weft yarns extending through the weft receiving openings provided by the binding warp yarns of the same pile warp yarn system.
16. The method according to claim 15, wherein, in association with at least one reed dent of a weaving machine, at least one warp yarn system is provided.
17. The method according to claim 12, wherein the method is a face-to-face weaving method for simultaneously weaving two fabrics.
18. The method according to claim 17, wherein, in association with each fabric to be woven, a plurality of warp yarn systems is provided following each other in the weft direction, at least one warp yarn system comprising two binding warp yarns crossing each other, at least one tension warp yarn, and at least one of the pile warp yarns, wherein, in the pile warp yarn systems, piles are provided by the pile warp yarns of a respective pile warp yarn system by interlacing these pile warp yarns with weft yarns extending through the weft receiving openings provided by the binding warp yarns of the same pile warp yarn system, wherein at least one, warp yarn system comprises the warp yarns for both fabrics to be woven.
19. The method according to claim 18, wherein, in association with at least one warp yarn system, the crossings of the binding warp yarns of one of the two fabrics to be woven are offset relative to the crossings of the binding warp yarns of the other one of the fabrics to be woven in the warp direction.
20. The method according to claim 12, wherein, in at least one fabric the crossings of the binding warp yarns defining the weft receiving openings in the two orientations of the warp direction are located at the same position in the warp direction.
Description
(1) The present invention will now be explained with respect to the drawings in which:
(2)
(3)
(4)
(5)
(6) Each one of the fabrics F.sub.1, F.sub.2 is constituted by a plurality of warp yarn systems comprising binding warp yarns B.sub.1, B.sub.2 and tension warp yarns T for providing the ground weave of respective backing fabrics BF as well as pile warp yarns PY.sub.1, PY.sub.2, PY.sub.3, PY.sub.4 for providing piles P extending out of the backing fabrics BF on a pile side PS. Each warp yarn system may comprise all the warp yarns for providing a ground weave of the two backing fabrics BF for both fabrics F.sub.1, F.sub.2 and all the pile warp yarns PY.sub.1, PY.sub.2, PY.sub.3, PY.sub.4 interlaced with the weft yarns E.sub.1, I, E.sub.2 for generating piles P or bound into the backing fabrics BF such as to extend substantially in the warp direction WA as dead pile warp yarns.
(7) When carrying out the face-to-face weaving method of the present invention, one warp yarn system may be associated with each reed dent of a weaving machine.
(8) It is to be noted that, in the sense of the present invention the cooperation of pile warp yarns with weft yarns extending through weft receiving openings defined by binding warp yarns, while other pile warp yarns and tension warp yarns extend within a respective backing fabric refers to warp yarns extending in close proximity to each other in the weft direction, preferably refers to warp yarns of one and the same warp yarn system.
(9) In the weaving structure shown in
(10) In the weaving structure of
(11) In a weft receiving opening O in which a change of the pile forming pile warp yarn occurs, especially if both pile-forming pile warp yarns are bound into the same fabric when not forming piles, both end weft yarns E.sub.1, E.sub.2 may be positioned on the back side BS relative to all the warp yarns bound into the backing fabric BF, such that all these warp yarns are used as weft separating warp yarns. This can, for example, be seen in the weft receiving opening O of the top fabric F.sub.1, where a change from the pile warp yarn PY.sub.1 to the pile warp yarn PY.sub.2 occurs.
(12) In some of the weft receiving openings O, the end weft yarns E.sub.1 positioned adjacent to the crossings C.sub.1 defining these weft receiving openings O in the first orientation OW.sub.1 are separated from the associated intermediate weft yarns I by means of the tension warp yarn T only and therefore are positioned on the pile side PS with respect to the dead pile warp yarns, while the end weft yarns E.sub.2 positioned adjacent to the crossings C.sub.2 defining these weft receiving openings O in the second orientation OW.sub.2 are separated from the associated intermediate weft yarns I by means of the tension warp yarn T and the dead pile warp yarns and therefore are positioned on the back side BS with respect to the dead pile warp yarns. However, in all the weft receiving openings O, or at least in the major portion of the weft receiving openings O, both end weft yarns E.sub.1, E.sub.2 are separated from the intermediate weft yarn I by the tension warp yarn T of a respective warp yarn system.
(13) For forming piles P, the pile-forming pile warp yarns are interlaced with one of the two end weft yarns E.sub.1, E.sub.2 received in the weft receiving openings O. For example, pile warp yarn PY.sub.1 is interlaced with the end weft yarns E.sub.1 received in the weft receiving openings O on the back side of the tension warp yarn T and the dead pile warp yarns, while pile warp yarn PY.sub.2 is interlaced with the end weft yarns E.sub.2 received in the weft receiving openings O on the back side of the tension warp yarn T and the dead pile warp yarns, such that, in each weft receiving opening O, a pile-forming pile warp yarn is interlaced with an end weft yarn E.sub.1 or E.sub.2 positioned at the back side of the tension warp yarn T and all the dead pile warp yarns bound into the backing fabrics BF acting as the weft separating warp yarns. This leads to a structure in which the piles P generated by pile warp yarn PY.sub.1 extend out of the backing fabric BF of each one of the two fabrics F.sub.1, F.sub.2 between the end weft yarn E.sub.1 with which they are interlaced and the intermediate weft yarn I of the same weft receiving opening O, and extend out of the backing fabric between the end weft yarns E.sub.1 with which they are interlaced and the immediately adjacent end weft yarn E.sub.2 of the weft receiving opening O following in the first orientation OW.sub.1 of the warp direction, if such a pile comprises two pile legs PL.sub.1, PL.sub.2, such that V-piles are provided. If a pile P comprises only one pile leg PL.sub.s, which is the case at locations where a pile warp yarn starts or ends forming piles P, this single pile leg PL.sub.s extends out of the backing fabric BF between the end weft yarn E.sub.1 with which it is interlaced and the immediately adjacent end weft yarn E.sub.2 of the weft receiving opening O following in the first orientation OW.sub.1 of the warp direction WA or the intermediate weft yarn I of the weft receiving opening O through which the end weft yarn E.sub.1 extends.
(14) Due to the fact that the intermediate weft yarns I are separated from each one of the end weft yarns E.sub.1, E.sub.2 by at least one weft separating yarn, i.e. the tension warp yarns T and the dead pile warp yarns or the tension warp yarns T only, in each case the piles P extend out of a respective one of the backing fabrics BF between two weft yarns I, E.sub.2 positioned adjacent to the weft yarn E.sub.1 with which a pile-forming pile warp yarn, for example, PY.sub.1, is interlaced. As can be seen in the top fabric F.sub.1 of
(15) This shadow effect depends on whether a respective pile-forming pile warp yarn is interlaced with an end weft yarn E.sub.1 or is interlaced with an end weft yarn E.sub.2 of a respective weft receiving opening O. As can be seen in
(16) As stated above, due to the forces applied to the weft yarns by the binding warp yarns and/or applied to the weft yarns during the weaving process, the sequence of the weft yarns in the warp direction and/or the distance of immediately adjacent weft yarns from each other may deviate from the ones shown in the drawings. The sequence of the weft yarns in the drawings corresponds to the sequence with which the weft yarns are introduced during the weaving process by weft insertion means. For example, for each one of the weft receiving openings, an end weft yarn, and intermediate weft yarn, and a further end weft yarn may be introduced one after the other for each one of the two fabrics. Due to the above stated forces applied to the weft yarns in the warp direction, in particular applied to the weft yarns not used for interlacing pile warp yarns, these weft yarns may become shifted in the warp direction, such that, for example, an intermediate weft yarn is closer to a crossing of two binding warp yarns than the one end weft yarn not used for interlacing a pile warp yarn (in a particular warp yarn system) which, when introducing this weft yarn, was closer to this crossing than the intermediate weft yarn. This can lead to a situation in which, in some of the weft receiving openings, in association with some of the warp yarn systems the sequence of the weft yarns in the warp direction is such that a weft yarn used for interlacing a pile warp yarn and being positioned immediately adjacent to a crossing of the two binding warp yarns of a respective warp yarn system is followed by the other end weft yarn not used for interlacing a pile warp yarn and then the intermediate weft yarn, i.e. the weft yarn which is separated from the end weft yarns by means of at least one weft separating warp yarn, preferably comprising at least the tension warp yarn(s) of a respective warp yarn system. Further there may be situation, in which two weft yarns not used for interlacing pile warp yarns, for example, comprising an intermediate weft yarn and an end weft yarn, due to the forces applied thereto, are positioned substantially one above the other in the direction D. However, it is to be expected that, in the major portion of the weft receiving openings, the sequence of the weft yarns corresponds to the sequence with which the weft yarns are introduced into the backing fabrics during the weaving process
(17) In an alternative weaving structure shown in
(18) For providing a symmetrical structure in both fabrics F.sub.1, F.sub.2, the crossings C.sub.1, C.sub.2 of the top fabric F1 are offset with respect to the crossings C.sub.1, C.sub.2 of the bottom fabric F.sub.2 in the warp direction. This leads to a corresponding offset of the weft receiving openings O and the weft yarns received in these weft receiving openings O, in particular the end weft yarns E.sub.1, E.sub.2 with which the pile-forming pile warp yarns are interlaced. When looking at the first pile P generated by means of the pile warp yarn PY.sub.1 in the bottom fabric F.sub.2, i.e. the pile P positioned on the left most side of
(19) While the crossings C.sub.1, C.sub.2 of the two fabrics F.sub.1, F.sub.2 preferably are shifted with respect to each other in the warp direction WA, for example, by one weft yarn, i.e. one weaving cycle, the crossings C.sub.1, C.sub.2 of different warp yarn systems following each other in the weft direction within each one of the two fabrics F.sub.1, F.sub.2 preferably are positioned at the same location in the warp direction WA. This leads to lines of crossings C.sub.1 and lines of crossings C.sub.2 within each one of the two fabrics F.sub.1, F.sub.2 extending substantially in the weft direction.
(20) By providing the weaving structure shown in
(21) What becomes clear from the above explanation of the embodiments shown in
(22) It is to be noted that in a fabric according to the present invention, more than one intermediate weft yarn may be used in the various weft receiving openings. In each case, in line with the principles of the present invention, a pile or a pile leg of a pile, respectively, will extend out of the backing fabric on the pile side between the weft yarn with which it is interlaced and an intermediate weft yarn of the same weft receiving opening. Further there may be additional weft yarns positioned on the back side relative to one or a plurality of weft separating warp yarns, which additional weft yarns may be positioned between the two end weft yarns of a respective weft receiving opening. In addition to interlacing the pile warp yarns with one of the end weft yarns, the pile warp yarns may be interlaced with such an additional weft yarn, such as to be interlaced with two adjacent weft yarns of the same weft receiving opening, one of these weft yarns being an end weft yarn. Further, when weaving such a structure as shown in the drawings, additional steps known to the man skilled in the art will have to be carried out. For example, when weaving these structures in a face-to-face weaving process, one of the last measures will be the cutting of the piles connecting the two fabrics with each other, such that the two separated fabrics will be obtained.
(23) A further embodiment of a fabric and a method of weaving fabric, respectively, is shown in
(24) In the transition zones Z of this embodiment, there is provided a weft receiving opening O in which both end weft yarns E.sub.1, E.sub.2 are used for interlacing the pile forming pile warp yarn PY.sub.1. Both end weft yarns E.sub.1, E.sub.2 of these weft receiving openings O are on the back side BS relative to the associated tension warp yarns T and relative to the dead pile warp yarns bound into the respective fabrics F.sub.1, F.sub.2 (four in the top fabric F.sub.1 and three in the bottom fabric F.sub.2). In this a weaving structure, in each one of the two fabrics F.sub.1, F.sub.2, in association with the respective weft receiving openings O, two piles P, each pile P comprising two pile legs PL.sub.1, PL.sub.2 are provided. This leads to an increased pile density in the area of this transition zones Z and avoids the occurrence of a pile gap in these transition zones Z.
(25) As shown in association with the top fabric F.sub.1, the immediately adjacent end weft yarn E.sub.2 of at least one weft receiving opening O positioned immediately adjacent to the weft receiving opening O of the transition zone Z and not used for interlacing with a pile-forming pile warp yarn may be positioned at the back side BS relative to the tension warp yarn T and the dead pile warp yarn PY.sub.2 bound into this fabric, such as to be on the same level as the immediately adjacent end weft yarn E.sub.1 of the transition zone Z. However, as shown on the right side of the top fabric F.sub.1 and as shown on both sides of the transition zone Z of the bottom fabric F.sub.2, the immediately adjacent end weft yarn of at least one immediately adjacent weft receiving opening O may be positioned on the pile side PS relative to the dead pile warp yarns and on the back side BS relative to the tension warp yarns T, such that only the tension warp yarns T are used as weft separating warp yarns between this immediately adjacent end weft yarn and the intermediate weft yarn of the weft receiving opening O and in these areas.