Method for weaving pile fabrics and for configuring a weaving loom therefor

Abstract

A weaving method for the double-face weaving of pile fabrics wherein at least five different pile warp threads (12-19), (20-27) with a yarn number of between 6 and 10 Nm final and at least two tension warp threads (8),(9); (10,11) are provided for each warp thread system (100) and for each fabric (28), (29), wherein the weft threads (1,2), (2,3) of each fabric are divided over at least three levels, while the ground weave repeat runs over at least eight insertion cycles (I-VIII), wherein between 200 and 1000 warp thread systems per meter are provided, and at least 16 pile rows per cm are formed in the warp direction.

Claims

1. Weaving method, wherein, on a double-face weaving loom, in successive weft insertion cycles, in each case one or more weft threads are inserted at respective insertion levels between the warp threads of a number of warp thread systems, while the warp threads are positioned such that two ground fabrics can be woven one above the other from respective weft threads, binding warp threads and tension warp threads, wherein the respective weft threads are bound in openings between binding warp threads wherein a number of different pile-warp threads are provided for each warp thread system (100), at least one of which is alternately interlaced with the upper and the lower round fabric to form pile, and wherein the pile-forming pile warp threads between both ground fabrics are cut, so that two pile fabrics are produced, characterized in that between 200 and 1000 warp thread systems per meter are provided on the double-face weaving loom, in that, in each warp thread system, at least five different pile warp threads with a yarn number between 6 and 10 Nm final and at least two tension warp threads are provided per ground fabric, in that the tension warp threads are positioned in such a way that they divide the weft threads of each pile fabric over at least three different levels, while a ground weave repeat is used which runs over at least eight weft insertion cycles, and in that at least 16 pile rows per cm are formed in the warp direction.

2. Weaving method according to claim 1, characterized in that the weft threads bound in each ground fabric are divided over at least two different levels by at least one tension warp thread per warp thread system, while other weft threads run on the back of the ground fabrics without being bound in said openings between binding warp threads.

3. Weaving method according to claim 2, characterized in that the weft threads running on the back of the ground fabrics are separated from the other weft threads by a tension warp thread.

4. Weaving method according to claim 2, characterized in that the warp thread systems comprise secondary binding warp threads which are positioned in such a way that each pile fabric comprises a number of secondary binding warp threads which are alternately interlaced with the ground fabric, and run over at least one weft thread running on the back thereof in order to fix these weft threads with respect to the ground fabric.

5. Weaving method according to claim 2, characterized in that the pile-forming pile warp threads are in each case interlaced with the weft threads running on the back.

6. Weaving method according to claim 1, characterized in that the non-pile-forming pile warp threads are bound in the ground fabrics in an extended state.

7. Weaving method according to claim 1, characterized in that the weft threads are inserted between the warp threads provided on the weaving loom, wherein N warp thread systems per meter are provided, each with K different pile warp threads, and wherein K10 and N is an integer between 200 and 1000, preferably between 250 and 600, and most preferably equals 500.

8. Weaving method according to claim 1 characterized in that the weft threads for the ground fabric have a yarn number of between 6 and 16 Nm final, and in that any external weft threads which do not have to be bound in the ground fabric have a yarn number of between 4 and 8 Nm final.

9. Weaving method according to claim 1, characterized in that the warp threads on the weaving loom extend through the openings of a weaving reed, and in that the warp threads of each warp thread system are in this case divided over two adjacent openings of the weaving reed, so that they are divided into two groups which are separated from one another by an intermediate reed dent.

10. Weaving method according to claim 9, characterized in that a first group of warp threads of a first warp thread system and a second group of warp threads of a second warp thread system extend through each reed opening.

11. Weaving method according to claim 10, characterized in that the first and the second group are situated in a left-hand part and a right-hand part of the reed opening, respectively, in that at least one tension warp thread of the first group extends in the reed opening along the right-hand side of the pile warp threads of this group, and in that at least one tension warp thread of the second group extends in the reed opening along the left-hand side of the pile warp threads of this group.

12. Weaving method according to claim 9, characterized in that the warp threads extend through the openings of the weaving reed in such a way that N warp thread systems are in each case divided over N openings or N+1 openings of the weaving reed.

13. Weaving method according to claim 1, characterized in that, on a three-gripper weaving loom, in each case three weft threads are inserted at respective insertion levels between the warp threads in the successive weft insertion cycles.

14. Weaving method according to claim 1, characterized in that the double-face weaving loom is configured to weave two pile fabrics according to a weaving method wherein N warp thread systems per meter are provided, each with K different pile warp threads, and in that this configuration is achieved by modifying the configuration of a double-face weaving loom which is configured to weave using (aN) warp thread systems per meter which each contain K/a different pile warp threads, this modification meaning that the (aN) warp thread systems are divided into N series of a successive warp thread systems, and that, within each series, the K/a pile warp threads of (a1) of these warp thread systems are replaced by K/a other pile warp threads, so that each series of a warp thread systems together contains K different pile warp threads and the warp threads (4-27) of each series together form one combined warp thread system, wherein K, K/a, N and a are integers, with a2, and wherein N is an integer between 200 and 1000.

15. Weaving method according to claim 14, characterized in that a=2.

16. Weaving method according to claim 14, characterized in that N=500, K=16 and a=2.

17. Weaving method according to claim 14, characterized in that the weaving loom is provided with positioning means which cooperate with a control device to position the warp threads in accordance with a predetermined control program, and in that the modification of the configuration of the weaving loom also means that the control program of the weaving loom is modified in such a way that the warp threads for each series of a warp thread systems are controlled as the warp threads of one combined warp thread system during weaving.

18. Weaving method according to claim 14, characterized in that the warp threads of the configured weaving loom extend through the reed openings of a weaving reed, and in that the number of combined warp thread systems per meter (N) of the configured weaving loom equals the number of reed openings, or is a multiple of this number.

19. Weaving method according to claim 14, characterized in that the warp threads of each combined warp thread system run through the same reed opening of a weaving reed together.

20. Weaving method according to claim 14, characterized in that the warp threads of each combined warp thread system are divided over two adjacent openings of the weaving reed, so that they are divided into two groups which are separated from one another by an intermediate reed dent.

21. Method for configuring a double-face weaving loom to weave two pile fabrics according to a weaving method, wherein, in successive weft insertion cycles, in each case one or more weft threads are inserted between warp threads provided on the weaving loom, wherein N warp thread systems per meter are provided, each with K different pile warp threads, wherein the warp threads are positioned in such a manner that two ground fabrics are woven, one above the other, from respective weft threads and binding warp threads, wherein at least one pile warp thread per warp thread system is alternately interlaced with the upper and the lower ground fabric to form pile, and wherein the pile-forming pile warp threads between both ground fabrics are cut, characterized in that the configuration of a double-face weaving loom which is intended for weaving with (aN) warp thread systems per meter which each contain K/a different pile warp threads, by dividing the (aN) warp thread systems into N series of a successive warp thread systems and by replacing, within each series, the K/a pile warp threads of (a1) of these warp thread systems by K/a other pile warp threads, so that each series of a warp thread systems together contains K different pile warp threads, and the warp threads of each series together form one combined warp thread system, wherein K, K/a, N and a are integers and wherein a2.

22. Method for configuring a double-face weaving loom according to claim 21, characterized in that a=2.

23. Method for configuring a double-face weaving loom according to claim 21, characterized in that N=500, K=16 and a=2.

24. Method for configuring a double-face weaving loom according to claim 21, characterized in that the weaving loom is provided with positioning means which cooperate with a control device to position the warp threads in accordance with a predetermined control program, and in that configuring the weaving loom also means that the control program of the weaving loom is modified in such a way that the warp threads for each series of a warp thread systems are controlled as the warp threads of one combined warp thread system during weaving.

25. Method for preparing a double-face weaving loom according to claim 21, characterized in that the warp threads of the configured weaving loom extend through the reed openings of a weaving reed, and in that the number of combined warp thread systems per meter (N) of the configured weaving loom equals the number of reed openings, or is a multiple thereof.

26. Method for configuring a double-face weaving loom according to claim 21, characterized in that the warp threads of each combined warp thread system run through the same reed opening of a weaving reed together.

27. Method for configuring a double-face weaving loom according to claim 21, characterized in that the warp threads of each combined warp thread system are divided over two adjacent openings of the weaving reed, so that they are divided into two groups which are separated from one another by an intermediate reed dent.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the following description, a preferred method for weaving a pile fabric according to the present invention is described in detail. The sole purpose thereof is to illustrate, and if necessary to clarify, what the particular features and advantages of this method and of the resultant pile fabrics are. This description can therefore by no means be seen as a limitation of the scope of protection of this patent.

(2) In this description, reference is made to the attached FIGS. 1 and 2, each of which shows a diagrammatic cross section along the warp direction of a part of a pile fabric which is woven on a double-face weaving loom according to the present invention, the two figures showing the warp threads and the warp threads of a first and a second adjacent warp thread system, respectively.

DETAILED DESCRIPTION OF EMBODIMENTS

(3) The double-face weaving loom is a triple-rapier weaving loom which is intended to insert three weft threads (1), (2), (3) in each insertion cycle (I-VIII) at respective insertion levels, one above the other, in a shed between warp threads (4-27). 500 warp thread systems per meter are provided (i.e. N=500), with each warp thread system containing the same warp threads. In the figures, the warp threads (4-27) of one such warp thread system are shown in each case. The figures also show the weft threads (1), (2), (3).

(4) Each warp thread system (4-27) contains: two binding warp threads (5),(6) for forming an upper ground fabric (28), two binding warp threads (7),(8) for forming a lower ground fabric (29), two tension warp threads (8),(9) belonging to the upper fabric (28), two tension warp threads (10),(11) belonging to the lower fabric (29), eight pile warp threads (12-19) with mutually different colours which are intended for binding in the upper ground fabric (28) when they do not have to form pile, and eight pile warp threads (20-27) with mutually different colours which are intended for binding in the lower ground fabric (29) when they do not have to form pile, and wherein these colours also differ from the eight colours of the other pile warp threads (12-19) of the warp thread system which are intended to be bound in the upper ground fabric (28) when they do not have to form pile.

(5) A jacquard machine cooperating with the weaving loom and/or a heddle frame drive cooperating with the weaving loom is provided to position the warp threads (4-27) according to a predetermined control program in each insertion cycle (I-VIII) in such a manner with respect to the three insertion levels that the fabric illustrated in the figure is produced.

(6) The warp threads (4-27) of the different warp thread systems (of which 500 are provided per meter) extend through the openings of a weaving reed. By a number of the measures which are described below, a theoretical pile density of 1600 pile rows per meter is achieved in the warp direction. In this case, the above-defined imbalance factor is therefore 6.4 (3200/500). Pile warp threads with a yarn number of 8 Nm final are provided. Due to this imbalance, the pile legs are moved in the weft direction and a uniform pile distribution is achieved.

(7) The warp threads of each warp thread system are divided into two groups which are situated in two adjacent reed openings, respectively. In this case, each group of eight pile warp threads contains two tension warp threads and two binding warp threads.

(8) The left-hand group is situated in the right-hand part of the reed opening, while the right-hand group extends in the left-hand part of the reed opening which is adjacent on the right-hand side. Both groups are thus separated by an intermediate reed dent.

(9) In each group, the two tension warp threads are provided to the left and right of the eight pile warp threads of this group, respectively, and they extend immediately next to these pile warp threads. As a result thereof, the pile warp threads are held in place well, thus supporting the formation of straight pile rows.

(10) The two binding warp threads of each group are then placed to the left and right of the tension warp threads of this group, respectively, so that the binding warp threads run in pairs between two tension warp threads of adjacent groups.

(11) If we consider the position of the warp threads of a warp thread system in the weaving reed (the so-called drawing-in) then we successively find, from left to right:

(12) a binding warp thread, a tension warp thread, eight pile warp threads, a tension warp thread, a binding warp thread, the intermediate reed dent, a binding warp thread, a tension warp thread, eight pile warp threads, a tension warp thread and a binding warp thread.

(13) In each insertion cycle (I-VIII), the binding warp threads (5),(6); (7),(8) and tension warp threads (9),(10); (11),(12) are positioned with respect to the three different insertion levels in such a manner that an upper (28) and a lower (29) ground fabric are woven one above the other, and that alternately,

(14) (i) the upper (1) and the middle (2) weft thread are inserted in the upper fabric, while the lower weft thread (3) is inserted in the lower fabric, and

(15) (ii) the upper weft thread (1) is inserted in the upper fabric, while the middle (2) and the lower (3) weft thread are inserted in the lower fabric, but,

(16) when two weft threads (1), (2) are inserted in the upper fabric, in each case a thicker weft thread is inserted for the upper weft thread (1), and the warp threads are positioned in such a manner that this thicker weft thread runs on the back of the upper fabric and is not bound in by the binding warp threads, and

(17) when two weft threads (2), (3) are bound in the lower fabric, in each case a thicker weft yarn is inserted for the lower weft thread (3), and the warp threads are positioned in such a manner that this thicker weft thread (3) runs on the back of the lower fabric and is not bound in by the binding warp threads.

(18) The other weft threads (1-3) (i.e. not running on the back) are bound in each ground fabric (28),(29) by a pair of binding warp threads (5),(6); (7),(8).

(19) In the upper fabric, one tension warp thread (8) is positioned in such a manner that it runs below the thicker weft thread (1) and runs above the other weft threads (2) of the fabric in each case. As a result thereof, the thicker weft threads (1) are reliably separated from the other weft threads (2) which are bound in the upper ground fabric (28) and these thicker weft threads (1) are reliably kept on the back of the ground fabric. Secondary binding warp threads may be provided in order to fix these weft threads (1) with respect to the ground fabric (28), but these are not shown in the figures. The other tension warp thread (9) is positioned in such a manner that it always runs between the upper (1) and the middle (2) weft thread, as a result of which the weft threads (1), (2) bound in the ground fabric (28) are divided over two different levels.

(20) In the lower fabric, one tension warp thread (10) is positioned in such a manner that it runs above the thicker weft thread (3) and below the other weft threads (2) of the fabric in each case. As a result thereof, the thicker weft threads (3) are reliably separated from the other weft threads (2) which are bound in the lower ground fabric (29) and these thicker weft threads (3) are reliably kept on the back of the ground fabric (29). Secondary binding warp threads (not shown in the figures) can also fix these weft threads (3) with respect to the lower ground fabric (29). The other tension warp thread (9) of the lower fabric is positioned in such a way that it always runs between the middle weft thread (2) and the lower weft thread of the ground fabric (29), as a result of which these weft threads (2),(3) bound in the lower ground fabric are divided over two different levels.

(21) For each pile point, one of the sixteen pile warp threads (12-27) is selected in accordance with a multi-coloured pattern to be woven in order to form pile by running alternately in the upper and the lower fabric over a weft thread (1), (3) which runs on the back. Thus, pile warp thread (27) forms pile over the weft threads (1), (3) which were inserted during the first (I), the second (II) and the third (III) insertion cycle which are shown furthest to the left in the figures.

(22) The non-pile-forming pile warp threads (12-27) are bound in the ground fabrics and in this case are divided over the upper (28) and the lower (29) ground fabric. They run in the ground fabrics (28), (29) in an extended state, alternately above and below the weft threads (1,2), (2,3) which are bound in the ground fabrics.

(23) In adjacent warp thread systems, the binding warp threads (4),(5); (6), (7) have a different path, as can be seen in FIGS. 1 and 2. The two sets of binding warp threads of two adjacent warp thread systems cooperate in each ground fabric to bind in the respective weft threads (1,2), (2,3) in the openings which they form between their successive crossings. Considering each warp thread system separately, there are relatively few such crossings, which benefits the weft thread density, as explained above. This also contributes to an increase in the pile density in the warp direction.

(24) The binding warp threads (5),(6); (7),(8) and the tension warp threads (8),(9); (10),(11) take up a sequence of positions with respect to the weft threads which have been inserted during the successive insertion cycles (I-VIII) and this sequence repeats for all these ground warp threads after eight insertion cycles (I-VIII), as can clearly be seen from the path of these warp threads shown in the figures.