EP2568065B1 - Method for weaving a carpet and carpet woven with such a method - Google Patents

Method for weaving a carpet and carpet woven with such a method Download PDF

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Publication number
EP2568065B1
EP2568065B1 EP11306105.5A EP11306105A EP2568065B1 EP 2568065 B1 EP2568065 B1 EP 2568065B1 EP 11306105 A EP11306105 A EP 11306105A EP 2568065 B1 EP2568065 B1 EP 2568065B1
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EP
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Prior art keywords
yarns
weft
warp
piles
yarn
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EP11306105.5A
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German (de)
English (en)
French (fr)
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EP2568065A1 (en
Inventor
Karsten Siebert
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Staeubli Bayreuth GmbH
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STAUBLI BAYREUTH GmbH
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Application filed by STAUBLI BAYREUTH GmbH filed Critical STAUBLI BAYREUTH GmbH
Priority to TR2018/08546T priority Critical patent/TR201808546T4/tr
Priority to EP11306105.5A priority patent/EP2568065B1/en
Priority to CN201210328789.4A priority patent/CN102995226B/zh
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    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D27/00Woven pile fabrics
    • D03D27/02Woven pile fabrics wherein the pile is formed by warp or weft
    • D03D27/06Warp pile fabrics
    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D27/00Woven pile fabrics
    • D03D27/02Woven pile fabrics wherein the pile is formed by warp or weft
    • D03D27/10Fabrics woven face-to-face, e.g. double velvet

Definitions

  • This invention belongs to the field of carpet weaving and relates to a method for weaving at least one carpet with a backing fabric including some areas with piles and some areas without piles.
  • weft yarns are visible and one speaks of "weft patterning". Actually, the weft yarns extend on the full width of the carpet but are only visible in areas without piles.
  • This type of carpet can be produced on a loom equipped with a weft selector which allows to use special weft threads on the inner side of the backing fabric, that is on its pile side, these special weft threads being visible only in areas without pile patterning. In these areas without pile patterning, the weft effect is obtained thanks to the position of the weft yarns with respect to the filling warp yarns. Since the filling warp yarns are under high tension, the weft yarns are either located above or under the filling warp yarns.
  • the invention aims at giving more freedom to a weaver in order to obtain an optimized weft effect, without substantially increasing the complexity of a weaving loom used to implement the method.
  • the invention relates to a method for weaving at least one carpet, with a backing fabric including at least one area with piles and at least one area without piles where
  • all the dead pile yarns are respectively maintained in the backing fabric under or above the inner weft yarns.
  • all the dead pile yarns of a warp yarn set follow, within a backing fabric, a path where for some picks, all the dead pile yarns are placed under the inner weft yarns and, for some other picks, at least two dead pile yarns of said warp yarn set are placed above the inner weft yarn and the other dead pile yarns are placed under the inner weft yarn.
  • the inner weft yarns are divided into at least two different kinds of inner weft yarns which are alternatively woven into the backing fabric.
  • the weaver it is possible for the weaver to select, in an area with no pile, zones where the inner weft yarns are visible and zones where they are not visible, along the weft direction. When they are not visible, the inner weft yarns are covered by some of the dead pile yarns, namely two or more, of the set of warp yarns which belong to the backing fabric.
  • This provides a solution to a weaver who wants to be able to produce different carpets on the width of a loom, with dedicated weft patterning zones, that is zones where a given weft effect is obtained.
  • this method incorporates at least one of the following features :
  • the invention also relates to a carpet which can be woven with a method as mentioned here-above. More specifically, the invention relates to a carpet with a backing fabric including at least one area with piles and at least one area without piles, where the backing fabric is woven with, on the one hand, filling warp yarns, binding warp yarns and dead pile yearns and, on the other hand, weft yarns inserted between the binding warp yarns and comprising inner weft yarns on the pile side of the filling warp yarns and outer weft yarns on the side of the filling warp yarns opposite to the piles.
  • the warp yarns are organized, along the weft direction, in identical warp yarn sets comprising filling warp yarns, binding warp yarns and dead pile yarns.
  • inner weft yarns are alternatively above all the dead pile yarns of some warp yarn sets or under at least two dead pile yarns of some other warp yarn sets, along the weft direction, whereas the inner weft yarns are divided into first and second inner weft yarns which alternate along the warp direction.
  • this carpet incorporates at least one of the following features:
  • Figure 1 is a schematic cross-section, in the warp direction, of two carpets simultaneously woven one above the other on a face-to-face loom with two non represented insertion means.
  • Picks P1 to P20 are represented on figure 1 .
  • Each carpet C1 or C2 includes a backing fabric F1 or F2 and piles D1 or D2 extending from one backing fabric F1 or F2 towards the other backing fabric.
  • Backing fabrics F1 and F2 might also be called ground fabrics.
  • the piles D1 and D2 are supposed to be separated from each other by a knife K belonging to a not further represented cutting device. Knife K is represented on figure 1 only, but the same kind of cutting device can be used with the other methods of the invention.
  • the warp yarns used in this method include binding warp yarns b1 and b'1 and a filling warp yarn f1 used for backing fabric F1. Binding warp yarns b2 and b'2 and filling warp yarn f2 are used for weaving backing fabric F2. One filling warp yarn f1 or f2 is represented in each backing fabric F1 or F2, but several filling warp yarns can be used in each backing fabric.
  • the warp yarns also include pile warp yarns which can extend from one backing fabric to the other in order to form the piles D1 and D2, as represented by pile warp yarn VI in a first area A 1 of carpets C1 and C2.
  • pile warp yarn VI in a first area A 1 of carpets C1 and C2.
  • Other pile warp yarns I to V, VII and VIII are represented on figure 1 and constitute dead pile yarns which remain in one backing fabric for picks P1 to P20. More precisely, dead pile yarns I to IV remain in backing fabric F1 whereas dead pile yarns V, VII and VIII remain in backing fabric F2 and pile yarn VI remains in backing fabric F2, as a dead pile yarn, as from pick P5.
  • Pile yarns I to VIII are of different colors.
  • the warp yarns are organized in sets of warp yarns, with all the warp yarns of one set going through the same reed dent space of a reed of the loom.
  • All the warp yarns represented on figure 1 that is binding warp yarns b1, b'1, b2 and b'2, filling warp yarns f1, f2 and pile warp yarns I to VIII belong to the same set of warp yarns.
  • a 0 denotes an area of carpets C1 and C2 without piles, that is an area of these two carpets where backing fabrics F1 and F2 are not provided with piles.
  • binding warp yarns b1 and b'1, filling warp yarn f1 and dead pile yarn I to IV belong to backing fabric F1
  • binding warp yarns b2 and b'2 filling warp yarn f2 and dead pile yarn V to VIII belong to backing fabric F2.
  • This area A 0 is produced between picks P5 to P20.
  • Binding warp yarns b1, b'1, b2, b'2 and filling warp yarns f1, f2 are drawn in through heddles which are connected to a shedding device, such as a dobby or a cam motion mechanism.
  • Pile warp yarns I to VIII are fed from a creel and drawn in through heddles which are connected to a three position Jacquard mechanism.
  • a weft yarn is inserted in each ground fabric F1 and F2 by two non represented insertion means which travel into two sheds respectively formed by the warp yarns, one above the other.
  • two weft yarns are inserted into the sheds at each pick.
  • a top shed is defined between warp yarns placed into a top position and a middle position.
  • a bottom shed is defined between warp yarns placed in a middle position and in a bottom position.
  • Weft yarns comprise inner weft yarns Wi and outer weft yarns Wo.
  • Inner weft yarns Wi are located, in each backing fabric F1 or F2, on the same side as the piles D1 or D2 with respect to the filling warp yarns f1 or f2.
  • Outer weft yarns Wo are located, in each backing fabric F1 or F2, opposite the piles D1 and D2 with respect to the filling warp yarns f1 or f2.
  • Inner weft yarns Wi are of two different colors respectively identified with references Wi1 and Wi2 on figure 1 . Thus, inner weft yarns Wi are divided into first inner weft yarns Wi1 and second inner weft yarns Wi2. As an example, one considers that the first color of inner weft yarns Wi1 is blue, whereas the second color of inner weft yarns Wi2 is red.
  • an outer weft yarn Wo is inserted into the top backing fabric F1 and a blue inner weft yarn Wi1 is inserted into the bottom backing fabric F2.
  • an outer weft yarn Wo is inserted into the bottom fabric F2 and a blue inner weft yarn is inserted into the top backing fabric F1.
  • an outer weft yarn is inserted into the top backing fabric F1 and a red inner weft yarn Wi2 is inserted into the bottom ground fabric F2.
  • an outer weft yarn Wo is inserted into the bottom backing fabric F2 and a red inner weft yarn Wi2 is inserted into the top backing fabric F1.
  • Pick P5 is similar to pick P1 for the weft yarns, according to a four pick repeat. In other words, for h between 1 and 16, pick Ph equals Ph+4, in terms of weft insertion.
  • a weft selector with at least three channels is used in order to feed the two insertion means with three types of weft yarns, that is the outer weft yarn Wo, which can be jute, and inner weft yarns Wi1 and Wi2 of two different colors.
  • the dead pile yarns I to IV, on the one hand, V to VIII, on the other hand, are respectively maintained in the backing fabrics F1 and F2.
  • no pile yarn is patterning between ground fabrics F1 and F2 as from pick P5.
  • the dead pile yarns V to VIII are maintained in a middle position by the Jacquard mechanism.
  • these dead pile yarns V to VIII go to the bottom position, so that the inner weft yarn Wi2 is inserted above these dead pile yarns.
  • picks P8, P9 and P10 the dead pile yarns V to VIII are back into their middle position.
  • pick P11 they go to the bottom position, as in pick P7.
  • dead pile yarns V to VIII are back into their middle position. They go back to their bottom position at pick 13, so that the blue inner weft yarn Wi1 is inserted above them.
  • the dead pile yarns are in their middle position, so that they cover the red inner weft yarn Wi2 inserted at pick P15 which is hidden from the pile side of carpet C2.
  • the same approach repeats for picks P17 to P20. Thus, between picks P13 and P20, only the blue inner weft yarns Wi1 are visible from the pile side of carpet C2.
  • the effect would be substantially the same if only a part of the dead pile yarns of a warp yarn set are placed above the inner weft yarns Wi which are not to be seen from the pile side. At least two dead pile yarns V to VIII are necessary to efficiently hide the inner weft yarn Wi from the pile side.
  • two types Wi1 and Wi2 of inner weft yarns Wi are alternatively used in each backing fabric, that is one inner weft yarn of a given type is inserted on every fourth pick since an outer weft yarn is inserted after each inner weft yarn and the two types of inner weft yarns Wi1, Wi2 are used one after the other.
  • backing fabric F1 the arrangement of the dead pile yarns I to IV with respect to the inner weft yarns Wi1 and Wi2 is selected, along the weft direction, for each set of warp yarns going through a given reed dent space.
  • backing fabric F2 the arrangement of the dead pile yarns V to VIII with respect to the inner weft yarns Wi1 and Wi2 is selected, along the weft direction, for each set of warp yarns going through a given reed dent space.
  • Those arrangements are variable along the width of a carpet woven with the method of the invention. In other words, the path of the dead pile yarns in each backing fabric F1 and F2 varies from one set of warp yarns to the other, along the weft direction.
  • the inner weft yarns Wi1 and Wi2 are selectively woven above or under all the dead pile yarns, in each warp yarn set.
  • the variation of the dead pile yarns arrangement along the weft direction can be selected warp yarns set by warp yarns set.
  • Several warp yarns sets, adjacent along the weft direction, can have the same arrangement with respect to the inner weft yarns.
  • arrow DA represents the warp direction, that is the direction of the warp yarns
  • arrow DE represents the weft direction, that is the direction of the weft yarns.
  • Some areas A 1 with piles of the carpets are represented with crosses X and the areas with no pile are represented with horizontal stripes.
  • carpet C11 is three meters long along direction DA and two meters wide along direction DE, whereas each of carpets C21 to C24 is one and half meter long and one meter wide.
  • Each carpet has at least one area with piles A 1 and one area without piles A 0 .
  • the light grey zones in areas A 0 represent zones where blue inner weft yarns Wi1 are visible from the pile side of a carpet and the dark grey zones represent zones where red inner weft yarns Wi2 are visible.
  • the dark grey zones represent zones where red inner weft yarns Wi2 are visible.
  • Outer weft yarns Wo are used on the side of the filling warp yarns opposite to the piles D1 and D2 and inner warp yarns Wi of two different colors, Wi1 and Wi2, are used on the pile side of each backing fabric F1 and F2.
  • the weaving machine also includes two insertion means for inserting two weft yarns at each pick.
  • the method makes use of a shedding device which can move the binding and filling warp yarns between two positions and the pile yarn between three positions, as in the first embodiment.
  • binding warp yarn b1 binds, to the outer weft yarns Wo, as many blue inner weft yarns Wi1 as red inner weft yarns Wi2.
  • binding warp yarn b1 binds five inner weft yarns Wi1 of the first type, that is blue, to the outer weft yarns Wo. This concerns inner weft yarns Wi1 inserted at picks P2, P6, P10, P14 and P18.
  • This same binding warp yarn b1 binds, to the outer weft yarns Wo, five inner weft yarns Wi2 of the second type, that is red inner weft yarns respectively inserted at picks P4, P8, P12, P16 and P20.
  • each binding warp yarn b1, b'1, b2, b'2 binds, to the outer weft yarns Wo, as many first inner weft yarns Wi1 and second inner weft yarns Wi2 implies that the length of all binding warp yarns is the same on the area A 0 where no pile is created, irrespective of the weft patterning.
  • each binding warp yarn binds as many first inner weft yarns Wi1 and second inner weft yarns Wi2 to the outer weft yarns, this is not the case.
  • the binding warp yarns of each ground fabric are divided into two groups which follow an eight pick repeat.
  • the weft yarns follow a four pick repeat.
  • Piles D1 and D2 are created by a pile warp yarn VI in a first area A 1 of the carpets C1 and C2 which correspond to picks P1 to P12. As from pick P13, all piles warp yarns I to VIII are dead pile yarns and are incorporated into the backing fabrics F1 and F2.
  • each binding warp yarn b1 to b"'1 and b2 to b"'2 binds the same number of first inner weft yarns Wi1 and second inner weft yarns Wi2 to the outer weft yarns Wo.
  • the binding warp yarns follow a twelve pick repeat and the weft yarns follow a four pick repeat.
  • binding warp yarn b2 between picks P15 and P27.
  • binding warp yarn b2 goes under outer weft yarns Wo.
  • binding warp yarn b2 goes above inner weft yarn Wi2.
  • binding warp yarn b2 goes above inner weft yarn Wi1. From pick P18 to pick P26, binding warp yarn b2 does not go above any other inner weft yarn Wi or under any outer weft yarn Wo.
  • binding warp yarn b2 goes above two inner weft yarns Wi, that is one weft yarn Wi1 of the first type at pick 17 and one weft yarn Wi2 of the second type at pick P16.
  • each zone Z1 or Z2 taken along the weft direction DE can be variable along the warp direction DA.
  • several zones Z1 can be located between two zones Z2 in the weft direction DE and between two other zones Z2 in the warp direction DA.
  • zone Z2 which can be located between two zones Z1 in the weft direction and two other zones Z1 in the warp direction.
  • the invention is implemented with a method where a carpet is woven on a single loom, that is a loom which produces one backing fabric at a time.
  • a carpet is woven on a single loom, that is a loom which produces one backing fabric at a time.
  • the same elements as in the first embodiments have the same references and are not described in detail.
  • the carpet C2 produced with the method of figure 6 has a backing fabric F2 and loop piles D2 formed by a pile warp yarn VI going over a dummy weft Wd inserted for some picks at the same time as a weft inner yarn Wi or the weft outer yarn Wo.
  • an outer weft yarn Wo is inserted in the backing fabric F2.
  • an inner weft yarn Wi2 of a second color, red is inserted in the backing fabric F2 and a dummy weft yarn Wd is inserted into the top shed.
  • an outer weft yarn Wo is inserted in the backing fabric F2.
  • Pick P5 is like pick P1 in terms of weft yarns insertion, according to a four pick repeat.
  • a weft selector with at least three channels is required for the insertion mean dedicated to the bottom shed.
  • pile yarn VI is patterning between the backing fabric F2 and the dummy weft yarns Wd which will be removed at a later stage.
  • pick P5 binding warp yarns b2 and b'2 filling warp yarn f2 and dead pile yarns V to VIII behave like in the first embodiment.
  • picks P5 and P12 only inner weft yarns of the second type Wi2 are visible from the pile side of carpet C2, in the direction of arrow H 2 .
  • picks P12 and P20 only inner weft yarns of the first type, namely blue inner weft sides Wi1, are visible.
  • each binding warp yarn b2 or b'2 has, in the area A 0 where no pile is created, a path similar to the path of binding warp yarns b2 and b'2 in the second embodiment.
  • the invention can be implemented with a carpet where the piles created in the first area A 1 can be of any type, namely cut pile, loop pile or false bouclé.
  • two carpets C1 and C2 are woven face to face and they include each a backing fabric F1 or F2 and piles D1 or D2.
  • This embodiment is close to the third embodiment and one describes here-after only the differences between the third and seventh embodiments.
  • three different inner weft yarns Wi1, Wi2 and Wi3 are used and they are inserted into the backing fabrics F1 and F2 at successive picks. For example, one can consider that the first inner weft yarn Wi1 is red, the second inner weft yarn Wi2 is blue and the third inner weft yarn Wi3 is green.
  • the first red inner weft yarn Wi1 is inserted, in fabric F1, at picks P4, P10, P16, etc and, in backing fabric F2, at picks P1, P7, P13 etc.
  • the second blue inner weft yarn Wi2 is inserted, in backing fabric F1 at picks P5, P11, P17 etc and, in backing fabric F2, at picks P2, P8 P14 etc.
  • the third green inner weft yarn Wi3 is inserted, in backing fabric F1, at picks P6, P12, P18 etc and, in backing fabric F2, at picks P3, P9, P15 etc.
  • Two binding warp yarns are used in each backing fabric, namely b1 and b'1 in backing fabric F1, b2 and b'2 in backing fabric F2.
  • binding warp yarn b2 between picks P17 and P29.
  • binding warp yarn b2 goes under outer weft yarns Wo.
  • binding warp yarn b2 goes above the first inner weft yarn Wi1 which is covered by dead pile yarns V and VI.
  • binding warp yarn b2 goes above the second inner weft yarn Wi2 which is above dead pile yarns V and VI.
  • binding war yarn b2 goes above third inner weft yarn Wi3 which is covered by dead pile yarns V and VI.
  • Form pick P22 to pick P29 binding warp yarn b2 does not go above any other inner weft yarn Wi or under any outer weft yarn Wo.
  • binding warp yarn b2 goes successively above three inner weft yarns, that is one inner weft yarn of each type, namely first inner weft yarn Wi1 at pick P19, second inner weft yarn Wi2 at pick P20 and third inner weft yarn Wi3 at pick P21.
  • the embodiment of figure 9 can be considered as an improvement to the embodiment of figure 4 where three kinds of inner weft yarns are used.
  • Figure 9 shows only two dead pile yarns I-II in backing fabric F1 and two other dead pile yarns V and VI in backing fabric F2. Actually, the same number of pile yarns can be used as in the other embodiments.
  • the invention is not limited by the number of pile yarns of each warp yarns set. Similarly, any number of binding warp yarns can be used.
  • a method with three inner weft yarns can be implemented on a single loom.
  • the features of the method of figure 9 can be used, for instance, with a method similar to the one of figure 8 .
  • the respective width of a weft patterning zone Z1 or Z2 shown on figure 5 , along the weft direction, is adapted by the number of weft yarns sets used in this zone. This number can be between one and one hundred.
  • the length of each zone Z1 or Z2 along the warp direction is adjusted by the number of inner weft yarns of a given color visible next to each other.
  • the pattern between picks P4 and P12 on figure 1 can be repeated along the warp direction in order to place a large number of inner weft yarns of the second type on top of the dead pile yarns, so as to obtain one zone Z2 of a substantive length, e.g. several centimeters.
  • the invention is not limited to a weft patterning effect based on inner weft yarns with different colors. Indeed, inner weft yarns with different diameters can also be considered, a particular type of inner weft yarns with different diameters being chenille weft yarns. This can be used instead of inner weft yarns with different colors or in combination with such inner weft yarns.
  • the weft selector used to feed the insertion means allows to use different weft yarns according to the needs.
  • the number of colors of the weft patterning design is not limited to two colors.
  • all the dead pile yarns of a set of warp yarns are placed under the inner weft yarn which is to be seen in the zones without piles. They all extend between the inner weft yarn and the filling warp yarn. They could also extend on the back of the ground fabric. They could also be divided into a first group which extends between the inner weft yarn and the filling warp yarn and a second group which extends on the back of the ground fabric.

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  • Textile Engineering (AREA)
  • Woven Fabrics (AREA)
EP11306105.5A 2011-09-06 2011-09-06 Method for weaving a carpet and carpet woven with such a method Active EP2568065B1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
TR2018/08546T TR201808546T4 (tr) 2011-09-06 2011-09-06 Halı dokuma yöntemi ve böyle bir yöntemle dokunmuş halı.
EP11306105.5A EP2568065B1 (en) 2011-09-06 2011-09-06 Method for weaving a carpet and carpet woven with such a method
CN201210328789.4A CN102995226B (zh) 2011-09-06 2012-09-06 编织地毯的方法和用该方法编织的地毯

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP11306105.5A EP2568065B1 (en) 2011-09-06 2011-09-06 Method for weaving a carpet and carpet woven with such a method

Publications (2)

Publication Number Publication Date
EP2568065A1 EP2568065A1 (en) 2013-03-13
EP2568065B1 true EP2568065B1 (en) 2018-04-11

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EP (1) EP2568065B1 (tr)
CN (1) CN102995226B (tr)
TR (1) TR201808546T4 (tr)

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BE1020430A3 (nl) * 2011-12-23 2013-10-01 Wiele Michel Van De Nv Werkwijze voor het weven van een poolweefsel met poolvrije zones.
BE1022393B1 (nl) * 2013-01-10 2016-03-21 Nv Michel Van De Wiele Werkwijze voor het weven van poolweefsels en werkwijze voor het daarvoor uitrusten van een weefmachine
EP2894244B1 (en) * 2014-01-09 2018-11-28 STÄUBLI BAYREUTH GmbH Method for weaving pile fabrics and pile fabric with shadow cut pile zones
EP3192909A1 (en) * 2016-01-15 2017-07-19 NV Michel van de Wiele Fabric, in particular carpet, and method of weaving a fabric
EP3638834B1 (en) * 2017-06-15 2021-10-20 STÄUBLI BAYREUTH GmbH Weaving machine, method for simultaneously weaving two pile fabrics on such a machine and pile fabric obtainable with such a method
EP3702500B1 (en) 2019-02-26 2022-04-06 STÄUBLI BAYREUTH GmbH Method for weaving pile fabrics and pile fabric woven with such a method
WO2020244720A1 (en) * 2019-06-03 2020-12-10 Hammer Tæpper A/S Method for manufacturing a carpet with a carpet pile and a backing and such carpet

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Publication number Priority date Publication date Assignee Title
GB656845A (en) 1947-11-03 1951-09-05 Hugh Mackay And Company Ltd Improvements in the manufacture of pile carpets, floor rugs and mats
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TR201808546T4 (tr) 2018-07-23
CN102995226B (zh) 2015-10-28
EP2568065A1 (en) 2013-03-13

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