EP3824126B1

EP3824126B1 - Weaving device equipped for preventing stripe formation in fabrics with a handmade appearance

Info

Publication number: EP3824126B1
Application number: EP19759740.4A
Authority: EP
Inventors: Steven DEBAES
Original assignee: Vandewiele NV
Current assignee: Vandewiele NV
Priority date: 2018-07-20
Filing date: 2019-07-03
Publication date: 2022-09-07
Anticipated expiration: 2039-07-03
Also published as: WO2020016690A1; BE1026477B1; BE1026477A1; EP3824126A1

Description

The present invention relates to a weaving machine for forming fabrics consisting of weft yarns, ground-warp yarns and pile-warp yarns, comprising:

shed-forming means provided for forming one or more sheds in successive operating cycles through the positioning of warp yarns;
a weft insertion device with at least one rapier provided for inserting one or more weft yarns into a shed between fabric-forming warp yarns and non-fabric-forming warp yarns in successive operating cycles, wherein during the inserting of a weft yarn the non-fabric-forming warp yarns support a rapier;
a reed provided for pushing, in each operating cycle by means of to and fro movements during beating-up, the inserted weft yarns against the fabric line of the fabrics formed by the weft yarns and the fabric-forming warp yarns.

The present invention relates in particular to a weaving machine (weaving device), preferably a rapier weaving machine, which is suitable for forming fabrics that have a handmade appearance ("handlook").
In a rapier weaving machine, an insertion system (weft insertion device) in the form of rapiers - at one or more weft insertion heights - inserts the weft yarns (the weft) through the shed. Each rapier consists of a taker rapier / giver rapier combination. The weft yarn is carried by a giver rapier and in the middle of the shed it is picked up by the corresponding taker rapier, which carries the weft yarn further through the shed. It is important that the transfer of the weft yarn takes place accurately and quickly, therefore it is crucial that at the level of the middle the taker rapier and the giver rapier are positioned really precisely relative to each other. To guarantee this, the rapiers consist of a rapier head and of strong, rigid rapier rods. In spite of that, these strong, rigid rapier rods cannot always guarantee completely accurate positioning in the middle owing to the large distance that must be covered, for example in weaving machines on which fabrics up to 4 or even 5 metres wide are woven. To obtain accurate positioning of the rapiers in the middle of the shed, besides supporting the rigid rapier rods at the sides of the fabric, supporting of the rapier in the shed is also necessary. Usually this additional support is provided by warp yarns, which support the rapiers during their motion through the shed. The rapiers are, as it were, partly carried by the warp yarns.
However, in the case of fabrics that have a handmade appearance, the weft, as explained in the appended Figs. 1 and 2, is inserted outside the ground fabric on the back, so that the bottom rapier cannot be supported at that moment by the warp yarns.
For supporting the bottom rapier, it is known, as explained in Figs. 1 and 2 and as described in EP 1 746 190 A1 (paragraphs [0038] and [0074]), to provide additional warp yarns (3) that do not form part of the fabric (1): so-called non-fabric-forming warp yarns (3) or supporting yarns (3) for a rapier (9). These warp yarns (3) may take up a fixed position or a position controlled by a shed-forming means, in order to support the (bottom) rapier (9) during insertion of a weft yarn for the (lower) fabric. These additional warp yarns (3) are more limited in number than the number of ground warp passes so that said additional warp yarn is not present in each ground warp pass. These additional warp yarns (3) should be removed later in a known way (see EP 1460157 ), since they do not form part of the fabric (1). These additional warp yarns (3) may also be made as fixed cords, which follow a path so that, at the level of the bottom rapier (9), they are located at a height below this rapier (9), so that the rapier (9) can be led over them.
However, in fabrics with high densities, the pile is pushed aside a bit by the non-fabric-forming warp yarns at the beat-up of the fabric. When the non-fabric-forming warp yarns are removed afterwards, the pile loops do not spring back completely, and some of the warp yarns remain visible on the back, which is manifested in the form of stripe formation on the back of the carpet. Consequently, fabrics are obtained with an imperfect back.
The present invention now aims to provide a weaving device that allows fabrics to be manufactured with high densities with a handmade appearance, with a clean back and which, during weaving, offers sufficient support to the rapiers during their motion through the shed. Such a weaving device has at least 1000 warp yarn systems or warp yarn passes per metre.
The aim of the invention is achieved by providing a weaving machine for forming fabrics consisting of weft yarns, ground-warp yarns and pile-warp yarns, comprising:

shed-forming means provided for forming one or more sheds in successive operating cycles through the positioning of warp yarns;
a weft insertion device with at least one rapier provided for inserting, in successive operating cycles, one or more weft yarns into a shed between fabric-forming warp yarns and non-fabric-forming warp yarns, wherein during the inserting of a weft yarn the non-fabric-forming warp yarns support the rapier;
a reed provided for pushing, in each operating cycle, by means of to and fro movements during beating-up, the inserted weft yarns against the fabric line of the fabrics formed by the weft yarns and the fabric-forming warp yarns;

At the level of the weft insertion device, the non-fabric-forming warp yarns are located just beneath the rapier that they support. Based on their function, in particular supporting, these non-fabric-forming warp yarns may also be regarded as supporting yarns. These supporting yarns will follow a path wherein they are deflected by the yarn removal device so that they will leave the shed. By allowing the non-fabric-forming warp yarns to follow a different path (trajectory) than the fabric-forming warp yarns, thus performing separation between the fabric-forming and the non-fabric-forming warp yarns before the fabric line, this prevents the non-fabric-forming warp yarns forming a temporarily apparent part of the beaten-up fabric during beating-up. After beating-up, they thus no longer need to be removed from the formed fabric and they also can no longer give rise to (white) stripe formation. In this way, fabrics may be formed with a good-looking, even back surface.
In an alternative embodiment the supporting yarns may be configured as fixed cords. In this way a system can be integrated on the weaving machine wherein the fixed cords are applied through the weaving machine, so as to support the rapiers during their motion through the shed. More preferably the fixed cords are made in a closed loop and these fixed cords move to distribute any wear uniformly over their total length.
In a preferred embodiment of the weaving machine according to the invention, the yarn removal device comprises a number of hook-shaped or eye-shaped elements, wherein each hook-shaped or eye-shaped element is provided for leading away at least one non-fabric-forming warp yarn. Preferably the number of hook-shaped or eye-shaped elements corresponds to the number of non-fabric-forming warp yarns. More particularly the hook-shaped or eye-shaped elements are installed slidably. Obviously other embodiments that fulfil a similar function, such as e.g. slot-containing or groove-containing elements, are also within the scope of protection of the present invention.
Alternatively or additionally, the yarn removal device comprises a diverting channel with an open structure suitable for leading away the non-fabric-forming warp yarns.
According to a more preferred embodiment of the weaving machine according to the invention the yarn removal device leads the non-fabric-forming warp yarns away in the direction of a collecting point, where the non-fabric-forming warp yarns are collected together and are then led away further in a group. Preferably the weaving machine comprises several collecting points over its width.
In a particular embodiment of the weaving machine according to the invention the weaving machine comprises a lower bridge over which a formed fabric is led away in the direction of a cutting device, wherein the yarn removal device is provided against the lower bridge. Preferably the yarn removal device is provided against the underside of the lower bridge and the non-fabric-forming warp yarns are led away under the lower bridge. More particularly the weaving machine also comprises an upper bridge wherein in this case the formed fabric is led away between the lower bridge and the upper bridge in the direction of the cutting device.
The terms upper bridge and lower bridge are used in this patent application to refer to the cross beams which are secured above and below the fabric over the weaving width of the machine, and serve for guiding the fabrics in the direction of a cutting knife. The space between the upper bridge and the lower bridge may be designated with the term "jaw".
The weaving machine according to the present invention is preferably a single-face weaving machine with one, two or three rapiers. In another preferred embodiment the weaving machine is a face-a-face weaving machine with one, two or three rapiers.
The weaving machine according to the invention is suitable in particular for forming fabrics that have a handmade appearance.
In a more particular embodiment of the weaving machine according to the invention, the weft insertion device is provided with at least one top rapier and one bottom rapier in order to insert a respective weft yarn along a top and a bottom insertion path, respectively, and wherein the non-fabric-forming warp yarns support the bottom rapier.
The present invention further relates to a method for forming fabrics consisting of weft yarns, ground-warp yarns and pile-warp yarns, wherein, in successive operating cycles, one or more sheds are formed by means of shed-forming means through the positioning of warp yarns and wherein, in successive operating cycles, one or more weft yarns are inserted in a shed between fabric-forming warp yarns and non-fabric-forming warp yarns via a weft insertion device with at least one rapier, wherein during the inserting of a weft yarn the non-fabric-forming warp yarns support a rapier and wherein in each operating cycle, by means of to and fro movements of a reed during beating-up, the inserted weft yarns are pushed against the fabric line of the fabrics formed by the weft yarns and the fabric-forming warp yarns, wherein the non-fabric-forming warp yarns are separated from the fabric-forming warp yarns before the fabric line so that the non-fabric-forming warp yarns are not located between the beaten-up fabric(s). With such a method it is possible to manufacture fabrics, especially fabrics that have a handmade appearance, with a clean back because the non-fabric-forming warp yarns are not located between the beaten-up fabric(s) and consequently do not have any disturbing effect on the position of the pile on the back of the carpet.
In a preferred method according to the invention the non-fabric-forming warp yarns are led away via hook-shaped or eye-shaped elements and/or via a diverting channel with an open structure. In a more particular method according to the invention the non-fabric-forming warp yarns are led away in the direction of a collecting point, where the non-fabric-forming warp yarns are collected together and are then led away further in a group.
The method according to the present invention is suitable in particular for being applied on the weaving machine according to the invention as described above.
The present invention is now explained in more detail on the basis of the detailed description given hereunder of a weaving machine according to the invention and a method for weaving fabrics with a handmade appearance on such a weaving machine. The purpose of this description is exclusively to give an explanatory example and to indicate further advantages and features of the present invention, and so should not be interpreted in any way as a limitation of the field of application of the invention or of the patent rights claimed in the claims.
In this detailed description, the appended drawings are referred to by means of reference numbers, wherein:

Fig. 1 : schematic representation of the situation at the level of the lower bridge of a weaving machine on which a fabric with handmade appearance is woven according to the prior art, in particular the positioning of the weft and the non-fabric-forming warp yarns;
Fig. 2 : is a sectional view along line A-A in Fig. 1 ;
Fig. 3 : is a schematic representation of the path of the supporting yarns according to the prior art;
Fig. 4 : schematic representation of the situation at the level of the lower bridge of a weaving machine on which a fabric with handmade appearance is woven according to the invention, in particular the positioning of the weft and the non-fabric-forming warp yarns;
Fig. 5 : is a sectional view along line A-A in Fig. 1 ;
Fig. 6 : is a schematic representation of the path of the supporting yarns according to the invention, in which the position of the reed movable to and fro can be seen in its first position and its second position at the level of the beat-up;
Fig. 7 : is a cross-section of the lower bridge with the yarn removal device;
Fig. 8 : is a representation of the lower bridge (dotted line) against which the yarn removal device is fastened, in which the path of the supporting yarns is illustrated according to the viewing direction K1 as indicated in Fig. 7 ;
Fig. 9 : shows a view of the lower bridge against which the yarn removal device is provided, viewed according to the viewing direction K2 as indicated in Fig. 7 ;
Fig. 10 : is a representation of the device shown in Fig. 8 but without a lower bridge.

The weaving machine according to the present invention is suitable for the manufacture of fabrics (1), preferably fabrics (1) that have a handmade appearance, and that consist of weft yarns, ground-warp yarns and pile-warp yarns (2). The weaving machine comprises:

shed-forming means (5) provided for forming one or more sheds in successive operating cycles through the positioning of warp yarns;
a weft insertion device with at least one rapier (9) provided for inserting, in successive operating cycles, one or more weft yarns in a shed between fabric-forming warp yarns and non-fabric-forming warp yarns (3), wherein during the inserting of a weft yarn the non-fabric-forming warp yarns (3) support a rapier (9); and
a reed (6) provided for pushing, in each operating cycle, by means of to and fro movements during beating-up, the inserted weft yarns against the fabric line of the fabrics formed by the weft yarns and the fabric-forming warp yarns.

The weaving machine according to the present invention provides additional support of the rapiers (9) of the weft insertion device during their motion through the shed, so that in the middle of the shed there is accurate positioning of the giver rapier relative to the taker rapier.
In order to achieve this additional support, the weaving machine according to the present invention is equipped with a yarn removal device (4) for leading away, as shown inter alia in Fig. 6, the non-fabric-forming warp yarns (3), wherein this yarn removal device (4) separates the non-fabric-forming warp yarns (3) from the fabric-forming warp yarns before the fabric line, so that the non-fabric-forming warp yarns (3) are not located between the beaten-up fabric(s). In practice, the yarn removal device (4) is provided (see Figs. 7 and 8) against the underside of the lower bridge (7) so that the non-fabric-forming warp yarns (3) are diverted under the lower bridge (7).
By providing the additional support in this way, it is possible to manufacture fabrics with a handmade appearance, which have a clean back, because the non-fabric-forming warp yarns (3) no longer form part of the beaten-up whole, so that they are not located between the beaten-up fabric(s), which was the case in the prior art because these non-fabric-forming warp yarns (3) passed through the jaw, as illustrated in Fig. 3.
In order to separate the non-fabric-forming warp yarns (3) from the fabric-forming warp yarns before the fabric line, the yarn removal device (4) comprises a number of hook-shaped or eye-shaped elements, each being provided for leading away at least one non-fabric-forming warp yarn (3). The number of hook-shaped or eye-shaped elements preferably corresponds to the number of non-fabric-forming warp yarns (3). The hook-shaped or eye-shaped elements may be installed slidably, so that they can be moved if necessary. In place of or in addition to the hook-shaped or eye-shaped elements, as can be seen from Figs. 8 to 10, it is also possible to use a diverting channel (8) with an open structure for diverting the non-fabric-forming warp yarns (3).
Just like the fabric-forming warp yarns, the non-fabric-forming warp yarns (3) are applied by the reed (6) in the openings between the reed dents. They are located at regular distances at the bottom through an opening between two reed dents. A non-fabric-forming warp yarn (3) is not applied in each opening. During beating-up by the reed (6) it is important that they do not come into contact with a reed dent, to prevent yarn breakage. Accurate positioning of the non-fabric-forming warp yarns (3) is required at the level of the yarn removal device (4) to obtain a correct yarn path so that contact with a reed dent is avoided during the complete reed motion during beating-up. Because the hook-shaped or eye-shaped elements are movable sideways, an accurate rectilinear path of the non-fabric-forming warp yarns (3) can be established. The diverting channel (8) with open structure, as shown in Figs. 8 to 10, is also movable sideways.
By separating the non-fabric-forming warp yarns (3), which form a supporting or guiding surface for the rapiers during their motion through the shed, from the fabric-forming warp yarns before the fabric line, these non-fabric-forming warp yarns (3) may, as shown schematically in Fig. 6, be led away under the jaw, in the direction of a collecting point (V) where the non-fabric-forming warp yarns (3) are collected together and are then led away further in a group. Several of such collecting points may be provided over the width of the weaving machine.

Claims

Weaving machine for forming fabrics (1) consisting of weft yarns, ground-warp yarns and pile-warp yarns (2), comprising:
- shed-forming means (5) provided for forming one or more sheds in successive operating cycles through the positioning of warp yarns;

- a weft insertion device with at least one rapier (9) provided for inserting, in successive operating cycles, one or more weft yarns in a shed between fabric-forming warp yarns and non-fabric-forming warp yarns (3), wherein during the inserting of a weft yarn the non-fabric-forming warp yarns (3) support a rapier (9);

- a reed (6) provided for pushing, in each operating cycle, by means of to and fro movements during beating-up , the inserted weft yarns against the fabric line of the fabrics formed by the weft yarns and the fabric-forming warp yarns;
characterized in that the weaving machine further comprises a yarn removal device (4) for leading away the non-fabric-forming warp yarns (3), wherein this yarn removal device (4) separates the non-fabric-forming warp yarns (3) from the fabric-forming warp yarns before the fabric line so that the non-fabric-forming warp yarns (3) are not located between the beaten-up fabric(s).
Weaving machine according to Claim 1, characterized in that the yarn removal device (4) comprises a number of hook-shaped or eye-shaped elements, wherein each hook-shaped or eye-shaped element is provided for leading away at least one non-fabric-forming warp yarn (3).
Weaving machine according to Claim 2, characterized in that the number of hook-shaped or eye-shaped elements corresponds to the number of non-fabric-forming warp yarns (3).
Weaving machine according to Claim 2 or 3, characterized in that the hook-shaped or eye-shaped elements are installed slidably.
Weaving machine according to one of the preceding claims, characterized in that the yarn removal device (4) comprises a diverting channel with an open structure (8) suitable for leading away the non-fabric-forming warp yarns (3).
Weaving machine according to one of the preceding claims, characterized in that the yarn removal device (4) leads away the non-fabric-forming warp yarns (3) in the direction of a collecting point (V), where the non-fabric-forming warp yarns (3) are collected together and are then led away further in a group.
Weaving machine according to Claim 6, characterized in that the weaving machine comprises several collecting points (V) over its width.
Weaving machine according to one of the preceding claims, characterized in that the weaving machine comprises a lower bridge (7), over which a formed fabric is led away in the direction of a cutting device, wherein the yarn removal device (4) is provided against the lower bridge (7).
Weaving machine according to Claim 8, characterized in that the yarn removal device (4) is provided against the underside of the lower bridge (7) and in that the non-fabric-forming warp yarns (3) are diverted under the lower bridge (7).
Weaving machine according to one of the preceding claims, characterized in that the weaving machine is a single-face weaving machine with one, two or three rapiers (9).
Weaving machine according to one of Claims 1 to 9, characterized in that the weaving machine is a face-a-face weaving machine with one, two or three rapiers (9).
Weaving machine according to one of the preceding claims, characterized in that the weft insertion device is provided with at least one top and bottom rapier in order to insert a respective weft yarn along an upper and a lower insertion path, respectively, and in that the non-fabric-forming warp yarns (3) support the bottom rapier (9).
Method for forming fabrics consisting of weft yarns, ground-warp yarns and pile-warp yarns (2), wherein in successive operating cycles, by means of shed-forming means (5), one or more sheds are formed through the positioning of warp yarns and wherein in successive operating cycles, via a weft insertion device with at least one rapier (9), one or more weft yarns are inserted into a shed between fabric-forming warp yarns and non-fabric-forming warp yarns (3), wherein during the inserting of a weft yarn the non-fabric-forming warp yarns (3) support a rapier (9) and wherein the inserted weft yarns are pushed, in each operating cycle, by means of to and fro movements of a reed (6) during beating-up, against the fabric line of the fabrics formed by the weft yarns and the fabric-forming warp yarns, characterized in that the non-fabric-forming warp yarns (3) are separated from the fabric-forming warp yarns before the fabric line, so that the non-fabric-forming warp yarns (3) are not located between the beaten-up fabric(s).
Method according to Claim 13, characterized in that the non-fabric-forming warp yarns (3) are diverted via hook-shaped or eye-shaped elements and/or via a diverting channel with an open structure (8).
Method according to Claim 13 or 14, characterized in that the non-fabric-forming warp yarns (3) are diverted in the direction of a collecting point (V), where the non-fabric-forming warp yarns (3) are collected together and are then led away further in a group.