GB2321258A - Preparing warp threads for weaving - Google Patents

Abstract

A set of warp threads (10) from spools (11) on a creel are wound as a warp section on a drum (15). Leasing cords are inserted on either side of a crossing between the warp threads at the inner ends adjacent the drum and again at their outer ends after the section has been wound. Futher sections are wound and leased in the same way, the creel and a leasing reed (16) being displaced axially of the drum in the process, and when the drum is fully wound its threads are transferred to a beam for weaving. The threads may be waxed as they are wound and may be sprayed with lubricant to facilitate piecing up.

Description

"A weaving process" This invention is concerned with the weaving of high quality cloth, and in particular with the weaving of cloth in multi-coloured designs.

According to the invention there is provided a weaving process, comprising the steps: leading a set of selected warp threads from associated warp thread spools rotatably mounted on a creel, passing the set of warp threads through a leasing reed and attaching a free end of the set of warp threads to a warping drum, separating the threads in the set of the warp threads into two complementary rows of threads, inserting a first inner leasing cord between the two rows of threads, crossing the rows of thread behind the first inner leasing cord, inserting a second inner leasing cord between the two rows of warp threads, reeling the set of warp threads on to the warp drum forming a first warp section of a desired length on the warp drum, separating the threads in the set of warp threads into two complementary rows of threads, inserting a first outer leasing cord between the two rows of threads, crossing the two rows of threads behind the first outer leasing cord, inserting a second outer leasing cord between the two rows of warp threads, cutting the set of warp threads downstream of the second outer leasing cord, securing the free outer ends of the set of warp threads on the warp drum thus securing the wound warp thread set on the drum, building up a number of juxtaposed wound warp thread sets on the warp drum in like manner using the same inner and outer leasing cords at inner and outer ends of each set of warp threads on the warp drum, spooling the associated sets of warp threads from the warp drum together onto a beam, supporting the beam at an inlet end of the loom, aligning the warp threads and delivering the warp threads through the loom in a desired orientation, inserting weft threads between the warp threads in the loom for weaving a cloth, reeling the cloth on the loom, removing the cloth from the loom and inspecting the cloth.

In one embodiment the process includes the step of moving the creel in a direction parallel to the axis of the warp drum for delivering the warp threads along a desired path between the creel and the warp drum.

In another embodiment the process includes the step of waxing the warp threads as they are being delivered from the beam on the loom.

In a further embodiment the process includes waxing the warp threads by drawing the warp threads over a wax rod.

In another embodiment the process includes the step of waxing the warp threads as they are being delivered between the warp drum and the beam by leading the warp threads over a rotating waxing roller rotatably mounted in a liquid wax bath, controlling the speed of rotation of the roller for regulating deposition of wax on the warp threads.

In a further embodiment the process includes the step of spraying the warp threads with a lubricant during the knotting-in of warp threads on the loom.

The invention will be more clearly understood by the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which; Fig 1 is a plan schematic view of a weaving process and apparatus according to the invention; Fig 2 is a detail side elevational view of portion of the apparatus; Fig 3 is an end elevational view of a creel forming portion of the apparatus; Fig 4 is a detail perspective view of a creel position controller forming portion of the apparatus; Fig 5 is a perspective view showing another portion of the creel position controller; Fig 6 is an elevational view of a warp drum used in the process; Fig 7 is a detail perspective view showing portion of the warp drum; Fig 8 is a detail perspective view showing the arrangement of leasing cords used with the warp threads; Fig 9 is a detail sectional elevational view of thread waxing apparatus used in the process; Fig 10 is an end elevational view of a loom used in the process; Fig 11 is a perspective view illustrating the knotting-in of warp threads at an inlet of the loom; and Fig 12 is a perspective view illustrating arrangement of the warp threads during the knotting-in process.

Referring to the drawings a process and apparatus for weaving a cloth according to the invention will be described.

A set of selected warp threads 10 are led from associated warp thread spools 11 which are rotatably mounted on a creel 12. The creel 12 is mounted between a pair of tracks 13. A motor 14 (Fig 3) is operable to drive the creel 12 along the tracks 13 in a direction parallel to the axis of a warp drum 15.

The warp threads 10 are delivered through a leasing reed 16 and wound up on the warp drum 15. The leasing reed 16 is mounted on a wheeled carriage 17 which is connected to a sliding bed 18 in front of the warp drum 15 for feeding the warp threads 10 generally perpendicularly onto the warp drum 15.

A creel drive controller 20 is connected by a swinging arm 22 with the carriage 17 so that as the carriage 17 moves along the warp drum 15 the arm 22 is deflected and the controller 20 operates the motor 14 to move the creel 12 along the tracks 13 to center the arm 22 and then the motor 14 is cut-out. This ensures that the warp threads are fed from the creel 12 at a relatively shallow angle to the leasing reed 16 thus preventing undue strain on the threads as they are delivered from the spools 11 and thereby minimising breakages.

A free end of the set of warp threads 10 is attached to the warp drum 15. Then the threads are separated into two complementary rows of threads 25, 26 (Fig 8). A first inner leasing cord 27 is inserted between the two rows 25, 26 of threads. Then the rows 25, 26 of threads are crossed over behind the first inner leasing cord 27. A second inner leasing cord 28 is inserted between the two rows of warp threads. The set of warp threads 10 are then reeled onto the warp drum 15 forming a first warp section of a desired length on the warp drum 15. Then the threads are separated again into the two rows 25, 26 of threads and a pair of outer leasing cords are inserted between the two rows of threads which cross over between the two outer leasing cords as previously described for the inner leasing cords. Then the set of warp threads 10 are cut away downstream of the second outer leasing cords and the free outer end of the set of warp threads 10 is secured on the drum 15.

The slide 18 is then moved sideways and a second warp thread set is wound in similar fashion on the drum 15. In this way a number of juxtaposed wound warp thread sets are built up along the warp drum 15 using the same inner and outer leasing cords. It will be noted that leasing cords are provided at both inner ends and outer ends of the threads and this double leasing arrangement has a number of advantages, described later.

The associated sets of warp threads are then spooled from the warp drum 15 onto a beam 30. Optionally the warp threads 10 may be led over a rotating waxing roller 32 (Fig 9) which is rotatably mounted in a liquid wax bath 33. The speed of rotation of the roller 32 is controlled for regulating the amount of wax deposited on the warp threads 10 as they are delivered between the warp drum 15 and the beam 30. A reservoir of liquid wax is provided by an inverted bottle 35 of liquid wax 36 which has a dispensing outlet 37 within the wax bath 33.

As the level of the wax in the bath 33 drops the lower end of the outlet 37 is uncovered allowing air into the bottle 35 and thus liquid wax 36 is discharged from the bottle 35 until the liquid wax in the bath 33 covers the outlet 37. This advantageously provides a simple and effective way of regulating the wax level within the wax bath 33.

The beam 30 is then supported at an inlet end of a loom 40 and the warp threads 10 from the beam 30 are drawn from the beam 30 and aligned and knotted-in with warp threads 42 from the tail end of a beam already mounted in the loom 40 to correctly deliver the warp threads 10 through the loom 40 for weaving. It will be appreciated that the leasing cord at the tail end of the used beam and the leasing cord at the leading end of the new beam are necessary to facilitate the rapid alignment of the threads on the two beams for correct alignment and orientation of the threads on the new beam 30 for delivery through the loom 40. Once the threads 10 have been correctly aligned the leasing cord 27 (Fig 12) can be removed and a leasing rod 45 inserted in place of the leasing cord 27 to facilitate manipulation of the warp threads 10. Once the warp threads from both beams are correctly aligned they can be knotted together for example by an automatic knotting machine 47 which is run across the rows of warp threads knotting each associated pair of warp threads. If desired a lubricant may be sprayed onto the warp threads during the knotting-in process to render the threads more supple and thus minimise breakages.

Once correctly knotted-in the warp threads are fed through the loom 40 and in the loom 40 weft threads are delivered between the warp threads in conventional fashion for weaving a cloth which is wound-up on a cloth beam 48 at an outlet end of the loom 40. If desired the warp threads may be waxed as they are drawn from the beam prior to passage through the loom. This can simply be achieved by resting a wax rod along the warp threads where they are drawn from the beam. This waxing helps minimise breakages especially, when handling relatively dry threads.

The cloth can be inspected and repaired as necessary. Any suitable finish may subsequently be applied to the cloth.

It will be appreciated that the double-leasing arrangement of the warp threads has a number of advantages. When changing over jobs on a loom, the leading ends of the warp threads on a new beam are knottedin to the trailing ends of the warp threads on the loom. Typically, 1,500 - 2,500 threads may have to be joined. Generally weavers provide a single leasing cord at a leading end of the threads on the new beam for ease of separation of the threads for knotting-in. The tail end of the warp threads on the loom can be separated by manipulation of the loom for alignment with the new warp threads, however this is somewhat laborious. The present invention provides a second leasing cord at a tail end of the warp threads also, so this can be used rather than the loom to separate the old warp threads on the loom for alignment with the new warp threads on the beam.

Separation and alignment of the warp threads is made quicker and easier due to the double leasing feature of the present invention. It will be appreciated that correct alignment of the threads is particularly critical for high quality multi-coloured designs. If the threads are not fed through the loom in the correct order then this would change the design or pattern woven in the cloth. The double leasing feature facilitates relatively quick set-up of the new beam on a loom with accurate alignment of the threads in the loom.

A further advantage of the double leasing feature is that it allows knotting-in to be carried out outside a loom. This is particularly advantageous when producing a number of smaller lengths of cloth of different designs. For example, the warp threads for producing eight different designs may be tied end to end and reeled on a single beam for feeding in one pass through the loom rather than having the warp threads for each design on separate beams and carrying out eight change-overs with consequent loom down time. Because both ends of the warp threads have the leasing cords, they can be easily separated and aligned and knotted and joined together in a single continuous set of threads. Therefore, there is only one change-over on the loom for producing eight pieces of cloth rather than eight change-overs. Thus the invention allows the loom to be used more efficiently with less down time.

A further advantage of the double leasing feature is that in some cases there is a need to re-beam warp threads prior to mounting the beam on a loom. This can be done in a single pass with the double leasing feature of the present invention as there is a lease cord at each end of the warp threads. If a single leasing cord is used then a double pass would be required to re-beam the warp threads while maintaining the single leasing cord outer most on the beam.

The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail.

Claims (8)

1. A weaving process, comprising the steps: leading a set of selected warp threads from associated warp thread spools rotatably mounted on a creel, passing the set of warp threads through a leasing reed and attaching a free end of the set of warp threads to a warping drum, separating the threads in the set of the warp threads into two complementary rows of threads, inserting a first inner leasing cord between the two rows of threads, crossing the rows of thread behind the first inner leasing cord, inserting a second inner leasing cord between the two rows of warp threads, reeling the set of warp threads on to the warp drum forming a first warp section of a desired length on the warp drum, separating the threads in the set of warp threads into two complementary rows of threads, inserting a first outer leasing cord between the two rows of threads, crossing the two rows of threads behind the first outer leasing cord, inserting a second outer leasing cord between the two rows of warp threads, cutting the set of warp threads downstream of the second outer leasing cord, securing the free outer ends of the set of warp threads on the warp drum thus securing the wound warp thread set on the drum, building up a number of juxtaposed wound warp thread sets on the warp drum in like manner using the same inner and outer leasing cords at inner and outer ends of each set of warp threads on the warp drum, spooling the associated sets of warp threads from the warp drum together onto a beam, supporting the beam at an inlet end of the loom, aligning the warp threads and delivering the warp threads through the loom in a desired orientation, inserting weft threads between the warp threads in the loom for weaving a cloth, reeling the cloth on the loom, removing the cloth from the loom and inspecting the cloth.

2. A process as claimed in claim 1 wherein the process includes the step of moving the creel in a direction parallel to the axis of the warp drum for delivering the warp threads along a desired path between the creel and the warp drum.

3. A process as claimed in claim 1 or 2 wherein the process includes the step of waxing the warp threads as they are being delivered from the beam on the loom.

4. A process as claimed in claim 3 wherein the process includes waxing the warp threads by drawing the warp threads over a wax rod.

5. A process as claimed in any preceding claim wherein the process includes the step of waxing the warp threads as they are being delivered between the warp drum and the beam by leading the warp threads over a rotating waxing roller rotatably mounted in a liquid wax bath, controlling the speed of rotation of the roller for regulating deposition of wax on the warp threads.

6. A process as claimed in any preceding claim wherein the process includes the step of spraying the warp threads with a lubricant during the knotting-in of warp threads on the loom.

7. A weaving process substantially as hereinbefore described with reference to the accompanying drawings.

8. A cloth whenever produced according to the process as claimed in any preceding claim.