A special organizing weaving method
By optimizing the relationship between the heddle and the reed, the problems of warp slippage and reverse loop lifting were solved, achieving high-quality and efficient special ground warp weaving, and improving the surface effect and production efficiency of yarn-dyed towels.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SUNVIM GROUP
- Filing Date
- 2026-03-12
- Publication Date
- 2026-06-19
AI Technical Summary
In traditional weaving methods, the warp threads of specially woven products are prone to slippage during the weaving process, leading to problems such as loop retraction and tufting, which affect product quality and reduce production efficiency.
An optimized heddle-cutting and reed-threading relationship is adopted to ensure that each hair warp is held by the ground warp. The heddle is cut in a cyclical sequence of 1 hair warp, 1 hair warp, 1 ground warp, and the hair warp is distributed into different reed teeth during reed-threading to ensure that each hair warp is held by the ground warp, thus forming a stable hair warp position.
It effectively prevents the slippage of the nap, significantly reduces the number of loops and tufts, improves product quality and production efficiency, and ensures the cleanliness and flatness of solid-color areas on the fabric surface.
Smart Images
Figure CN122235888A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a special warp weaving method, belonging to the field of textile technology. Background Technology
[0002] Yarn-dyed towels are popular due to their rich patterns, vibrant colors, and strong three-dimensional textures. To achieve a richer visual effect, these products often incorporate different shapes of recessed pile structures into ordinary terry patterns. These recessed pile areas are required to display a solid color where the ground warp and weft yarns interweave, while the pile warp needs to form a full loop on the reverse side of the fabric and not participate in the interweaving on the front side.
[0003] When weaving products with a special ground warp structure (concave pile structure), traditional methods typically employ a double-pile, double-ground heddle method. This involves threading the heddles in a cyclical sequence of two pile warps and two ground warps, with the two pile warps threaded into the same reed tooth and the two ground warps into another. While this method can alleviate fabric tangling to some extent, it introduces new drawbacks: because the two pile warps within the same reed tooth lack direct clamping and constraint from the ground warps, they are prone to relative slippage and positional instability during weaving. Simultaneously, in the concave pile section, the pile warps, having not participated in the front weaving for extended periods, become loose and easily bulge on the fabric surface, forming pile loops, or even be accidentally lifted to form reverse loops, severely impacting the product's appearance quality. To address these issues, production often necessitates measures such as reducing loop height and loom speed, resulting in low production efficiency and failing to completely eliminate quality problems, frequently requiring manual repairs, increasing costs and uncertainty.
[0004] Therefore, there is an urgent need in this field for a new weaving method to fundamentally solve the problems of warp slippage, loop lifting, and yarn shedding in products with special warp weaves, so as to improve product quality while ensuring production efficiency. Summary of the Invention
[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a special ground warp weaving method. This method optimizes the cooperation between the heddle and the reed, so that each warp can be effectively clamped by the ground warp, thereby stabilizing the warp position, preventing slippage, and significantly reducing the phenomenon of reverse lifting loops and tufts at the concave pile, thus improving product quality and weaving efficiency.
[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a special method for warp weaving, the method comprising the following steps: S1. Provides warp, weft, and yarn; S2. Perform the digging in a cyclical order of 1 mao, 1 mao, 1 di, 1 di; S3. Thread the reed in the following manner: Thread the first hair thread into a first reed tooth alone, then thread the second hair thread, the first ground thread, and the second ground thread together into a second reed tooth. The second reed tooth contains two ground threads and one hair thread. The second hair thread in the second reed tooth is paired with and held by one of the first or second ground threads. The first hair thread in the first reed tooth is paired with and held by another ground thread in an adjacent reed tooth, so that each hair thread is held and reinforced by a ground thread.
[0007] As a further improvement of the present invention, the method is applicable to fabrics with a square weight of 320-450 g / m².
[0008] As a further improvement of the present invention, the loop height of the fabric woven by the method is 0.85-1.0 cm.
[0009] As a further improvement of the present invention, the fabric is a yarn-dyed jacquard towel, the concave part of the fabric is a plain fabric structure formed by the interlacing of ground warp and weft yarns, and the pile warp of the concave part forms a full-fall loop on the reverse side of the fabric.
[0010] As a further improvement of the present invention, the yarn count of the warp is 20s / 1.
[0011] As a further improvement of the present invention, the yarn count of the ground warp is 32s / 2.
[0012] As a further improvement of the present invention, the weft yarn count is 20s / 1.
[0013] As a further improvement of the present invention, the weft density of the fabric is 45-52 threads / 2.54cm.
[0014] Compared with the prior art, the present invention has at least the following beneficial effects: This invention uses an innovative reed threading method to "physically isolate" two hair threads that are prone to slippage within the same reed tooth, and ensures that each hair thread has a dedicated ground thread to clamp and fix it within the reed tooth or between adjacent reed teeth, greatly enhancing the lateral stability of the hair thread and fundamentally solving the slippage problem.
[0015] The stable position of the bobbin in this invention, combined with the improvement effect of the original double bobbin and double ground heddle on the fabric surface reverse twisting, makes it less likely for the loose bobbin to bulge and form bobbles or be accidentally snagged by the weft yarn in the concave bobbin structure. This significantly reduces the occurrence rate of reverse bobbin loops and bobbles, and improves the cleanliness and smoothness of the solid color area of the fabric surface.
[0016] Because the quality of this invention is fundamentally improved, there is no need to excessively reduce the loop height or loom speed in order to avoid defects, allowing production to be carried out under more optimized process parameters.
[0017] This invention provides preferred ranges for applicable fabric weight per square meter, loop height, yarn count configuration, and weft density, offering clear and feasible process guidance for the application of this technology in specific high-quality yarn-dyed jacquard towel products. Attached Figure Description
[0018] Figure 1 This is a warp weave diagram of the special warp weave method of this invention; Figure 2 This is a warp weave diagram of the specific warp weave method of this invention; Figure 3 This is a schematic diagram of the heddle and reed threading in the traditional double-wool double-ground weaving method in the existing technology; Figure 4 This is a schematic diagram of the heddle threading and reed threading in the special warp weaving method of this invention; Figure 5 This is a schematic diagram of the fabric surface effect of a product woven using existing technology (before improvement); Figure 6 This is a schematic diagram of the fabric surface effect (after improvement) of a product woven using the method of this invention.
[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. Detailed Implementation
[0020] Example 1: The core of this invention lies in combining a specific warp threading sequence with an innovative reed threading method to construct a new warp yarn configuration pattern. This example provides a special warp weaving method, which includes the following steps: S1. Provides warp, weft, and yarn; S2. Perform the digging in a cyclical order of 1 mao, 1 mao, 1 di, 1 di; S3. Thread the reed in the following manner: Thread the first hair thread into a first reed tooth alone, then thread the second hair thread, the first ground thread, and the second ground thread together into a second reed tooth. The second reed tooth contains two ground threads and one hair thread. The second hair thread in the second reed tooth is paired with and held by one of the first or second ground threads. The first hair thread in the first reed tooth is paired with and held by another ground thread in an adjacent reed tooth, so that each hair thread is held and reinforced by a ground thread.
[0021] Example 2: The specific implementation of the special warp weaving method in this example is as follows: First, prepare the warp and weft yarns required for weaving. The warp system includes the pile warp and the ground warp. In this embodiment, the pile warp uses yarn with a count of 20s / 1, the ground warp uses yarn with a count of 32s / 2, and the weft yarn uses yarn with a count of 20s / 1.
[0022] Next, the heddle threading process is carried out. Heddle threading employs a "two-ply, two-ground" heddle loop, meaning the warp yarns are threaded into the heddles in a fixed sequence: one ply warp, then another ply warp, then one ground warp, then another ground warp (1 ply, 1 ply, 1 ground). This sequence is consistent with the traditional double-ply, double-ground heddle loop method, and its main function is to optimize the warp yarn opening sequence and improve the reverse twisting problem that may be caused by uneven interlacing points on the fabric's surface.
[0023] Next comes the crucial reed-threading process, which no longer follows the traditional simple rule of "two hairs threading through one reed tooth, two hairs threading through one reed tooth." The specific operation is as follows: Insert the first hair thread (denoted as hair thread A) in the heddle sequence into the first reed tooth (reed tooth 1) separately.
[0024] The three warp threads—the second hair warp (hair warp B), the first ground warp (ground warp A), and the second ground warp (ground warp B)—are all threaded into the adjacent second reed tooth (reed tooth 2). Therefore, reed tooth 2 contains "1 hair (B), 1 ground (A), 1 ground (B)," that is, a structure in which two ground warp threads sandwich one hair warp thread.
[0025] This reed threading pattern (1 warp threaded alone; 1 warp threaded together with 2 ground threads) is combined with the aforementioned heddle-cutting pattern (1 warp, 1 warp, 1 ground, 1 ground) and repeated until all warp yarns are threaded.
[0026] Through this reed-threading method, two reed warps that were originally located on the same reed tooth in the traditional method (such as warp A and warp B within the same reed tooth) are separated into two adjacent reed teeth. For warp B within reed tooth 2, it is directly held by the inner warp A and the outer warp B within the same reed tooth. For warp A, which is "single" within reed tooth 1, there must be an outer warp within the adjacent reed tooth (the preceding or following reed tooth following the same reed-threading pattern) that provides effective lateral constraint and holding. This achieves the technical effect of "ensuring that each warp warp is held by an outer warp," firmly locking the lateral position of each warp warp.
[0027] Finally, the fabric is woven on the loom according to the set fabric structure (i.e., the ground warp and weft yarns interweave to form a plain weave at the napped area, and the pile warp forms loops on the reverse side) and process parameters.
[0028] Preferred process parameters in this embodiment include: fabric weight per square meter controlled at 320-450 g / m², loop height set between 0.85-1.0 cm, and weft density controlled at 45-52 ends / 2.54 cm.
[0029] These parameters, combined with this innovative warp configuration, enable yarn-dyed jacquard towels to achieve optimal surface quality and physical properties while showcasing a solid color effect.
[0030] Figure 5 This indicates the adoption Figure 3 Products woven using traditional methods may exhibit unevenness in their solid-color areas due to tufts, reverse loops, and slippage of the yarn. Figure 6 This illustrates the method of the present invention ( Figure 4 Products woven with these fibers have a smoother, cleaner surface, especially in the napped areas, with a more uniform color and no of the aforementioned defects.
[0031] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in this invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of this invention.
Claims
1. A special method for weaving warp-structured fabrics, characterized in that, The method includes the following steps: S1. Provides warp, weft, and yarn; S2. Perform the digging in a cyclical order of 1 mao, 1 mao, 1 di, 1 di; S3. Thread the reed in the following manner: Thread the first hair thread into a first reed tooth alone, then thread the second hair thread, the first ground thread, and the second ground thread together into a second reed tooth. The second reed tooth contains two ground threads and one hair thread. The second hair thread in the second reed tooth is paired with and held by one of the first or second ground threads. The first hair thread in the first reed tooth is paired with and held by another ground thread in an adjacent reed tooth, so that each hair thread is held and reinforced by a ground thread.
2. The special warp weaving method according to claim 1, characterized in that, The method is applicable to fabrics with a weight per square meter of 320-450 g / m².
3. The special warp weaving method according to claim 1, characterized in that, The fabric woven by the method has a loop height of 0.85-1.0 cm.
4. The special warp weaving method according to claim 1, characterized in that, The fabric is a yarn-dyed jacquard towel. The concave part of the fabric is a solid-color plain weave structure formed by the interlacing of ground warp and weft yarns, and the pile warp of the concave part forms a full-fall loop on the reverse side of the fabric.
5. The special warp weaving method according to claim 1, characterized in that, The yarn count of the warp is 20s / 1.
6. The special warp weaving method according to claim 1, characterized in that, The yarn count of the ground warp is 32s / 2.
7. The special warp weaving method according to claim 1, characterized in that, The weft yarn has a count of 20s / 1.
8. The special warp weaving method according to claim 1, characterized in that, The weft density of the fabric is 45-52 threads / 2.54cm.