A cleaning looped pile fabric without bottom and integrated weaving method thereof
By using a double-layer double-shed loom and slotted height plate technology, the warp cutting and weft three-dimensional coil forming of cleaning fabric are realized simultaneously, solving the problem of exposed bottom layer when cleaning fabric is dynamically bent, and providing efficient cleaning effect and structural stability.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- HAINING JIAZHE BRUSH CO LTD
- Filing Date
- 2026-04-29
- Publication Date
- 2026-07-03
AI Technical Summary
Existing cleaning fabrics are prone to showing the backing material when dynamically bent. Current technology cannot simultaneously generate independent, spatially orthogonal warp cut pile and weft three-dimensional loops in the same weaving cycle.
Using a double-layer double-shed loom, combined with a slotted height plate and a specially made rapier head, the warp and weft yarn systems are configured to achieve the synchronous formation of warp cutting and weft three-dimensional loops. The slot and stem structure of the slotted height plate is used to form orthogonal cutting and loop layers. The pile warp and weft yarns interweave and lock into loops. After the pile warp is cut, the cutting surface is formed.
It achieves a three-dimensional coverage network when bending, with cut pile providing fine polishing and initial dust capture, and weft loops providing extra-large dust holding space and hooking ability, resulting in excellent cleaning performance, a robust integrated structure, efficient and environmentally friendly production, high safety, and stable quality.
Smart Images
Figure CN122327445A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of textile weaving technology, and in particular to a non-exposed loop pile fabric for cleaning and its integrated weaving method. Background Technology
[0002] High-performance cleaning fabrics (such as wiping cloths, bathroom mats, and car interior cleaning wipes) need to maintain a continuous and dense surface fiber layer when cleaning complex curved surfaces and hard-to-reach corners, avoiding the exposure of the base fabric due to bending or lateral pressure (i.e., "exposed base"), which would lead to cleaning failure.
[0003] To achieve better cleaning results, existing technologies typically attempt to combine the delicacy of "fluff" with the three-dimensionality of "loops," but all of these technological approaches have fundamental limitations: 1. Warp structure combination technology (mainstream path): These technologies attempt to achieve the effect of "pile" and "loop" within the warp system, but are limited by the same warp yarn, and the two structures restrict each other and cannot be independent and full.
[0004] a. Long and short weft beating method: By controlling the weft beating process, what is obtained is actually a deformed form of "warp pile" and "warp loop", and the pile feel is not real and does not last.
[0005] b. Water-soluble yarn borrowing method: This method uses water-soluble yarn to help form larger warp loops, which need to be dissolved and removed in a later process. The process is cumbersome, not environmentally friendly, and still results in a single warp structure.
[0006] c. Grooved Height Plate Auxiliary Method: Although a grooved height plate is used, its grooves are used to place the "false weft" that needs to be removed later, in order to help form warp loops or pile. The essence of the product is still a combination of "warp-cut pile" and "warp-forming loops", the process is complex, and the structure does not break through the warp dimension.
[0007] 2. Post-processing composite technology: Pre-woven cut pile fabric is bonded to looped fabric through methods such as bonding and quilting. This method has drawbacks including a stiff feel, easy delamination, easy exposure of the base fabric at the joints, high cost, and environmental unfriendliness.
[0008] Summary of technical bottlenecks: Existing technologies cannot simultaneously generate independent, spatially orthogonal "warp-cut pile" and "weft-shaped three-dimensional loops" within the same weaving cycle. This is the deep-seated technical root cause of the persistent "backing material exposure" problem in existing clean fabrics under dynamic bending conditions. Summary of the Invention
[0009] The purpose of this invention is to provide a loop pile fabric for cleaning without exposing the bottom and its integrated weaving method. The advantages are that the loop pile fabric integrates real warp-cut pile and three-dimensional weft loops, solving the problem of the bottom being exposed when bending during cleaning from the structural source; the weaving method can achieve one-time synchronous forming of two orthogonal structures, eliminating the need for complex post-processing.
[0010] The above-mentioned technical objective of the present invention is achieved through the following technical solution: The present invention, in a first aspect, provides a method for integrally weaving a non-exposed loop pile fabric for cleaning, comprising the following steps: S1: Configure the warp and weft yarn system. The warp yarn system includes the ground warp: upper ground warp, lower ground warp, and pile warp; the weft yarn system includes the base fabric weft yarn: upper base fabric weft yarn, lower base fabric weft yarn, and loop weft yarn: upper loop weft yarn, lower loop weft yarn. S2: On a double-layer double-shed loom, a slotted height plate is arranged at the position for installing the height plate, and the length direction of the slot of the slotted height plate is parallel to the warp direction. The slotted height plate is located below the upper rapier and above the lower rapier on the double-layer double-shed loom. In addition, a middle rapier weft inserter is set between the upper and lower rapiers and can pass through the upper and lower stalks of the slotted height plate. S3: This causes the upper and lower ground warp threads to form independent sheds above and below the slotted height plate on the loom. S4: A) Weft insertion: The base fabric weft yarn and the starting loop weft yarn are inserted sequentially into the upper and lower sheds; the base fabric weft yarn and the starting loop weft yarn located in the same shed are inserted alternately into the shed where they are located, while the starting loop weft yarn is driven through the shed and through the groove of the slotted height plate by the rapier weft inserter. B) Changing the shed: The base fabric weft yarn and the loop weft yarn located in the same shed interweave with the ground warp of the shed where they are located. The ground warp presses down on the upper or lower loop weft yarn and closely adheres to the upper or lower stem of each slotted fixed-height piece, leaving loops. C) Loop Locking: The fabric is wound up and moved forward, but the loops of the starting weft yarn are "locked" by the upper or lower stalk of the slotted height plate and gradually withdrawn from the upper or lower stalk of the height plate, finally forming loops on the fabric surface. D) Continuous weaving: The base fabric weft yarns interweave with the ground warp to gradually form the upper and lower base fabrics. The loop weft yarns form loops on the base fabric under the support of the grooved height plate and the fixation of the ground warp. S5: While S4 is being performed, the pile warp moves back and forth between the upper and lower sheds. When the pile warp moves to a certain shed, it interweaves with the weft yarn in that shed. After interweaving for a while, it moves to another shed and interweaves with the weft yarn in that shed for a while. This cycle continues. The pile warp connects the upper and lower base fabrics. At the same time, the pile warp is fixed by the upper and lower base fabrics and temporarily separated by the slotted height plate to form a pre-pile. S6: Cutting pile: The cutting pile knife moves laterally along the groove of the slotted height plate to cut the pile warp surrounding the slotted height plate. The cut pile warp is locked at both ends by the upper and lower base fabrics respectively to form the cut pile surface.
[0011] Furthermore, the upper geodetic trajectories include: upper second geodetic trajectories, upper first geodetic trajectories, and upper third geodetic trajectories; the lower geodetic trajectories include: lower second geodetic trajectories, lower first geodetic trajectories, and lower third geodetic trajectories. In the upper shed, the upper first ground track and the upper third ground track are located on the same side of the upper shed, and the upper second ground track is located on the other side of the upper shed; In the lower shed, the lower first ground track and the lower third ground track are located on the same side of the lower shed, and the lower second ground track is located on the other side of the lower shed; Step B in S4 specifically includes: Weaving the upper loop: The first and third upper ground warps are located below the upper shed, and the second upper ground warp is located above the upper shed. The upper loop weft yarn is fed in by the rapier, and the first and third upper ground warps are lifted upward. The first and third upper ground warps pass through both sides of the upper stalk of the slotted height plate and press down on the upper loop weft yarn that passes through the slot of the slotted height plate by the weft inlet of the rapier, so that the upper loop weft yarn wraps around the upper stalk of the slotted height plate, leaving loops on the upper stalk. Weaving the lower layer loops: The first and third lower layer ground warps are located on the upper side of the lower layer shed, and the second lower layer ground warp is located on the lower side of the lower layer shed. After the lower layer starting weft yarn is inserted by the rapier, the first and third lower layer ground warps are lowered. The first and third lower layer ground warps pass through both sides of the lower stalk of the slotted height plate and press down on the lower layer starting weft yarn that passes through the slot of the slotted height plate using the rapier weft inserter, so that the lower layer starting weft yarn wraps around the lower stalk of the slotted height plate, leaving loops on the lower stalk.
[0012] Furthermore, the pile warp has two sets, which alternately move up and down between the upper and lower sheds. When one set of pile warp moves to the upper shed and interweaves with the weft yarn of the upper shed, the other set moves to the lower shed and interweaves with the weft yarn of the lower shed. After the two sets of pile warp interweave with the weft yarn of their respective layers for a period of time, the two sets of pile warp exchange layers and continue to interweave with the weft yarn of their respective layers. This cycle continues, and the two sets of pile warp connect the upper and lower base fabrics.
[0013] Furthermore, the pile warp includes a first pile warp and a second pile warp; In the integrated loop pile fabric weaving method, step S5 of one cycle specifically includes: a: Lift the first warp strand upwards and let the second warp strand sink downwards; b: Insert the first weft yarn into the upper and lower sheds respectively; c: Place the first warp in the middle, and the second warp in the middle; d: Insert the second shuttle weft yarn into the upper and lower sheds respectively; f: Lift the first warp upwards and let the second warp sink downwards; g: Insert the third shuttle weft yarn into the upper and lower sheds respectively; h: The first pile warp is lowered into the lower ground warp, and the second pile warp is raised into the upper ground warp. At this time, the first pile warp interweaves with the first, second and third weft yarns of the upper shed, and the second pile warp interweaves with the first, second and third weft yarns of the lower shed. i: Insert the fourth shuttle weft yarn into the upper and lower sheds respectively; j: Place the first pile warp in the middle, and the second pile warp in the middle; k: Insert the fifth shuttle weft yarn into the upper and lower sheds respectively; l: Sink the first warp and lift the second warp; m: The sixth weft yarn is inserted into the upper and lower sheds respectively. At this time, the first pile warp interweaves with the fourth, fifth and sixth weft yarns of the lower shed, and the second pile warp interweaves with the fourth, fifth and sixth weft yarns of the upper shed; and so on in a cyclical manner.
[0014] Furthermore, the slotted height-fixing plate is a rigid sheet with a profile similar to that of a stop-warp piece used for warp yarn detection in weaving. A narrow, elongated slot is formed at the center of the height of the slotted height-fixing plate, extending along its length. This slot divides the height-fixing plate into an upper section, a slot, and a lower section.
[0015] Furthermore, the pile is stretched between the upper and lower layers, and wraps around the upper, lower, and upper sections of the slotted height sheet in a circular manner with the upper and lower weft yarns.
[0016] In this application, the second aspect provides a loop pile fabric made by the weaving method according to the present invention, comprising: Base fabric: woven from ground warp and base weft yarns; Warp-cut pile layer: formed by cut pile warps and embedded in the base fabric; Weft-direction three-dimensional loop layer: formed by loop-forming weft yarns, fixed to the fabric surface in the form of raised loops. The cut pile layer and the loop pile layer are in a positive complementary relationship in three-dimensional space, supporting each other.
[0017] Furthermore, the height of the pile corresponds to the height of the slotted fixed-height piece.
[0018] Furthermore, the looped fabric contains no residue of any environmentally hazardous materials such as water-soluble yarn used to form the loops.
[0019] In summary, the present invention has the following advantages: 1. Eliminate the problem of exposed base layer: The warp cut pile and weft three-dimensional coils complement each other to form a three-dimensional covering network. They support each other when bending, so the base layer will never be exposed.
[0020] 2. Superior cleaning performance: Cut pile provides a delicate polish and initial dust capture, while weft loops provide a large dust holding capacity and hooking ability to achieve deep cleaning.
[0021] 3. Robust integrated structure: The pile and loops are generated simultaneously during weaving, resulting in a high bonding strength with the base fabric, making it durable and washable.
[0022] 4. Highly efficient and environmentally friendly production: One-step synchronous weaving replaces the traditional multi-step composite process, saving time and energy, and eliminating the need for environmentally hazardous materials such as fake weft water-soluble yarn.
[0023] 5. Flexible design: By controlling the position and frequency of the weft insertion at the center of the seam through programming, various loop pile distribution patterns can be easily achieved.
[0024] 6. High safety and stable quality: The physical isolation design of "cutting the wool in the groove and forming the coil on the stem" fundamentally avoids the risk of damaging the coil during the production process, resulting in excellent yield and quality stability. Attached Figure Description
[0025] Figure 1 This is a schematic cross-sectional view of the loop pile bending process of the present invention. Figure 2 : Schematic diagram of the appearance of the slotted height-fixed plate; Figure 3 : Schematic diagram of the three-barrel operation; Figure 4 : Schematic diagram of the shearing process; Figure 5 : Schematic diagram of the weft section of the fabric during weaving; Figure 6 : A dynamic diagram of the upper weft loop during the weaving of the first shuttle; Figure 7 : A dynamic diagram illustrating the lower weft loop during the weaving of the second shuttle; Figure 8 : Schematic diagram of the napping structure of the warp section of the fabric.
[0026] Figure reference numerals: TW represents the base fabric of the loop pile fabric; R represents the pile layer; Q represents the loop layer; 10. Grooved and height-fixed plate; 11. Upper part of the stem; 12. Lower the embankment; 13. The groove for the slotted plate with a fixed height; 14. For slotted and fixed-height plates, the long slot waist hole is made; 21. To send the weft rod to the upper sword; 22. To send the weft rod down the sword; 23. To deliver the weft rod to the central sword; 31. To connect the upper sword to the weft rod; 32. For connecting the lower sword to the weft rod; 33. For connecting the middle sword to the weft rod; 40. A cutting knife; 41. It is a left-hand rotating wheel; 42. It is a right-hand drive wheel; 43. The guide rope for the shearing knife; 50. For pile warp weaving beams; 51. For ground warp weaving beam; 61. It is a terry cloth; 62. It is plush; T is the first warp yarn in the upper layer; T is the second warp yarn in the upper layer; T is the third warp yarn in the upper layer; W1, W4, and W7 are the first weft yarns of the upper layer; W2 and W5 are the second weft yarns of the upper layer; W on 3, W on 6, W on 9, W is the third weft yarn in the upper layer; T below 1 is the first warp yarn of the lower layer; T below 2 is the second warp yarn in the lower layer; T below 3 is the third warp yarn in the lower layer; W1, W4, and W7 are the first weft yarns of the lower layer; W below 2, W below 5, and W below 8 are the second weft yarns of the lower layer; W below 3, W below 6, W below 9, W is the third weft yarn in the lower layer; R1 is the first warp yarn; R2 is the second warp. Detailed Implementation
[0027] The following description is merely a preferred embodiment of the present invention, and the scope of protection is not limited to this embodiment. All technical solutions falling within the scope of the present invention should be considered within the protection scope of the present invention. It should also be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the protection scope of the present invention.
[0028] See Figure 3 , Figure 4 , Figure 6 and Figure 7 A method for integrated weaving of a non-exposed loop pile fabric for cleaning, wherein the method can simultaneously weave a fabric with both warp-cut pile and weft-three-dimensional loop pile in one operation, and the method combines weaving and post-forming in the same process, including the following steps: S1: Configure the warp and weft yarn system. The warp yarn system includes ground warp: upper ground warp and lower ground warp; pile warp: first pile warp and second pile warp; the weft yarn system includes: base fabric weft yarn: upper base fabric weft yarn and lower base fabric weft yarn; loop weft yarn: upper loop weft yarn and lower loop weft yarn. S2: On a double-layer double-shed loom, a slotting height plate 10 is arranged at the position used for installing the slotting height plate 10, and the length direction of the slot 13 of the slotting height plate is parallel to the warp direction. The slotting height plate 10 is located below the upper rapier and above the lower rapier on the double-layer double-shed loom. On a double-layer double-shed loom, a rapier weft inserter is installed, which can pass between the upper stalk 11 and the lower stalk 12 of the slotted height plate 10; S3: This causes the upper and lower ground warp threads to form independent sheds above and below the slotted height plate 10 on the loom. A large opening is set between the upper warp threads. When the central heald thread is inserted, the rapier and the middle rapier weft inserter can be accommodated within the opening. Therefore, only two workstations are required. b. Set a large opening between the lower warp threads. When the central heald thread is inserted, the rapier and the middle rapier weft inserter can be accommodated within the opening. Therefore, only two workstations are required. c. The pile warp opening is still set to the normal three-position opening of the double-layer double-shed loom, that is, when the pile warp is at the top and middle, it can be at the top or bottom of the upper rapier respectively, and when the pile warp is at the bottom and middle, it can be at the top or bottom of the lower rapier respectively, requiring three positions.
[0029] S4: A) Weft insertion: Insert the base fabric weft yarn and the loop-forming weft yarn sequentially into the upper and lower sheds; the base fabric weft yarn and the loop-forming weft yarn located in the same shed are inserted alternately into the shed where they are located, and the loop-forming weft yarn passes through the shed and through the groove 13 of the slotted height plate at the same time. Changing the shed: The base fabric weft yarn and the loop weft yarn located in the same shed interweave with the ground warp of the shed where they are located. The ground warp presses down on the upper or lower loop weft yarn and closely adheres to the upper stem 11 or lower stem 12 of each slotted fixed height piece 10, leaving loops. Locking loops: The fabric is wound up and moved forward, but the loops of the starting weft yarn are "locked" by the upper or lower stalk of the slotted height plate 10. The loops are gradually withdrawn from the upper or lower stalk of the height plate 11 or 12, and finally, loops are formed on the surface of the fabric. D) Continuous weaving: The base fabric weft yarns interweave with the ground warp to gradually form the upper and lower base fabrics. The loop weft yarns form loops on the base fabric under the support of the slotted height plate 10 and the fixation of the ground warp. See Figure 5 and Figure 7 S5: Simultaneously with S4, the warping process is performed. Taking one cycle as an example, it specifically includes: A. Raise the first warp to the upper layer of the warp, and lower the second warp to the lower layer of the warp; B. Insert the first shuttle weft yarn into the upper and lower sheds respectively; C. Place the first pile warp in the middle, and the second pile warp in the middle; D. Insert the second shuttle weft yarn into the upper and lower sheds respectively; E. Lift the first warp strand upwards and let the second warp strand sink downwards; F. Insert the third shuttle weft yarn into the upper and lower sheds respectively; G. The first pile warp is lowered into the lower ground warp, and the second pile warp is raised into the upper ground warp. At this time, the first pile warp interweaves with the first, second and third weft yarns of the upper shed, and the second pile warp interweaves with the first, second and third weft yarns of the lower shed. H. Insert the fourth shuttle weft yarn into the upper and lower sheds respectively; I. Place the first pile warp in the middle, and the second pile warp in the middle; J. Insert the fifth shuttle weft yarn into the upper and lower sheds respectively; K. Sink the first warp and lift the second warp; L. The sixth weft yarn is inserted into the upper and lower sheds respectively. At this time, the first pile warp interweaves with the fourth, fifth and sixth weft yarns of the lower shed, and the second pile warp interweaves with the fourth, fifth and sixth weft yarns of the upper shed. This process is repeated. The pile warp is stretched between the upper and lower layers, connecting the upper and lower base fabrics. It wraps around the upper and lower contours of the slotted height plate 10 (including the upper stem 11, the slotted area, and the lower stem 12) with the upper and lower weft yarns. At the same time, the pile warp is fixed by the upper and lower base fabrics and temporarily separated by the slotted height plate 10 to form a pre-pile.
[0030] S6: Cutting pile: The cutting pile knife 40 moves laterally along the groove of the slotted height plate 10 to cut the pile warp surrounding the slotted height plate 10. The cut pile warp is locked at both ends by the upper and lower base fabrics respectively to form a cut pile surface.
[0031] When it is necessary to form weft yarn loops at a specific slotted height plate 10 according to the pattern design, the following special weft insertion operation shall be performed: 1. Knit the upper layer of loops: a. Weft insertion at the center: The weft inserter (such as a specially made rapier head) precisely passes through the slot 13 of the slotted height setting plate.
[0032] b. Positioning and release: Insert a special loop-starting weft yarn at the middle position between the upper stem 11 and the lower stem 12.
[0033] c. Pressing and forming: Subsequently, the ground warp of the upper layer, which can go directly from the upper layer to the lower layer or from the lower layer to the upper layer through the heddle hole of the three work stations, is immediately lifted from the lower layer to the upper layer and interwoven with this weft yarn. This special loop weft yarn is wrapped around the upper stem 11 of the slotted height plate 10 and pressed tightly into the upper base fabric, leaving loops close to the upper stem 11 of the slotted height plate 10.
[0034] d. Locking loops: The winding motion moves the fabric forward, but the loops of this weft yarn are "locked" by the upper base fabric and the grooved height plate 10 upper rod 11, and gradually withdraw from the height plate 11, finally forming loops on the surface of the upper base fabric.
[0035] 2. Knit the lower layer: a. Weft insertion at the center: The weft inserter (such as a specially made rapier head) precisely passes through the slot 13 of the slotted height setting plate.
[0036] b. Positioning and release: Insert a special loop-starting weft yarn at the middle position between the upper stem 11 and the lower stem 12.
[0037] c. Pressing and forming: Subsequently, a lower layer ground warp that can go directly from the upper layer to the lower layer or from the lower layer to the upper layer through the heddle hole of the three work stations is immediately lifted from the upper layer to the lower layer and interwoven with this weft yarn. This special loop weft yarn is wrapped around the lower stem 12 of the slotted height plate 10 and pressed tightly into the lower base fabric, leaving loops close to the lower stem 12 of the slotted height plate 10.
[0038] d. Locking loops: The winding motion moves the fabric forward, but the loops of this weft yarn are "locked" by the lower base fabric and the lower stem 12 of the slotted height plate 10, and gradually withdrawn from the upper stem 11 of the height plate, finally forming loops on the surface of the lower base fabric.
[0039] 3. Alternating Operations and Pattern Implementation: Based on the preset electronic pattern, the control system selectively and alternately performs the "weft insertion in the middle" operation of step 1 (weaving the upper layer loop) or step 2 (weaving the lower layer loop) at different slotted height plates 10. This forms a distributed, programmable weft loop pattern on both the upper and lower surfaces of the fabric.
[0040] See Figure 2 Furthermore, the slotted height plate 10 is a rigid plate with a shape similar to the warp stop plate used for weaving warp detection. The height of the slotted height plate 10 is determined based on the pile height. The slot is set based on the pile loop height and the minimum distance that the weft insertion dart can travel. A narrow slot is opened at the center of the height direction of the slotted height plate 10 along its length direction. The slot 13 of this slotted height plate divides the slotted height plate 10 into an upper stalk 11, a slot and a lower stalk 12. The slotted height plate 10 also has a long slot waist hole at its tail.
[0041] More specifically, this method is implemented by combining the following existing equipment and technologies. In a traditional double-layer double-shed loom, a slotted height plate 10 is installed on the loom and placed between the upper and lower base fabrics to determine the pile height. The slot 13 of the slotted height plate serves as both the weft insertion channel and the cutting channel, while the upper and lower bobbins 12 serve as the support for the formation of the weft loops.
[0042] The weft insertion mechanism is equipped with specially designed, extremely thin-section (to accommodate the width of the slot) weft inserters 23 and 33 (such as ultra-thin rapier heads or special flexible weft insertion devices), and its high-precision drive and control system, which ensures that the weft yarn can be reliably passed through the narrow slot and released at the designated position.
[0043] 3. In-groove cutting system: including a thin cutting knife 40 that can be precisely positioned and extended into the groove, a mechanism for driving the cutting knife 40 to move laterally along the groove, a left rotating wheel 41, a right rotating wheel 42, a traction rope 43 for the cutting knife, and a corresponding control unit.
[0044] 4. Fully utilize the upper-hole heddles, lower-hole heddles, and center-hole heddles held by the original double-shed loom, so that the upper-hole heddles can perform two-position operation with upper and lower openings on the upper side of the slotting height plate 10, the lower-hole heddles can perform two-position operation with upper and lower openings on the lower side of the slotting height plate 10, and the center-hole heddles can perform upper and lower openings on the upper side of the slotting height plate 10, or on the lower side of the slotting height plate 10, or from the slotting height plate. The upper side of the slotted height plate 10 directly reaches the lower side of the slotted height plate 10, which has three working positions for the slotted height plate 10. Moreover, most importantly, it can also make the upper hole heddle wire make a large span of opening at the top and bottom of the slotted height plate 10 and the slot 13 of the slotted height plate, or it can also make the lower hole heddle wire make a large span of opening at the bottom and bottom of the slotted height plate 10 and the slot 13 of the slotted height plate, which has two working positions for the slotted height plate 10.
[0045] 5. Intelligent Collaborative Control System: Based on an industrial computer or programmable logic controller (PLC), it unifies the programming control of the coordination of warp opening, pile warp feeding, weft insertion (timing and position selection), fabric take-up, and cutter action to realize the digital design and production of patterns.
[0046] Combining the above-mentioned technology and equipment, the following is a specific embodiment of the method: This invention discloses a non-exposed loop pile fabric for cleaning, comprising an upper base fabric consisting of an upper first warp yarn Tupper1, an upper second warp yarn Tupper2, an upper third warp yarn Tupper3, and an upper first weft yarn Wupper1, an upper second weft yarn Wupper2, and an upper third weft yarn Wupper3; a lower base fabric consisting of a lower first warp yarn Tlower1, a lower second warp yarn Tlower2, a lower third warp yarn Tlower3, and a lower first weft yarn Wlower1, a lower second weft yarn Wlower2, and a lower third weft yarn Wlower3; and a first pile warp R1 and a second pile warp R2 formed by cutting the upper and lower base fabrics together with a pile-cutting knife 40. The special dynamic process of the formation of the upper third weft yarns Wupper3, Wupper6, and Wupper9 that constitute the upper coil Q and the lower third weft yarns Wlower3, Wlower6, and Wlower9 that constitute the lower coil Q.
[0047] The upper first warp yarn T1, the upper second warp yarn T2, the upper third warp yarn T3, the lower first warp yarn T1, the lower second warp yarn T2, and the lower third warp yarn T3 are all aligned on a single warp beam.
[0048] Insert the upper second warp yarn T2 into the upper heddle hole, which is unique to double-shed looms, into the upper heddle hole among the central heddle holes. Insert the upper first warp yarn T1 and the upper third warp yarn T3 into the central heddle hole, which is unique to double-shed looms. Insert the second warp yarn T_2 of the lower layer into the lower heddle hole, which is a special feature of double-shed looms. Insert the first warp yarn T_1 of the lower layer and the third warp yarn T_3 of the lower layer into the center heddle hole, which is a special feature of double-shed looms. The first pile warp R1 and the second pile warp R2 are inserted into the center heddle hole, which is a special feature of double shed looms, and the center heddle hole is located between the upper and lower heddle holes.
[0049] Adjusting the shuttle's weft: In the first shuttle, the second warp yarn of the upper layer, T2, is placed down below the upper rapier 21. Place the first warp yarn T1 and the third warp yarn T3 of the upper layer in the middle, below the center rapier 23. Place the second warp yarn from the lower layer, T2, upwards onto the lower rapier 22. Place the first warp yarn T1 and the third warp yarn T3 of the lower layer below the lower rapier 22. The first pile is lifted upwards via R1, and the second pile is lowered downwards via R2. The upper rapier 21 receives the first weft yarn Wupper1, and the lower rapier receives the first weft yarn Wlower1. The middle layer rapier 23 is fed into the upper layer loop weft yarn W3. Weft weaving.
[0050] In the second shuttle, place the upper second warp yarn T2 onto the upper rapier 21. Raise the first warp yarn T1 and the third warp yarn T3 of the upper layer to above the upper rapier 21. Place the second warp yarn T below 2, and then lower it below the lower rapier 22. Place the first warp yarn T below 1 and the third warp yarn T below 3 of the lower layer in the middle, above the center rapier 23. Place the first pile wire R1 in the middle, and the second pile wire R2 in the middle. Upper rapier 21 inserts the upper second weft yarn Wupper 2, lower rapier 22 inserts the lower second weft yarn Wlower 2. The middle layer rapier 23 is inserted into the lower layer weft yarn W3. Weft weaving.
[0051] In the third shuttle, the second warp yarn of the upper layer, T2, is placed down below the upper rapier 21. Place the first warp yarn T1 and the third warp yarn T3 of the upper layer in the middle, below the center rapier 23. Place the second warp yarn from the lower layer, T2, upwards onto the lower rapier 22. Place the first warp yarn T1 and the third warp yarn T3 of the lower layer below the lower rapier 22. The first pile is lifted upwards via R1, and the second pile is lowered downwards via R2. The upper rapier 21 receives the first weft yarn Wupper 4, and the lower rapier receives the first weft yarn Wlower 4. The middle layer rapier 23 is inserted into the first loop of weft yarn W on the upper layer 6. Weft weaving.
[0052] The fourth shuttle places the second warp yarn T2 of the upper layer onto the upper rapier 21. Raise the first warp yarn T1 and the third warp yarn T3 of the upper layer to above the upper rapier 21. Place the second warp yarn T below the lower layer (2), and then lower it below the lower rapier (22). Place the first warp yarn T below 1 and the third warp yarn T below 3 of the lower layer in the middle, above the center rapier 23. The first pile is lowered via R1, and the second pile is raised via R2. Upper rapier 21 inserts the upper second weft yarn W (upper 5), lower rapier 22 inserts the lower second weft yarn W (lower 5). The middle layer rapier 23 is inserted into the first loop of weft yarn W below the lower layer 6. Weft weaving.
[0053] For the fifth shuttle, place the second warp yarn T2 of the upper layer down below the upper rapier 21. Place the first warp yarn T1 and the third warp yarn T3 of the upper layer in the middle, below the center rapier 23. Place the second warp yarn from the lower layer, T2, upwards onto the lower rapier 22. Place the first warp yarn T1 and the third warp yarn T3 of the lower layer below the lower rapier 22. Place the first pile wire R1 in the middle, and the second pile wire R2 in the middle interval. The upper rapier 21 inserts the first weft yarn W_upper 7, and the lower rapier inserts the first weft yarn W_lower 7. The middle layer rapier 23 is inserted into the first loop of weft yarn W on the upper layer 9. Weft weaving.
[0054] For the sixth shuttle, place the second warp yarn T2 of the upper layer onto the upper rapier 21. Raise the first warp yarn T1 and the third warp yarn T3 of the upper layer to above the upper rapier 21. Place the second warp yarn T below the lower layer (2), and then lower it below the lower rapier (22). Place the first warp yarn T below 1 and the third warp yarn T below 3 of the lower layer in the middle, above the center rapier 23. The first pile is lowered via R1, and the second pile is raised via R2. Upper rapier 21 inserts the upper second weft yarn W_upper 8; lower rapier 22 inserts the lower second weft yarn W_lower 8. The middle layer rapier 23 is inserted into the first loop of weft yarn W9 of the lower layer. Weft weaving.
[0055] At this point, the six-shuttle unit weaving process is complete, and the next cycle of weaving begins.
[0056] See Figure 4 and Figure 5 After a period of continuous weaving and manufacturing, the following steps are performed: Preparation for cutting pile: After the fabric has been woven to a certain length, the blade of the cutting pile knife 40 will (due to the fabric winding and active drive) precisely extend into the groove 13 of the grooving height plate and move laterally in the groove 13 of the grooving height plate.
[0057] 2. Safe Pile Cutting: The pile cutting blade 40 moves laterally within the groove 13 of the slotted height plate, cutting the pile yarns surrounding the slotted height plate 10. Key safety mechanism: Because the weft yarns forming the loops are attached to the outside of the slotted height plate 10 (the lower surface of the upper stalk 11 or the upper surface of the lower stalk 12), while the cutting blade moves laterally inside the groove 13 of the slotted height plate, the pile cutting blade 40 does not physically contact these looping weft yarns at all, thus achieving "safe pile cutting without damaging the loops".
[0058] 3. Simultaneous film removal and final shaping: a. The cut pile warp, with its two ends locked by the upper and lower base fabrics respectively, forms the cut pile surface.
[0059] b. The starting weft yarn attached to the stem comes off the "stem" as the fabric leaves the slotted height plate 10. However, since it has been firmly locked into the fabric surface by the ground warp, it forms a three-dimensional, permanent weft loop on the fabric surface.
[0060] c. Ultimately, the fabric, within the same area and structure, simultaneously presents the smoothness and delicacy of cut pile and the three-dimensional fullness of weft loops, forming a unified whole and supporting each other.
[0061] See Figure 1 , one Loop pile fabric produced according to the above-described weaving method includes: Base fabric: woven from ground warp and base weft yarns; Warp-cut pile layer: formed by cut pile warps and embedded in the base fabric; Weft-direction three-dimensional loop layer: formed by loop-forming weft yarns, fixed to the fabric surface in the form of raised loops. The cut pile layer and the loop layer are in a positive complementary relationship in three-dimensional space, supporting each other, and there are no environmentally hazardous materials such as water-soluble yarn used to form loops inside the fabric.
Claims
1. A method for integrally weaving a looped pile fabric without showing the bottom for cleaning, characterized in that, Includes the following steps: S1: Configure the warp and weft yarn system. The warp yarn system includes the ground warp: upper ground warp, lower ground warp, and pile warp; the weft yarn system includes the base fabric weft yarn: upper base fabric weft yarn, lower base fabric weft yarn, and loop weft yarn: upper loop weft yarn, lower loop weft yarn. S2: On a double-layer double-shed loom, a slotted height plate is arranged at the position for installing the height plate, and the length direction of the slot of the slotted height plate is parallel to the warp direction. The slotted height plate is located below the upper rapier and above the lower rapier on the double-layer double-shed loom. In addition, a middle rapier weft inserter is set between the upper and lower rapiers and can pass through the upper and lower stalks of the slotted height plate. S3: This causes the upper and lower ground warp threads to form independent sheds above and below the slotted height plate on the loom. S4: A) Weft insertion: The base fabric weft yarn and the starting loop weft yarn are inserted sequentially into the upper and lower sheds; the base fabric weft yarn and the starting loop weft yarn located in the same shed are inserted alternately into the shed where they are located, while the starting loop weft yarn is driven through the shed and through the groove of the slotted height plate by the rapier weft inserter. Changing the shed: The base fabric weft yarn and the loop weft yarn located in the same shed interweave with the ground warp of the shed where both are located. The ground warp presses down on the upper or lower loop weft yarn until the base fabric structure forms an upper or lower loop that is close to each slotted height piece, leaving loops. Locking loops: As the fabric is wound up and moved forward, the loops of the starting weft yarn are "locked" by the upper or lower stalk of the slotted height plate and gradually withdrawn from the upper or lower stalk, eventually forming loops on the fabric surface. Continuous weaving: The base fabric weft yarns interweave with the ground warp to gradually form the upper and lower base fabrics. The loop-forming weft yarns form loops on the base fabric under the support of the slotted height plate and the fixation of the ground warp. S5: While S4 is being performed, the pile warp is moved up and down between the upper and lower sheds. When the pile warp moves to a certain shed, it interweaves with the base fabric weft yarn in that shed. After interweaving for a while, it moves to another shed and interweaves with the base fabric weft yarn in that shed for a while. This cycle continues. The pile warp connects the upper and lower base fabrics. At the same time, the pile warp is fixed by the upper and lower base fabrics and temporarily separated by the slotted height plate to form a pre-pile. S6: Cutting pile: The cutting pile knife moves laterally along the groove of the slotted height plate to cut the pile warp surrounding the slotted height plate. The cut pile warp is locked at both ends by the upper and lower base fabrics respectively, forming the cut pile pile head.
2. The integrated weaving method of the looped pile fabric without showing the bottom for cleaning according to claim 1, wherein, The upper-layer geodetic system includes: the upper-layer second geodetic system, the upper-layer first geodetic system, and the upper-layer third geodetic system; the lower-layer geodetic system includes: the lower-layer second geodetic system, the lower-layer first geodetic system, and the lower-layer third geodetic system. In the upper shed, the upper first ground track and the upper third ground track are located on the same side of the upper shed, and the upper second ground track is located on the other side of the upper shed; In the lower shed, the lower first ground track and the lower third ground track are located on the same side of the lower shed, and the lower second ground track is located on the other side of the lower shed; Step B in S4 specifically includes: Weaving the upper loop: The first and third upper ground warps are located below the upper shed, and the second upper ground warp is located above the upper shed. After the upper loop weft yarn is fed in by the rapier, the first and third upper ground warps are lifted upwards. The first and third upper ground warps pass through both sides of the upper stalk of the slotted height plate and press down on the upper loop weft yarn that passes through the slot of the slotted height plate by the weft inlet of the rapier, so that the upper loop weft yarn wraps around the upper stalk of the slotted height plate, leaving loops on the upper stalk. Weaving the lower layer loops: The first and third lower layer ground warps are located on the upper side of the lower layer shed, and the second lower layer ground warp is located on the lower side of the lower layer shed. After the lower layer starting weft yarn is inserted by the rapier, the first and third lower layer ground warps are lowered. The first and third lower layer ground warps pass through both sides of the lower stalk of the slotted height plate and press down on the lower layer starting weft yarn that passes through the slot of the slotted height plate using the rapier weft inserter, so that the lower layer starting weft yarn wraps around the lower stalk of the slotted height plate, leaving loops on the lower stalk.
3. The method for integrated weaving of a non-exposed loop pile fabric for cleaning, as described in claim 1, is characterized in that... The pile warp consists of two sets that alternately move up and down between the upper and lower sheds. When one set of pile warp moves to the upper shed and interweaves with the weft yarn of the upper shed, the other set moves to the lower shed and interweaves with the weft yarn of the lower shed. After each set of pile warp interweaves with the weft yarn of its respective layer for a period of time, the two sets of pile warp exchange layers and continue to interweave with the weft yarn of their respective layers. This cycle continues in turn, and the two sets of pile warp connect the upper and lower base fabrics.
4. A method for integrated weaving of a non-exposed loop pile fabric for cleaning, as described in claim 1 or 3, characterized in that, The pile warp includes a first pile warp and a second pile warp; S5 A loop specifically includes a: Lift the first warp strand upwards and let the second warp strand sink downwards; b: Insert the first weft yarn into the upper and lower sheds respectively; c: Place the first pile warp in the middle, and the second pile warp in the middle; d: Insert the second shuttle weft yarn into the upper and lower sheds respectively; e: Lift the first warp strand upwards and let the second warp strand sink downwards; f: Insert the third shuttle weft yarn into the upper and lower sheds respectively; g: The first pile warp is lowered into the lower ground warp, and the second pile warp is raised into the upper ground warp. At this time, the first pile warp interweaves with the first, second and third weft yarns of the upper shed, and the second pile warp interweaves with the first, second and third weft yarns of the lower shed. h: The fourth shuttle weft yarn is inserted into the upper and lower sheds respectively; i: Place the first pile warp in the middle, and the second pile warp in the middle; j: Insert the fifth shuttle weft yarn into the upper and lower sheds respectively; k: Sink the first warp and lift the second warp; l: The sixth weft yarn is put into the upper and lower sheds respectively. At this time, the first pile warp interweaves with the fourth, fifth and sixth weft yarns of the lower shed, and the second pile warp interweaves with the fourth, fifth and sixth weft yarns of the upper shed. This process continues in a cyclical manner.
5. The method for integrated weaving of a non-exposed loop pile fabric for cleaning, as described in claim 1, is characterized in that... The slotted height plate is a rigid sheet with a shape similar to a stop warp piece used for warp yarn detection in weaving. A narrow slot is opened at the center of the height direction of the slotted height plate along its length direction. This slot divides the slotted height plate into an upper section, a slot, and a lower section.
6. The method for integrated weaving of a non-exposed loop pile fabric for cleaning, as described in claim 4, is characterized in that... The pile is stretched between the upper and lower layers, and wraps around the upper, lower, and upper sections of the slotted height sheet in a circular manner with the upper and lower weft yarns.
7. A loop pile fabric manufactured by the weaving method according to any one of claims 1 to 4, characterized in that, The looped fleece fabric includes: Base fabric: woven from ground warp and base fabric weft yarns; Warp-cut pile layer: formed by cut pile warps and embedded in the base fabric; Weft-direction three-dimensional loop layer: formed by loop-starting weft yarns, which are fixed to the fabric surface in the form of raised loops; The cut pile layer and the loop pile layer are in a positive complementary relationship in three-dimensional space, supporting each other.
8. The cleaning non-exposed loop pile fabric and its integrated weaving method according to claim 1, characterized in that, The height of the pile corresponds to the height of the slotted fixed-height piece.
9. The loop pile fabric according to claim 7, characterized in that, The fabric contains no residue of environmentally hazardous materials such as water-soluble yarn used to form terry loops.