Automated Woven Carpet with Patchwork Seam Appearance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual assembly of patchwork rugs is time-consuming and costly, as it requires hand sewing of different pieces, making the manufacturing process inefficient and expensive.
Innovation Solution
An automated process using warp and weft yarns, where the weft yarns are interlaced in a predefined pattern, creating seams that distinguish between different areas of the carpet, mimicking the appearance of manually assembled patchwork without the need for hand sewing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual hand sewing is used to assemble different pieces of carpet, then the patchwork rug can be assembled with visible seams, but the manufacturing time increases and manufacturing cost increases
Solution Approach 1:
The patent replaces the manual mechanical sewing process with an automated weaving mechanism. The weaving machine automatically interlaces weft yarns with warp yarns according to a predefined insertion pattern, eliminating the need for manual hand sewing while producing the same patchwork appearance with visible seams.
Solution Approach 2:
The patent changes the operational parameters of the weaving process by implementing a predefined insertion pattern for weft yarns that is interrupted at specific locations. This controlled interruption creates visible seams that mimic hand-sewn patchwork, while the overall process remains automated and efficient.
2Productivity
If automated weaving with predefined insertion pattern is used, then productivity increases and manufacturing cost decreases, but the ability to create visible seams mimicking hand-sewn appearance must be achieved through process control
Solution Approach 1:
The patent segments the weft yarn insertion pattern into distinct sections with interruptions at specific locations. These segmented patterns create visible seams that divide the carpet into different zones, maintaining the patchwork appearance while allowing automated high-speed production.
Solution Approach 2:
The patent changes the operational parameters of the weaving process by implementing a predefined insertion pattern for weft yarns that is interrupted at specific locations. This controlled interruption creates visible seams that mimic hand-sewn patchwork, while the overall process remains automated and efficient.
Data Source
AI summary
The invention provides a method for the manufacture of a carpet having a patchwork appearance comprising the following steps: arranging in a plane warp threads next to each other without overlapping them; inserting and interlacing weft yarns through said warp yarns such that said weft yarns are positioned in consecutive lines and substantially perpendicular to said warp yarns; the weft yarns are inserted into the same line repeatedly and according to a predefined insertion pattern. Said insertion pattern is interrupted at least once so as to create, on one of the faces of the carpet, at least one line of seams. Said line of seams represents a border between two zones of the carpet having different appearances and is defined by a plurality of segments of warp threads. The invention also provides a carpet produced by said process.