Carpet Pile Transition Zone Segmentation
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Solution Overview
Problem
Existing fabric weaving methods require a transition zone extending over multiple weft threads to change the direction of pile inclination, which is inefficient and affects the optical appearance of the fabric.
Innovation Solution
A fabric and method where a transition zone involving only two transition weft yarns, positioned at the same level perpendicular to the warp and weft directions, are used to change the inclination of piles without additional warp yarns, enhancing the optical appearance by reducing the number of weft threads required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a transition zone extending over five immediately adjacent weft yarns is used to change the direction of pile inclination, then the pile direction can be changed, but the transition zone extends over a large number of weft threads which adversely affects the optical appearance of the fabric
Solution Approach 1:
The transition zone is segmented into exactly two transition weft yarns (E1, E2) that are positioned at the same level perpendicular to the warp and weft directions. This segmentation reduces the transition zone from extending over five weft yarns to just two specific weft yarns, thereby minimizing the number of weft threads involved while still achieving the pile direction change function.
Solution Approach 2:
The patent applies local quality by positioning the two transition weft yarns at a specific location within the transition zone - at the same level perpendicular to the warp and weft directions. This localized positioning ensures that only the necessary minimal number of weft yarns are involved in the transition, improving optical appearance while maintaining the pile direction change capability.
2Adaptability or versatility
If a transition zone extending over multiple weft threads is used, then the pile direction can be changed, but the optical appearance of the fabric is adversely affected
Solution Approach 1:
The transition zone is segmented into exactly two transition weft yarns positioned at the same level, which minimizes the visual disturbance in the fabric's optical appearance. By limiting the transition to just two weft yarns instead of five or more, the optical continuity of the fabric is better preserved.
Solution Approach 2:
The transition is localized to two specific weft yarns at the same level perpendicular to the warp and weft directions. This localized approach ensures that the optical appearance is affected only minimally at the transition point, while the rest of the fabric maintains its uniform appearance.
3Adaptability or versatility
If traditional transition zones are used to change pile direction, then the inclination can be changed, but the number of weft threads required is large which reduces weaving efficiency
Solution Approach 1:
The transition zone is segmented into exactly two transition weft yarns, reducing the number of weft threads that need to be processed during weaving. This segmentation from five or more weft yarns to just two significantly improves weaving efficiency while maintaining the pile direction change function.
Solution Approach 2:
The patent changes the parameter of transition zone length from extending over five immediately adjacent weft yarns to exactly two transition weft yarns positioned at the same level. This parameter change optimizes the weaving process by reducing the number of operations required while maintaining the functional requirement of pile direction change.
Data Source
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AI summary
A fabric, in particular carpet, having a shadow effect, comprises a backing fabric (BF) having binding warp yarns (B1, B2) repeatedly crossing each other for providing weft receiving openings (O) between crossings (C1, C2) thereof following each other in a warp direction (WA) and weft yarns (E1, E2) substantially extending in a weft direction through the weft receiving openings (O), and pile warp yarns (PY1, PY2, PY3, PY4) interlaced with weft yarns (E1, E2) of the backing fabric (BF) for providing piles (P) extending out of the backing fabric (BF) at a pile side (PS), wherein, through at least one weft receiving opening (O), preferably the majority of the weft receiving openings (O), most preferably each weft receiving opening (O), two weft yarns (E1, E2) extend, wherein in at least one weft receiving opening (O), preferably the majority of the weft receiving openings (O), one of the weft yarns (E1, E2) is positioned at a back side (BS) relative to at least one weft separating warp yarn (PY1, PY2, PY3, PY4, T) extending in the backing fabric (BF) substantially in the warp direction (WA) and the other one of the weft yarns (E1, E2) is positioned at the pile side (PS) relative to the at least one weft separating warp yarn (PY1, PY2, PY3, PY4, T), wherein, for providing a pile (P) in association with this weft receiving opening (O), a pile warp yarn (PY1, PY2, PY3) is interlaced with the weft yarn (E1, E2) of this weft receiving opening (O) positioned at the back side (BS) relative to the at least one weft separating warp yarn (PY1, PY2, PY3, PY4, T), such as to extend out of the backing fabric (BF) between this weft yarn (E1, E2) and the other weft yarn (E1, E2) of this weft receiving opening (O), wherein, for changing the direction of inclination of the piles (P), at least one transition zone (Z) is provided, wherein, in at least one transition zone (Z), two transition weft yarns (TE1, TE2) provided immediately adjacent to each other in the warp direction (WA) extending through at least one weft receiving opening (O) are positioned at substantially the same level in a direction (D) that is substantially perpendicular with respect to a plane defined by the warp direction (WA) and the weft direction and/or are not separated by a weft separating warp yarn (PY1, PY2, PY3, PY4, T).