Carpet Shadow Effect via Static Weft Offset
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Solution Overview
Problem
Existing methods for creating a fabric with a shadow effect, such as carpets, require the use of a jacquard machine to move tension warp yarns, which complicates the weaving process and is not necessary for achieving a clear shadow effect.
Innovation Solution
A fabric design where weft yarns are positioned such that piles extend out of the backing fabric with an offset in the direction perpendicular to the warp and weft directions, allowing for a simple and constant ground weave without the need to move tension warp yarns using a jacquard machine, by interlacing pile warp yarns with end weft yarns to create piles that provide a shadow effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a jacquard machine is used to move tension warp yarns to create a shadow effect, then the shadow effect is achieved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the tension warp yarns from the active weaving process and positions them as static elements in the backing fabric. By removing the need for dynamic control of these yarns through a jacquard machine, the system achieves the shadow effect through the fixed geometric arrangement of piles rather than through active manipulation of tension yarns during weaving.
Solution Approach 2:
Instead of using tension warp yarns to create the shadow effect by moving them with a jacquard machine, the invention inverts the approach by using pile warp yarns whose interlacing positions with weft yarns naturally create the shadow effect. The shadow is achieved through the passive geometric arrangement of piles extending between different weft yarns rather than through active tension yarn manipulation.
2Illumination intensity
If tension warp yarns are moved by a jacquard machine to achieve shadow effect, then the shadow effect is obtained, but the productivity decreases due to complex weaving process
Solution Approach 1:
The patent removes the time-consuming jacquard machine operation from the weaving process by extracting the shadow-effect creation function from active yarn manipulation. The shadow effect is achieved through the static geometric arrangement of piles during normal weaving, eliminating the need for slow, complex jacquard machine operations and thereby increasing productivity.
3Ease of manufacture
If a simple ground weave is used without moving tension warp yarns, then the weaving process is simplified, but the shadow effect may not be sufficient
Solution Approach 1:
The patent applies local quality by creating variation in the pile arrangement specifically in the transition areas where shadow effect is needed, while maintaining a simple constant ground weave elsewhere. By locally adjusting the interlacing positions of pile warp yarns with specific weft yarns in transition zones, the invention achieves the shadow effect without complicating the overall weaving process.
Solution Approach 2:
The invention creates the shadow effect by utilizing the third dimension - the vertical extension of piles between different weft yarns. Instead of manipulating yarns in the horizontal plane through a jacquard machine, the shadow effect is achieved by controlling which weft yarns the piles extend between, using the vertical dimension of pile extension to create the optical effect.
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), tension warp yarns (T) substantially extending in a warp direction (WA), and weft yarns (E1, I, E2) substantially extending in a weft direction through the weft receiving openings (O), - 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, in at least one weft receiving opening (O), preferably the majority of the weft receiving openings (O), most preferably each weft receiving opening (O), at least one weft yarn (E1, E2) positioned immediately adjacent to one of the crossings (C1, C2) of the binding warp yarns (B1, B2) defining this weft receiving opening (O) in the warp direction (WA), preferably each one of the two weft yarns (E1, E2) positioned immediately adjacent to the two crossings (C1, C2) of the binding warp yarns (B1, B2) defining this weft receiving opening (O) in the warp direction (WA), provides an end weft yarn (E1, E2) positioned at a back side (BS) relative to at least one weft separating warp yarn (T, PY1, PY2, PY3, PY4) extending in the backing fabric (BF) substantially in the warp direction (WA), and at least one intermediate weft yarn (I) positioned adjacent to such an end weft yarn (E1, E2) in the warp direction (WA) is positioned at the pile side (PS) relative to the at least one weft separating warp yarn (T, PY1, PY2, PY3, PY4), wherein for providing a pile (P) in association with this weft receiving opening (O) a pile warp yarn (PY1, PY2, PY3) is interlaced with an end weft yarn (E1, E2) of this weft receiving opening (O) such as to extend out of the backingfabric (BF) between this end weft yarn (E1, E2) and an intermediate weft yarn (I) of this weft receiving opening (O).