Carpet Weaving Method for Selective Weft Visibility Control
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Solution Overview
Problem
Current carpet weaving methods lack the flexibility to create dedicated weft patterning zones with visible and invisible weft yarns without increasing the complexity of the weaving loom, limiting the ability to produce diverse carpets with specific weft effects.
Innovation Solution
The method involves weaving carpets with areas of piles and areas without piles, using filling warp yarns, binding warp yarns, and dead pile yarns, where inner and outer weft yarns are inserted between the binding warp yarns, with dead pile yarns positioned above or under the inner weft yarns to control visibility, allowing for alternating patterns of inner weft yarns of different colors or diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dead pile yarns are positioned to cover inner weft yarns in areas without piles, then visibility of inner weft yarns is controlled, but flexibility to create varied weft patterning zones is limited
Solution Approach 1:
The carpet width is divided into multiple independent warp yarn sets, each capable of producing different weft patterning effects. Each set can be independently controlled to create visible or invisible inner weft yarn zones, allowing diverse patterning across the carpet without requiring multiple looms or complex mechanisms.
Solution Approach 2:
Different regions of the carpet can have different dead pile yarn configurations - some areas with dead pile yarns covering inner weft yarns (invisible zones) and other areas with inner weft yarns visible. This local variation in yarn positioning creates diverse weft patterning effects within a single carpet production run.
2Adaptability or versatility
If multiple types of inner weft yarns are alternatively woven into the backing fabric, then design variety is enhanced, but manufacturing complexity increases
Solution Approach 1:
Multiple types of inner weft yarns (e.g., different colors or diameters) are woven into the backing fabric in alternating periodic sequences. This periodic insertion creates predictable, repeatable patterning zones that can be controlled through regular picking intervals, maintaining manufacturing simplicity while achieving design variety.
3Manufacturing precision
If dead pile yarns are selectively placed above or under inner weft yarns, then visible and invisible zones are created, but control complexity increases
Solution Approach 1:
The positioning of dead pile yarns relative to inner weft yarns is dynamically controlled during the weaving process. Each warp yarn set can independently adjust whether dead pile yarns cover or expose inner weft yarns based on the desired patterning effect, allowing precise control of visibility without requiring complex post-processing mechanisms.
Data Source
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AI summary
This method is for weaving at least one carpet (C1, C2) with a backing fabric (F1, F2) including at least one area (A1) with piles and at least one area (A0) without piles. The backing fabric (F1, F2) is woven with, on the one hand, filling warp yarns (f1, f2), binding warp yarns (b1, b'1, b2, b'2) and dead pile yarns (I-VIII) and, on the other hand, weft yarns (Wi, Wo) which are inserted in successive insertion cycles (P1-P20) between the binding warp yarns and comprise inner weft yarns (Wi) inserted on the pile side of the filling warp yarns and outer weft yarns (Wo) inserted on a side of the filling warp yarns opposite to the piles. The warp yarns are organized, along the weft direction, in respective sets with all the filling warp yarns (f1, f2), binding warp yarns (b1, b'1, b2, b'2) and dead pile yarns (I-VIII) of one set going through a same reed dent space. In at least one area (Ao) without piles of the backing fabric (F1, F2) of a given carpet (C1, C2) and for each warp yarn set, either all the dead pile yarns (I-IV; V-VIII) of said warp yarn set are placed above the inner weft yarns (Wi) or at least two dead piles of said warp yarn set are placed above the inner weft yarns (Wi). In the area (Ao) of the carpet (C1, C2) without piles, inner weft yarns (Wi) are alternatively above all the dead pile yarns (I-VIII) of some warp yarn sets or under at least two dead pile yarns of some other warp yarn sets, along the weft direction.