Double-Face Weaving Loom Pile Fabric Configuration
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Solution Overview
Problem
Current weaving methods on certain looms are limited in producing pile fabrics with high variation and uniform distribution due to physical constraints and technical limitations, which restrict the number of pile warp threads per warp thread system, resulting in reduced pile density and variation.
Innovation Solution
The method involves providing between 200 and 1000 warp thread systems per meter on a double-face weaving loom, with at least five different pile warp threads and two tension warp threads per system, using a long ground weave repeat and dividing weft threads over three levels to increase weft thread density and pile rows per cm, thereby achieving a higher imbalance factor that enhances pile variation and density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of pile warp threads per warp thread system is increased to achieve higher pile variation, then pile variation is improved, but the number of warp thread systems per metre must be decreased which reduces pile density
Solution Approach 1:
The patent introduces a third dimension by dividing weft threads into multiple levels (at least three levels) using tension warp threads. This vertical stratification allows pile warp threads to form pile at different heights and positions, increasing pile variation without reducing the number of warp thread systems per metre, thereby maintaining pile density while achieving higher pile variation.
Solution Approach 2:
The weft threads are segmented into multiple levels by introducing tension warp threads that divide the weft insertion space. This segmentation creates distinct zones for pile formation at different heights, allowing multiple pile rows per cm in the warp direction while maintaining high warp thread system density.
2Adaptability or versatility
If the number of warp thread systems per metre is decreased to allow more pile warp threads per system, then pile variation increases, but intermediate spaces between pile rows increase reducing pile density
Solution Approach 1:
By introducing vertical level differentiation through tension warp threads, the patent creates multiple stacking levels for pile rows. This allows pile rows to be distributed more uniformly across the fabric structure in the warp direction, with at least 16 pile rows per cm, eliminating large intermediate spaces while maintaining high pile variation through multi-level positioning.
3Quantity of substance
If tension warp threads are used to divide weft threads over three levels, then weft thread density increases and pile rows per cm increases, but device complexity increases
Solution Approach 1:
The tension warp threads serve multiple functions: they divide weft threads into levels, provide structural support for pile formation, and control the positioning of pile rows. This multi-functionality increases weft thread density and pile row density without proportionally increasing device complexity, as the same elements perform multiple roles in the weaving structure.
Data Source
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AI summary
The invention relates to a weaving method for the double-face weaving of pile fabrics wherein at least five different pile warp threads (12-19), (20-27) with a yarn number of between 6 and 10 Nm final and at least two tension warp threads (8),(9);(10,11) are provided for each warp thread system (100) and for each fabric (28), (29), wherein the weft threads (1,2), (2,3) of each fabric are divided over at least three levels, while the ground weave repeat runs over at least eight insertion cycles (I-VIII), wherein between 200 and 1000 warp thread systems per metre are provided, and at least 16 pile rows per cm are formed in the warp direction.