Face-to-Face Figure Warp Weaving With Shared Thread Allocation

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Solution Overview

Problem

Existing methods for producing two fabrics with pattern variation on a face-to-face weaving machine result in high yarn consumption, increased production costs, and fabric weight due to the need for multiple figure warp threads per system to achieve desired color variation.

Innovation Solution

A method and machine design that allocates eight figure warp threads per pair of warp thread systems using specific allocation plans, allowing each warp thread system to share figure warp threads with different appearances between two fabrics, reducing the number of required threads per system to half while maintaining pattern quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple figure warp threads per warp thread system are used to achieve color variation, then pattern variation is improved, but yarn consumption and fabric weight increase

Engineering Contradiction:

Improvepattern variationVSAvoidyarn consumption

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The patent merges the functionality of multiple figure warp threads into a shared pool of figure warp threads that serve both warp thread systems. Instead of having separate figure warp threads for each system, a common set of figure warp threads is allocated to both systems through coordinated shed formation, reducing total yarn consumption while maintaining pattern variation capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The figure warp threads are designed to serve multiple functions and multiple fabrics simultaneously. The same figure warp threads can be allocated to different fabrics in different weaving cycles, allowing one set of threads to create patterns in both the first and second fabrics, thereby reducing the total number of threads needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple figure warp threads per warp thread system are used to achieve color variation, then pattern variation is improved, but production costs increase

Engineering Contradiction:

Improvepattern variationVSAvoidproduction costs

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If multiple figure warp threads per warp thread system are used to achieve color variation, then pattern variation is improved, but fabric weight increases

Engineering Contradiction:

Improvepattern variationVSAvoidfabric weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Quantity of substance

If figure warp threads are allocated to different fabrics in paired warp thread systems, then yarn consumption is reduced, but device complexity increases

Engineering Contradiction:

Improveyarn consumptionVSAvoidallocation control complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent segments the figure warp threads into sets that can be independently allocated to different fabrics. By dividing the figure warp threads into manageable groups that can be selectively assigned to the first or second fabric, the system achieves flexible allocation while maintaining organized control structures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The allocation of figure warp threads to fabrics is made dynamic rather than fixed. The shed forming devices can change which figure warp threads are allocated to which fabric from one weaving cycle to the next, allowing flexible pattern creation while using a shared pool of threads, thereby reducing yarn consumption without being constrained by fixed assignments.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP3374552B2Method for face-to-face weaving of fabrics with figure warp threads

Publication Date: 2025.12.03 VANDEWIELE NV

Figure 1
Figure 2I~2II
Figure 3

AI summary

The invention relates to a method for face-to-face weaving of two at least partially pile-free fabrics (I), (II) in which weft threads (101-104), (201-204) are inserted between warp threads (1a- 14a, 1b-14b) of warp thread systems with figure warp threads (1a-8a), (1b-8b) that are allocated to respective fabrics (1, 11) and are either pattern-determining in that fabric or are incorporated therein, whereby at least one set (1a, 1b),... (8a, 8b) of two identical figure warp threads is provided per pair of neighbouring warp thread systems, while the two figure warp threads of each set belong to a different warp thread system (1a- 14a), (1b- 14b) and are allocated to a different fabric (1, 11), so that each set of figure warp threads per pair of neighbouring warp thread systems provides a figure warp thread in both fabrics (1, 11) to determine the pattern.