Floating-Weft Carpet Relief Structure Without Vulnerable Loops
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Solution Overview
Problem
Existing carpet manufacturing methods using loops of varying height for relief struggle with uniformity and risk of loop damage from external objects, leading to potential fabric damage.
Innovation Solution
Incorporating weft yarns inserted perpendicularly into warp yarns in specific patterns to create high and low relief areas, forming zones with upper or lower floating threads, which enhances visual and formal appearance while reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If loops of varying height are used to create relief in carpet, then visual appearance is improved, but uniformity of loop height in determined sections deteriorates and risk of loop damage increases
Solution Approach 1:
The patent changes the fundamental parameter of how relief is created - instead of varying loop heights within a pile structure, it uses flat-woven zones with different thread float characteristics. This parameter change allows relief effect without the uniformity and damage problems of loop-based approaches
Solution Approach 2:
The patent extracts the relief creation mechanism from the pile/loop structure and places it in the flat-weave zone structure. By separating the relief function from the pile structure, it eliminates the inherent uniformity problems of loop-based relief while maintaining the visual effect
2Shape
If loops of varying height are used to create relief in carpet, then visual appearance is improved, but risk of loop damage from external objects increases
Solution Approach 1:
The patent fundamentally changes the structural parameter from loops/piles to flat-woven zones with thread floats. This eliminates the vulnerable loop structure that catches on objects while preserving the relief appearance through differential thread float in different zones
Solution Approach 2:
Instead of creating relief by making some parts protrude upward (loops), the patent creates relief by making some zones have longer thread floats that visually appear raised. This inverted approach achieves the same visual effect without the mechanical vulnerability of actual loops
3Manufacturing precision
If zones with upper or lower floating threads are formed to create high and low relief areas, then manufacturing precision of relief uniformity is improved, but device complexity increases
Solution Approach 1:
The patent segments the carpet into distinct zones with different weave characteristics - some zones with upper floating threads for high relief, others with lower floating threads for low relief. This segmentation achieves uniform relief within zones while using standard weaving mechanisms
Solution Approach 2:
The patent uses the same basic weaving mechanism to create both high and low relief areas by simply changing which threads float on which side. This multi-functional approach uses one system to achieve multiple relief effects without requiring complex specialized equipment
Data Source
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AI summary
The present invention provides a carpet with one or more raised areas comprising a series of weft yarns, inserted substantially perpendicularly into and woven with a series of warp yarns in one or more insertion patterns, wherein said carpet comprises one or more several zones with essentially upper or lower floating yarns, thereby forming respectively a high relief or a low relief and in which one or more weft yarns are chenille yarns.