Pile Height Variation in Double-Face Weaving via Tension Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for weaving pile fabrics with different pile heights are limited in density, design options, and require additional steps or complex machinery, making them costly and inefficient.
Innovation Solution
A method and device for interlacing pile-warp threads with varying strain levels into the fabric, allowing for the creation of fabrics with multiple pile heights without the need for additional machinery or complex operations, using a feed control device to manage tension and achieve desired pile heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If pile-warp threads are interlaced over multiple wefts to achieve longer pile height, then pile height is increased, but pile density is reduced and additional scratching operations are required
Solution Approach 1:
The invention divides the fabric structure into two faces (first and second face fabrics) with different pile heights, allowing each face to have optimized pile density independently. The segmentation of the weaving structure enables long pile on one face without compromising the density on the other face.
Solution Approach 2:
Different pile heights are applied locally to different faces of the fabric rather than uniformly throughout. The first face fabric receives pile-warp threads with longer float lengths for higher pile, while the second face fabric receives threads with shorter float lengths for higher density, allowing each region to have optimized properties.
2Adaptability or versatility
If cutting knife operates at different heights to change pile height cycle after cycle, then pile height variation is achieved, but design options are limited to one height per cutting movement
Solution Approach 1:
The invention segments the fabric into two independent faces that can be woven simultaneously with different pile heights. This eliminates the need for complex cycle-based cutting knife adjustments, as both pile heights are achieved in a single continuous weaving process without requiring the cutting knife to move between different heights.
Solution Approach 2:
The invention combines the production of two different pile heights into a single weaving operation on a double-face weaving machine. Both face fabrics are produced simultaneously with their respective pile heights determined by the float length of pile-warp threads, merging what would otherwise require separate operations into one efficient process.
3Adaptability or versatility
If removable wefts are used to achieve different pile heights, then pile height variation is possible, but additional removal steps are required which increase cost and complexity
Solution Approach 1:
Instead of using removable wefts to create pile height differences, the invention inverts the approach by using non-removable pile-warp threads with different float lengths. The pile height variation is achieved by how the threads are inserted and tensioned during weaving, not by removing supporting elements afterward, thereby simplifying the manufacturing process.
Solution Approach 2:
The invention extracts the concept of removability from the system entirely. Rather than using removable wefts that must be taken out after weaving, the solution uses permanently integrated pile-warp threads whose float lengths are determined during the weaving process itself, eliminating the need for any post-weaving removal operations.
4Length of stationary object
If pile-warp threads are inserted with high strain to reduce pile height, then smaller pile heights are achieved, but freedom in choosing pile height is constrained by machine geometry
Solution Approach 1:
The invention introduces dynamic control of pile-warp thread insertion through variable tensioning mechanisms. A tensioning device adjusts the strain applied to pile-warp threads during insertion based on the desired pile height, allowing continuous variation of pile height independent of fixed machine geometric constraints. This dynamic adjustment enables freedom in pile height selection.
Solution Approach 2:
The invention changes the physical state and parameters of pile-warp threads during insertion by controlling tension and strain levels. By varying the insertion parameters (tension, strain, float length) rather than being constrained by fixed machine geometry, the system achieves continuous pile height adjustment and greater versatility in pile height selection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of fabrics with varied pile heights on single-face and double-face weaving machines, offering flexible positioning and height choices while simplifying the process and reducing costs.
Implementation Method 1
The elastic portion of the strain is that portion of the strain which is abolished upon the loss of the tension associated with the cutting through... the elastic portion of the strain of the pile-warp threads determines the height difference
Data Source
Figure 1
Figure 2
AI summary
The present invention relates, on the one hand, to a method for weaving pile fabrics with at least two different pile heights (a, b) in the same pile row, wherein the fabrics comprise weft threads, ground warp threads and pile- warp threads (1, 2), wherein these pile-warp threads are interlaced in the fabric, according to a pattern, in a figure- forming manner or are inwoven in a non-f?gure-forming manner, and which, when they are figure-forming, form pile with a well-defined pile height. On the other hand, the present invention relates to a device for manufacturing such fabrics.