Terry Weave Fabric Weight Distribution via Five-Pick Insertion
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Solution Overview
Problem
Traditional terry fabric weaving methods are inefficient as they result in a higher weight and cost contribution from expensive pile warp yarns, and the weaving process is not optimized for faster production and fabric quality.
Innovation Solution
The terry fabric weaving process involves a double insertion of weft yarns in the first and second sheds and a single insertion in the third shed, with the weft and pile warp yarns being beaten up to form loops, reducing the contact surface area and coefficient of friction, thereby distributing weight more evenly and reducing production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional three-pick terry weaving is used, then the pile warp yarns form the majority of the fabric weight, but this increases cost since pile warp yarns are the most expensive component
Solution Approach 1:
The patent changes the weaving parameters by implementing a five-pick sequence with double insertion of weft yarns in first and second sheds, and single insertion in third shed. This parameter change redistributes the weight contribution from pile warp yarns (traditionally 60-70%) to a more balanced distribution, reducing reliance on expensive pile warp yarns while maintaining terry fabric characteristics
Solution Approach 2:
The weaving process is segmented into five distinct pick operations with different insertion patterns. The first and second picks insert weft yarns twice, the third pick inserts once, and the fourth and fifth picks complete the sequence. This segmentation allows optimization of yarn placement to reduce expensive pile warp yarn usage
2Productivity
If traditional weaving processes are used, then production speed is limited, but increasing speed may compromise fabric quality
Solution Approach 1:
The patent implements a periodic five-pick weaving sequence that repeats cyclically. This periodic action with standardized insertion patterns (double, double, single, single, single) enables consistent fabric quality while optimizing production rhythm and speed, as each pick follows a predetermined pattern that can be executed efficiently
Solution Approach 2:
The weaving pattern is predetermined with weft yarns inserted in specific sequences before the beating-up action forms the loops. This preliminary arrangement of yarns in specific positions ensures that when the beating-up occurs, the loops form correctly with proper orientation, maintaining quality while enabling faster production through pre-planned sequences
3Shape
If pile warp yarns are beaten up to form loops, then terry loops are created, but excessive contact surface area increases friction and may cause twisting
Solution Approach 1:
The patent applies different insertion patterns to different sheds: double insertion in first and second sheds, single insertion in third shed. This creates local variations in yarn density and contact surface area, optimizing loop formation in some areas while reducing friction and twisting risk in others, achieving balanced loop quality throughout the fabric
Data Source
AI summary
A terry fabric includes a plurality of longitudinally-oriented ground warp yarns, a plurality of pile warp yarns in parallel with the ground warp yarns and a plurality of weft yarns oriented substantially laterally to the ground warp yarns. Each weave sequence of the terry fabric includes first and second placements of weft yarns in a first shed of the ground warp yarns, third and fourth placement of weft yarns in a second shed of the ground warp yarns and a fifth placement of weft yarn in a third shed of the ground warp yarns and the pile warp yarns such that the pile warp yarns form a pile loop over the first, second, third and fourth placements of weft yarns.