Weaving machine, method for simultaneously weaving two pile fabrics on such a machine and pile fabric obtainable with such a method
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Solution Overview
Problem
Current carpet weaving machines are inefficient due to high pile density limitations, time-consuming and costly installation, and difficulty in changing designs, as they require numerous bobbins and pre-dyed materials, making it challenging to produce high-quality pile patterns on both sides of the fabric.
Innovation Solution
A weaving machine that simultaneously weaves two pile fabrics with a control unit, treatment unit, and adjusting sub-assembly, allowing for precise control of pile warp yarns, binding warp yarns, and weft insertion, enabling the creation of complex patterns on both sides without dead piles, and allowing for easy adaptation of designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If numerous bobbins and pre-dyed materials are used to achieve high pile density and complex patterns, then manufacturing precision and adaptability improve, but device complexity and installation time increase significantly
Solution Approach 1:
The patent extracts the coloring function from the weaving process by introducing a separate treatment unit that applies color to warp yarns after weaving. This eliminates the need for numerous pre-dyed bobbins and complex creel configurations, while maintaining the ability to produce complex pile patterns. The coloring operation is separated from the mechanical weaving process, simplifying the overall device.
Solution Approach 2:
The treatment unit applies color segments to warp yarns in advance before the weaving process begins. This preliminary coloring action allows the weaving machine to use undyed or uniformly dyed yarns, eliminating the need for complex pre-configuration of multiple colored bobbins. The patterns are prepared beforehand through treatment rather than through complex initial setup.
2Adaptability or versatility
If traditional weaving machines are used with fixed creel configurations, then manufacturing stability is maintained, but adaptability to new designs and productivity decrease
Solution Approach 1:
The patent replaces the mechanical system of multiple colored bobbins and complex creel configurations with a treatment unit that applies color through a different mechanism (spraying, coating, or impregnation). This substitution allows rapid design changes without mechanical reconfiguration, as the coloring parameters can be adjusted digitally or chemically rather than physically changing bobbin arrangements.
Solution Approach 2:
The treatment unit serves multiple functions: it can apply different colors, create various pattern types, and adapt to different design requirements all through a single device. This multi-functionality replaces what previously required multiple specialized bobbins and creel configurations, enabling rapid adaptation to new designs while maintaining continuous production.
3Manufacturing precision
If pre-dyed materials and multiple bobbins are used to create patterns, then manufacturing precision improves, but material consumption and production time increase
Solution Approach 1:
The treatment unit operates continuously during the weaving process, applying color segments to warp yarns as they pass through, without interrupting the weaving cycle. This eliminates the time losses associated with stopping production to change bobbins or reconfigure the creel for different patterns. The useful action of coloring continues uninterrupted alongside weaving.
Solution Approach 2:
Color segments are applied to warp yarns in advance through the treatment unit before the yarns are woven into the final product. This preliminary coloring allows patterns to be established during the weaving process itself rather than requiring post-processing or complex pre-arrangement of pre-dyed materials, reducing overall production time while maintaining pattern accuracy.
4Manufacturing precision
If high pile density is achieved through numerous bobbins, then manufacturing precision improves, but device complexity and maintenance difficulty increase
Solution Approach 1:
The patent extracts the pile density control function from the complex multi-bobbin system and places it under the control of the treatment unit. By applying color segments at controlled intervals and positions, the treatment unit can define pile patterns and density without requiring numerous individual bobbins, thereby simplifying the mechanical structure while maintaining precise control over pile characteristics.
Solution Approach 2:
The treatment unit controls pile density and pattern characteristics by changing parameters such as color application frequency, segment length, and positioning, rather than by changing the physical number of bobbins. This parametric control allows precise adjustment of pile density while maintaining a simple, maintainable device structure.
Data Source
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AI summary
This weaving machine (2) is for simultaneously weaving a top pile fabric (F2) and a bottom pile fabric (F4), each pile fabric presenting some pile patterns (P2, P2', P4) and including tufts, made from warp yarns (24), binding warp yarns (14, 16) and inwoven weft yarns. This machine comprises a pile warp yarns feeding unit (20), a binding warp yarns feeding unit (18), a shedding unit (6) for creating a shed with the pile warp yarns and the binding warp yarns (14, 16). A weft insertion unit (8) is used for inserting the weft yarns in the shed in successive insertion cycles. A beating-up mechanism (32) is used for beating the weft yarns into the shed. A take up system (70) is used for taking-up the two pile fabrics. A drawing-in unit (26) draws the pile warp yarns from the pile warp yarn unit (20) and a control unit (80) controls operation of the weaving machine (2). This weaving machine also comprises a treatment unit (90) located, along a path of the pile warp yarns (24), between the pile warp yarns feeding unit (26) and the shedding unit (6), for applying different segments of treatment on at least some of the pile warp yarns (24).