Weaving Method Hiding Warp Yarns in Fabric Backing
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Solution Overview
Problem
Conventional weaving methods, such as face-to-face weaving, result in a fabric backside that is different from hand-knotted carpets due to visible backing warp yarns, lacking the quality and appearance of hand-knotted fabrics.
Innovation Solution
A method involving a backing fabric with binding and tension warp yarns, pattern forming pile warp yarns interlaced around third weft yarns situated outside the backing fabric, and non-pattern forming pile warp yarns that float between weft yarns or are removed, to create a fabric with a backside resembling hand-knotted carpets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional face-to-face weaving is used, then productivity is high, but the back of the fabric shows visible backing warp yarns and lacks the quality of hand-knotted fabrics
Solution Approach 1:
The invention extracts the problematic binding warp yarns from the visible back surface by having them interlace weft yarns completely outside the backing fabric. The third weft yarns are inserted through the entire fabric structure, allowing binding warp yarns to secure the back without appearing on the surface, thus removing the visual defect while preserving weaving efficiency
Solution Approach 2:
The invention moves the interlacing action of binding warp yarns to a different spatial dimension by positioning it outside the backing fabric. The third weft yarns extend through the entire fabric thickness, enabling binding warp yarns to function in a dimension that does not compromise the aesthetic quality of the back surface
2Manufacturing precision
If hand-knotting is used, then the back of the fabric shows no visible warp yarns and has perfect pattern, but the production method is very labour intensive
Solution Approach 1:
The invention creates a woven structure that copies the essential characteristic of hand-knotted fabric backs - the absence of visible warp yarns - by using third weft yarns that extend through the entire fabric and binding warp yarns that interlace outside the backing. This replicates the hand-knotted appearance while maintaining mechanized weaving productivity
Solution Approach 2:
The invention replaces the manual knotting mechanism with a automated weaving system that achieves similar results. Instead of manually tying knots around warp yarns, the system uses interlaced third weft yarns and binding warp yarns positioned outside the backing to achieve the same effect of hiding warp yarns on the back surface
3Stability of the object's composition
If binding warp yarns interlace weft yarns in the backing fabric, then the backing fabric structure is secured, but the binding warp yarns become visible at the back of the fabric
Solution Approach 1:
The invention extracts the binding function from the backing fabric interior and relocates it to the exterior. Binding warp yarns interlace third weft yarns outside the backing fabric, securing the structural integrity without compromising the aesthetic appearance of the back surface
Data Source
Figure 1~2
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AI summary
On the one hand, the invention relates to a method for weaving a fabric comprising: - a backing fabric (100, 200) formed by backing warp yarns, comprising binding warp yarns (101, 201) and first an second weft yarns (3, 4); - one or several tension warp yarns (102, 202, 103, 203); - non-pattern forming and/or pattern forming pile warp yarns (7, 6), the pattern forming pile warp yarns (6) forming pattern forming pile burls (6a), and each pattern forming pile burl (6a) being interlaced round at least one third weft yarn (5), and each pattern forming pile burl being interlaced over at least one third weft yarn situated at the back of the fabric (1, 2) with respect to the tension warp yarns (102, 202, 103, 203). On the other hand, the invention relates to a fabric (1, 2) woven in accordance with such a method and a weaving machine provided for weaving such a method and for weaving such a fabric (1, 2).