Weaving Method Hiding Warp Yarns for Hand-Knotted Carpet Quality
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional weaving techniques, such as face-to-face weaving, result in a fabric backside that is different from hand-knotted carpets due to visible backing warp yarns, whereas hand-knotted methods are labor-intensive and limited in productivity.
Innovation Solution
A method involving a backing fabric with binding and tension warp yarns, where pattern forming pile warp yarns are interlaced around third weft yarns situated outside the backing fabric, and binding warp yarns interlace second weft yarns on the pile face, creating a weave structure that hides warp yarns and achieves high density and quality similar to hand-knotted fabrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional face-to-face weaving is used, then productivity is improved, but the back of the fabric shows visible backing warp yarns resulting in poor quality
Solution Approach 1:
The patent introduces a third weft yarn that passes through the backing fabric to the pile face, creating a new dimensional path for pile warp yarns to interlace. This allows pile burls to be formed on the pile face while using weft yarns that originate from the backing fabric, effectively hiding backing warp yarns and improving back quality while maintaining weaving productivity
Solution Approach 2:
The third weft yarn acts as an intermediary element that connects the backing fabric to the pile face. It enables pattern forming pile warp yarns to interlace round weft yarns on the pile face without requiring direct interlacing with backing warp yarns, thus improving back quality while maintaining productivity
2Manufacturing precision
If hand-knotted method is used, then back quality is improved with no visible warp yarns, but productivity deteriorates due to labor-intensive process
Solution Approach 1:
The patent creates a woven fabric structure that copies the essential characteristic of hand-knotted fabrics - a clean back with no visible warp yarns - by using pattern forming pile burls interlaced round weft yarns on the pile face. This achieves hand-knotted quality appearance through a mechanized weaving process, maintaining high productivity
3Productivity
If pattern forming pile warp yarns are interlaced round weft yarns at the back, then productivity is improved, but visible warp yarns appear at the back reducing quality
Solution Approach 1:
The patent applies different quality requirements to different parts of the fabric: the pile face allows visible pattern forming pile burls for design, while the backing fabric uses third weft yarns that are not interlaced by backing warp yarns to create a clean back appearance. This local differentiation of quality characteristics resolves the contradiction between productivity and back quality
Data Source
AI summary
A method for weaving a fabric having:a backing fabric (100, 200) formed by backing warp yarns, having binding warp yarns (101, 201) and first and second weft yarns (3, 4);one or several tension warp yarns (102, 202, 103, 203); andnon-pattern forming and/or pattern forming pile warp yarns (7, 6), the pattern forming pile warp yarns (6) form pattern forming pile burls (6a), and each pattern forming pile burl (6a) is interlaced round at least one third weft yarn (5) situated at the back of the fabric (1, 2) with respect tote tension warp yarns (102, 202, 103, 203).