CN1005489B - Jacquard double-layer plush fabric - Google Patents

Abstract

The invention relates to a fabric structure constituting a double layer of plush weaving with weft insertion in the shed. Wherein the buried pile is woven into the upper and lower fabrics. During the weaving process, each weft in the upper and lower fabrics consolidates the pile structure, which is achieved by means of each weft being equipped with a separate jacquard plate to control the pile diameter in the single weft pile consolidation structure. The fabric is woven to ensure that these piles are not pulled out and mixed contours are completely eliminated. It is also possible to obtain a production rate approximately equivalent to that of a single weft pile consolidation structure.

Description

Jacquard double-layer plush fabric

The invention relates to a structure of a double-layer plush fabric. The plush fabric is divided into an upper part and a lower part after double-layer weaving, and has the structural characteristic that one weft is introduced into each shed and each weft is fixedly connected with a U-shaped pile bundle (a double-layer plush carpet is a typical product).

In the production process of the double-layer plush, the upper and lower layers of fabrics are simultaneously connected with additionally woven pile warps and are overlapped and interwoven together. After weaving, pile warp between the upper and lower fabric layers is cut off, and vertical pile bundles are separated, so that two fabrics with vertical piles on one side are produced.

For the weaving-in of pile warp yarns joining two ground fabrics, a single-weft pile consolidation structure formed by the initially selected single-shed weft yarn insertion method can be considered. In this construction, however, each time a pile-in warp occurs, it is against the back of the lower fabric. These temporarily non-napped pile yarns float out on the back of the lower fabric. It must be doctored off in a subsequent doctoring process. Half of the pile bundles in the pile warp change position are also pulled out during scraping. Accordingly, a weft defect occurs in the lower fabric layer at each pile change. Despite its poor quality of the underlying fabric, such a single pile consolidation with a countersunk pile warp emerging at the bottom is still used in large numbers even in many countries for the production of double-pile carpets and other similar fabrics, since the corresponding weaving technique is relatively simple and it is sufficient to form the shed using a conventional high-shed jacquard machine. Furthermore, the production efficiency of single weft pile consolidated fabrics is relatively high, since each weft yarn consolidates a row of pile bundles, with the result that a denser pile coverage can be obtained without the need to introduce additional auxiliary weft yarns.

To counteract the low quality of the underlying fabric caused by the so-called single pick pile consolidation, a three pick consolidation pile structure may be employed. This construction can also be woven in single shed weft insertion on a conventional high shed jacquard machine. Unlike single weft yarn pile consolidation structures, the use of this structure allows pile warp texture change points to be transferred to two different weft yarns for entry into the upper fabric layer. Although the countersunk pile remains attached to the back of the lower fabric and must be scraped off in this configuration, the lower fabric does not suffer defects during the scraping process. With this structure, the following advantages can be obtained: the production loss is reduced, and the loss of a large amount of valuable pile diameter material in the pile forming process, including the scraping process of the countersunk pile warp, is reduced, so that the production cost is reduced.

In both of the above-mentioned consolidation structures, the countersunk pile which has emerged on the back of the lower fabric can only be used as a scrap. To avoid this loss and improve the quality of carpets containing valuable pile material, a two-weft pile consolidated structure capable of being woven by single-shed weft insertion has been developed. In the structure, the countersunk pile warps are distributed in the upper and lower layers of fabrics when being woven, so that the upper and lower layers of fabrics become equal in weight, and the front and back surfaces of the fabrics present clear patterns. However, a total of up to four weft yarns in the upper and lower layers of fabric are necessary to form a complete tuft bind structure. Each weft must be provided with a jacquard card which is changed in the interval of two picks. Since the hook on the blade box must always be moved to a lower position for reading for this purpose, the blade box must perform a complete up-and-down movement in each revolution of the loom, with the result that the rotational speed of a conventional high-shed loom used in this case is only about half that of a single-weft pile consolidation structure.

Therefore, many weaving methods using a double-shed weft insertion method have been used to improve the productivity of double-layer pile fabrics. It is clear that a much higher productivity can be achieved if, in each turn of the automatic loom, not only one weft thread can be alternately woven into the upper and lower fabric layers, but two weft threads are simultaneously introduced, overlapping each other, into the upper and lower fabric layers, respectively, in each turn. The double weft pile consolidation structure is the simplest of such weaving techniques. This structure can be woven by a double-shed weft insertion method. However, in this construction, a relatively rough upper surface is produced due to the blended contour occurring once during either a full tissue cycle or half of a full tissue cycle as a result of the upstanding split of the pile.

Therefore, a three-weft pile consolidation structure using a two-shed weft insertion method is created. The most common use in carpet factories today is this construction. In this weaving technique, a third weft yarn is further introduced between the two weft yarns of the double weft pile consolidated structure. This third weft yarn covers the countersunk pile warp on the lower surface of the carpet and prevents it from being squeezed out. Although productivity is relatively low due to the need for three weft yarns to consolidate the tufts, there is currently no more satisfactory alternative to this three-weft pile consolidation structure from a technical, aesthetic, and economic perspective.

It is an object of this invention to develop a fabric structure that combines the advantages of a triple fill pile consolidated structure woven using a double shed weft insertion process with the advantages of a single fill pile consolidated structure woven using a single shed weft insertion process. In this construction, therefore, neither pullout of the pile warp occurs, nor a mixed contour occurs, while the number of weft threads per pile bundle is minimized. In addition, a clear pattern can be produced on the front and back of the upper and lower layer fabrics despite the use of a single shed weft insertion device.

According to the invention, the jacquard plush fabric which is divided into an upper layer and a lower layer after weaving is provided. The fabric has a structure that one weft is introduced into each shed, each weft is fixedly connected with a U-shaped pile bundle, and the countersunk pile warp is woven into the upper layer fabric and the lower layer fabric and distributed in the upper layer fabric and the lower layer fabric.

Further, according to the present invention, there is provided a double-layer pile fabric in which a continuous pile warp constituting upper and lower layers of the fabric alternately extends into the two layers of the fabric. The continuous pile warp yarns are threaded through a continuous series of weft yarn sequences, each sequence of weft yarns including two lower weft yarns of the two-layer fabric and two upper weft yarns of the two-layer fabric, and at least one countersunk pile warp yarn is threaded between the adjacent upper and lower weft yarns in each sequence, whereby the upper and lower weft yarns of each layer of fabric secure the countersunk pile warp yarns and make the U-shaped pile bundles more secure.

The method of weaving the double layer plush fabric of this invention consists of using a single jacquard card for each of the upper and lower weft yarns in the upper and lower layer fabrics to control all the pile countersunk warp yarns.

In this way, the result is obtained that a double-layered plush structure of single-weft pile consolidation structures can be woven with a single-shed weft insertion device, which does not waste pile warp, or which wastes exactly the same amount of pile warp in the upper and lower layer fabrics. Thus, the invention combines the following advantages:

A) has a so-called single-weft pile consolidation structure woven by a single-shed weft insertion method without the disadvantage that a countersunk pile warp floats on the back of the lower fabric.

B) For a full weave repeat of the two-weft pile consolidation structure, it is also possible to weave with single shed weft insertion while requiring as little as half weft yarn.

C) A much less expensive machine can be used to produce a three-weft pile consolidated structure woven using a two-shed weft insertion process. For example: according to the invention each operator can see two or more machines, whereas each operator can only see one double-shed machine.

In the method according to the invention, each weft thread must have a jacquard card. In the introduction of single-shed weft yarns into conventional weaving production, double-lift, full-shed jacquard machines are used in combination with corresponding weaving machines in order to accomplish this. However, the hook stroke of this type of conventional jacquard is not sufficient for weaving double layer fabrics. Since double lift full shed looms have only a knife box stroke suitable for the production of single layer fabrics, when used for double pile weaving, the stroke of the harness and the harness, weight, etc. hanging on the harness, as well as the hook and the knife box, must be doubled. The stroke lengthening action must be completed in a substantially unchanged time if the production efficiency is not reduced, and therefore the mechanisms in the machine must withstand considerable forces (up to several tons in a frame several meters wide).

Thus, according to the invention, it is improved if a pulley is suspended from each of the castellated plates and the harness connected thereto is guided by the pulley. One end of the harness cord is connected with the heddle, and the other end of the harness cord is firmly connected with the frame, so that a double-acting full-open shed jacquard machine which is only used for weaving common fabrics can be converted into a double-layer plush jacquard machine which is used for weaving a single-weft fluff consolidation structure by single-shed weft insertion. When the hook is lifted and lowered along the usual travel for producing normal fabrics, the harness cord and heddle are dragged up and down, over a distance corresponding to twice the travel of the hook (and twice the speed of movement).

In this method, each individual hook determines that a lifting pulley must be fitted, but this reduces the harness cord, heddle and weight added to the hook by half, and in this way, a double-layer long pile fabric having a single-shed weft insertion, a countersunk pile diameter knitted and distributed in a single-weft pile consolidation structure of the upper and lower layers of fabric can be produced on a double lift full open shed jacquard machine used for the production of ordinary single-layer fabrics. Thus, if the above-mentioned pulleys are used to couple the hooks of the respective jacquard machines with the harness, it is possible to produce the fabric of the structure proposed in this invention on machines which are substantially mass-produced.

According to the invention, a separate perforated card must be used for each weft thread to be inserted. In order to control the necessary movements, taking into account that on average half of the pile diameters of the countersunk head are woven into the upper and lower fabric layers each time, the card is read in each revolution of the loom. The weave of the punched card can be manually woven on a punching machine by a common method or can be finished by a computer.

The invention will now be described by way of example with reference to the schematic drawings, in which:

figure 1 shows a fully-woven consolidated double-pick double-layer plush fabric structure woven by the so-called single shed weft insertion technique.

FIG. 2 shows a single weft consolidated structure according to the invention.

Figure 3 shows a heddle structure for producing a fabric structure according to the invention.

For a full weave repeat pile structure in the upper and lower fabric layers, two wefts at a time are necessary to obtain a double pick pile consolidation structure using the single shed weft insertion method of fig. 1, whereas for weaving using the single shed weft insertion method of fig. 2, only one weft is required to consolidate each pile in accordance with the invention.

In the fabric structure of fig. 1 and 2, pile paths 3 are located between the upper fabric 1 and the lower fabric 2, which pile paths are cut off from the middle after weaving is completed. The upper layer fabric 1 and the lower layer fabric 2 also comprise a ground diameter 4 and a binding diameter 5, and the weft yarn structures of the upper layer fabric 1 and the lower layer fabric 2 are respectively composed of lower weft yarns 6 and upper weft yarns 7 which are woven in alternately. The countersunk pile diameters 8 and 9 are, on average, woven half-way into the upper and lower fabric layers 1 and 2, respectively. An essential difference between the constructions of fig. 1 and 2 is that in the so-called double pick consolidation construction of fig. 1, the upper weft yarns only serve to secure the countersunk pile paths 8 and 9, while the upper weft yarns 7 (and also each lower weft yarn 6) also have the function of forming a pile tuft according to the invention.

The single-weft consolidated structures woven by single-shed weft insertion according to the invention are characterized in that the countersunk pile warp 8, 9 is woven into the upper fabrics 1 and 2 on average and in approximately equal proportions. According to this invention, the effect of distributing the weave of the countersunk pile warp 8, 9 in the upper and lower layer fabrics 1 and 2 can be obtained, similar to the double weft consolidated structure woven by the single shed weft insertion method in fig. 1. In this case, for each weft a jacquard plate has to be programmed and read. Since according to the invention a pile is produced per weft, the production is considerably higher than in the construction according to fig. 1. The production yield is the same as that of a single-shuttle-opening weft yarn insertion method for producing a single-weft pile bundle consolidation structure in which a pile warp bundle with a countersunk head possibly spreads on the back surface of a lower layer fabric.

For shedding when producing the fabric according to the invention, double lift, full shed jacquard machines are suitable. The connecting piece of the loom and the jacquard is a thread which transmits the control information of the jacquard to a heddle. According to fig. 3, the thread hanging on the jacquard castellated plate 11 consists of a head thread 12, a lifting pulley support 13, a harness cord 14, a heddle 15 and a weight 16. The heddle 15 is provided with a heddle eyelet 17 for passing through the pile diameter. The broach (not shown) engages the hook 18 and causes the hook to rise and travel the necessary stroke H for shed formation and then to fall again. The carabiner can rest on the bottom plate 19 when lowered. The lifting sheave bracket (generally indicated at 13 in the drawings) is comprised of a sliding clamp plate 20 and a lifting sheave 21. The length of the slide clamp 20 and the leader line 12 should be greater than the lift stroke H. The dimensions are such that when the associated hook 11 is lifted, the lower end of the leader line 12 is not pulled out of the base plate 19 and the adjacent lifting pulley bracket 13 is always in the normal position even during relative movement without jamming. In the example of fig. 3, it is important that the harness cord 14 is guided by means of a lifting pulley and that the upper end of the harness cord, which is opposite the heddle 15, is fixed to a component of the machine frame, which component can serve as a bottom support 23 for the harness cord carrier, and that the harness cord 14, which is fixed at its upper end 22 to the harness cord carrier support 23, completes a stroke of 2H when the carabiner is lifted through the stroke H, and that the heddle eyelet 17 is lifted to the same height together with the pile warp thread passing therethrough. By this method, a double lift full open shed jacquard loom with a designed hook stroke of H can be formed with a shed height equivalent to the stroke of 2H hook without overloading the jacquard.

Claims (1)

1. A jacquard double-layer plush fabric divided into two layers after weaving, comprising one weft yarn per shed, each weft consolidating a U-shaped pile bundle, buried pile warps (8, 9) woven into the upper and lower fabric layers (1, 2), and distributed in the two layers, a continuous pile warp constituting the upper and lower fabric layers (1, 2) alternately extending into the two fabric layers, the pile warp being wound in a continuous series of weft yarn sequences, characterized in that each weft yarn sequence comprises two lower weft yarns of the two-layer fabric and two upper weft yarns of the two-layer fabric, at least one buried pile warp passing between adjacent upper and lower weft yarns in each sequence, whereby the upper and lower weft yarns (6, 7) of each fabric layer secure the buried pile warp (8, 9) and make the U-shaped pile bundle (3) more secure.

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