EP1489211B1 - Method of manufacturing a face to face pile fabric on a double-plush loom - Google Patents

Description

The invention relates to a method for producing a Doppelpolgewebes on a Doppelpolwebm aschine with at least two weft insertion levels using weft yarns, Füllkettfäden and groups of binding warp threads for the formation of an upper and a lower base goods and choirs of pile threads per warp course for the formation of a patterned between The Polymers separable pile fabric, the Totpole, are integrated between the back and inner shots to stabilize the basic goods.

EP 1 217 114 A1 discloses a method for producing a double carpet fabric with symmetrically arranged patterning poles. The patterning pile threads bind exclusively via simultaneously registered back shots of upper fabric and lower fabric. At regular intervals, so-called inner shots are recorded, which bind the non-eye pile threads - the so-called tot poles - to the basic fabric by crossing them with corresponding binding warp threads. For this purpose, the weft insertion rhythm is changed. The repeat of the weft insertion extends over at least four loom tours. The pile binding on back shots of each product is not changed by the entry of the inner shots.

The binding warp threads include the back shots of successive tours predominantly individually or in pairs between them. In the area of the registered inner shots, individual binding warp threads also wrap around this inner weft. To compensate for the integration length, a rhythm change usually takes place twice between the binding warp threads within a repeat and a group, so that the binding warp threads within a repeat of the group of binding warp threads all have a uniform integration length.

This type of binding is advantageous because a Polfadenwechsel can be done practically every other tour and each Polhenkel can be anchored with high strength and vertical arrangement in its basic product.

Another advantage of this product is that the clamping of the pole leg between consecutively inserted shots in the warp direction takes place exclusively in the region of the back shots. The lower number of inner shots allows one hand, a saving of weft material. On the other hand, the smaller number of inner shots allow a limited lateral deflection of the pole legs. The pile layer, which determines the tread elasticity and the pedaling comfort, thus already begins immediately inside, adjacent to the back shots.

A disadvantage of this type of binding is primarily the mandatory predetermined symmetrical arrangement of all mustering poles. With a clean color pattern, this requires a higher number, namely twice the number of choruses. That in turn requires a more elaborate machine with multiple control points.

Another disadvantage is that the majority of the crossing points of the binding warp threads is arranged in the plane of the back shots and is therefore located in the region of the highest concentration of pile material between the back shots. This limits the weft density and thus the row width density (in the warp direction).

EP 1 180 556 A1 describes a process for the production of a double-pole fabric with asymmetric Polhenkeleinbindung. With the zweischützigen mode of operation is in each tour in each of the basic goods (upper or Unterware) shot a shot. One of the shots is a back shot, a second shot is an inside shot. The number of back shots is therefore identical to the number of inscribed shots - based on one of the two goods.

The patterning pile threads bind exclusively on the outside of the back. Each pole leg has two terminal points per base product, which are arranged one above the other in the depth of the tissue. Two pole legs are regularly clamped between two consecutive back shots and also between two consecutive shots in the same way.

Are z. B. in a dreischützigen mode of operation and two-speed pole binding and so-called. Intermediate shots between filler and Totpolen registered, also produce the intermediate shots nor an additional nip.

The carpet produced in this way has a very high pull-out strength of all pole handles. The legs of the pole loops regularly protrude vertically from the base fabric.

The disadvantage, however, is that the area of the free pole leg, which essentially co-determines the tread elasticity or the tread comfort of a carpet fabric, only begins to adjoin the area of the inner shots. This weaving process leads to an increased thread consumption of pile material and weft material because of the greater depth of the base fabric.

The document describes binding reports for the binding warp threads which extend over a greater number of weft insertion cycles. The illustrated binding reports are based on the fact that - in addition to one sufficient firm binding of the inner shots on the back shots in the depth - and a firm bond in the warp direction adjacent weft threads (weft density) is ensured.

It depends on the design of the binding rapport, the nip binding in the field of Grundbindu ng the terminal points in the plane of the back shots and the inner and / or intermediate shots to make so that at a given high density, a solid and largely vertical binding of Pole legs can be guaranteed.

To ensure a saving of thread material, the binding warp threads of a group are divided into adjacent warp courses.

In this context, a group of binding warp threads is understood to mean the binding warp threads usually associated with a warp course which, within a weave repeat, cross each weft thread (back or inner weft) at least once.

With the aim of saving binding chain material bind z. B. pairs of binding warp threads in sections only with back or inner shots. The number of shifts between the level of back shots and the level of inside shots is reduced. The consequent saving in binder warp material is desirable.

To ensure a uniform integration length of the binding warp threads of the group drawn from a warp beam, rhythm changes are provided within a weave repeat. Due to the rhythm changes, the function of the change of subject between the mentioned weft planes, which regularly requires a higher length of integration, is distributed uniformly over all binding warp threads.

A further saving of binding warp material is achieved by distributing the binding warp threads of a group to adjacent warp courses.

The disadvantage is that the nature of the chosen bindings makes a pairwise assignment of an inner weft to each backshot necessary. But this leads - as already described above - to double clamping points and thus to an increased pile thread consumption.

From DE 21 64 948 A1, a weaving method is described in which the weft threads are entered in an example four-speed rapport. Two weft pairs are first entered in successive tours. One each of these pairwise registered weft threads is an inner weft in a first product (upper or lower fabric) and a back weft in a second product. In the following tour the assignment changes. In the following episode two single shots will be entered. A first single shot is a back shot in the second and another single shot is a back shot in the first.

The three shots in each product entered in the four tours are enclosed by two binding warp threads of a group in a common opening. The inner shot is located between two back shots, which are encompassed by a binding warp thread.

The highest concentration of pile threads between successively inserted weft threads is in the plane of the back shots of each article. At the same level, even after every fourth weft insertion cycle, the binding warp threads in each warp course intersect simultaneously.

With asymmetric pile weaving, this method can already achieve a somewhat higher, but still clearly limited, weft density and thus pile-up density.

A further disadvantage of this procedure shown here is that the non-eye pile threads (the tot poles) float at the base of the pile layer of one of the two base fabrics and are held exclusively in this area by the pattern-changing pole binding. The advantage of higher tread elasticity, which results from the lower number of inner shots with the lowest possible total pile height, is compensated again, because a certain, larger pile height is required for covering the floating totepole.

If you decide in view of a large-scale pattern design for the removal of these little bound Totpole, then this is a significant technical effort in a further operation connected. In addition, a substantial portion of the pile material is no longer available for the design of the pedaling comfort. It becomes waste.

According to another example of DE 21 64 904, the non-poling poles (Totpole) by means of internal shot and a correspondingly guided binding chain polseitig held on the back. The three weft threads per ware (upper fabric, lower fabric) which are registered within four turns (weft insertion cycles) are enclosed in a single opening of two binding warp threads per ware. At the same time, the three shots mentioned - two back shots and one inside shot - enclose the filler chain and the dead poles in the depths. The inner shots of both goods are entered in pairs. By contrast, the back shots are always introduced alternately into the two goods by discharging one shot entry at a time as a single shot. Patterning pole handles are - apart from the pile thread change - spread by back shots of both goods. When Polfadenwechsel single legs of Polhenkeln are clamped by inner shots.

Apart from the limited productivity - during the Innenschusteintrages in a tour no Polhenkel are formed - is at this binding a Polfa-denwechsel only possible after every fifth weft insertion cycle. Each pattern point must therefore necessarily consist of at least two pole handles. This significantly limits the pattern resolution. The shot density is also limited here.

Finally, EP 1 152 076 A2 describes a weaving method in a similar manner as disclosed by DE 21 64 904. The only difference is that the pole loops of the upper or lower fabric are alternately spanned between back shots of both goods and arranged between within the filler chain "intermediate shots" of both goods.

The three shots of each product registered within a four-speed report are thus in three different planes which extend parallel to the plane of the filling warp threads of the fabric.

The highest density of the pole legs is achieved equally in the plane of the intermediate shots and, in almost the same way, in the plane of the inner shots. In the plane of the intermediate shots, the density is therefore slightly higher, because here the binding warp threads cross each other and actively apply forces in the direction of attack.

However, this effect of binding warp threads occurs only after every third shot per commodity once. The binding chain is thus unable to fix the achievable at the shooting stop high density. The pole row density is limited.

The object of the present invention is to increase the density of Polhenkelreihen of Doppelpolgeweben with the most economical use of Pol, weft and binder warp yarn material, with asymmetric Polhenkelanordnung and securing a high Polhenkel-Ausziehfestigkeit. To ensure a sufficient productivity of tissue production should be possible at least in sections a zweischützige mode of operation and a two-speed pile weave.

This object is achieved by the combination of the features of claim 1. The decisive advantage of the procedure defined in claim 1 is that in almost every tour per binding thread group a professional representation takes place, which is suitable to fix the Schussansch reached by the reed density. In the areas of the highest concentration of the patterning pile threads between successive back shots - by dividing the binding warp threads of a group on two adjacent warp courses - crossings of the binding chains within a warp course are largely avoided.

Due to the significantly lower density of the shots in the plane of the inner shots compared to those in the plane of the back shots - especially in the attack of inner shots - the effective force component of the setting Bindekettfadens be increased at Fachvertritt in weaving.

By this combination of the solution elements a shot or pile row density is achieved, which was previously unimaginable with interwoven two-speed two-shot bindings. With an appropriate choice of thread materials for weft threads and binding warp threads u. U. reached a doubling of density.

Due to the arrangement of the highest weft density in the plane of the back shots, all pole side sections lying above this layer serve with their greater lateral expansion capacity to form elastic tread properties without reducing the pull-out strength of the pole legs. The total pole height can therefore be reduced. A saving of pile material is the result.

A significant saving of weft material takes place by the known omission of inner shots. Material savings on binding warp threads are effective in that fewer inner shots must be tied to the back shots.

With the modification of the method according to claim 2 also clean pattern contours and a high pattern resolution are possible at high density. A pattern-appropriate color change of the pile threads is possible in every second tour.

With the design of the binder yarn repeat according to claim 3, a sufficient density is achieved with a limited number of shafts and with the least control effort for the shafts.

The procedure according to claim 4 increases the number of opposing Fachvertritte a binder warp thread group per Schussrapport and ensures a significantly higher pile row density. The limited differentiated integration length of the individual binding warp threads of a group is compensated automatically for most thread materials. If necessary, the conditions for a uniform incorporation of the binding warp threads can be achieved by regular rhythm changes.

The method of claim 5 is comparable in terms of advantages to those achievable by claim 3. Also with this type of binding one can work analogously to claim 4 with two binding warp thread pairs.

Although the embodiment according to claim 6 requires a greater effort in the control of the individual shafts, but leads to a higher density and a further reduced cost of materials for the binding warp threads.

The practically measured highest shot density can be achieved with the design of the binder thread repeat according to claim 6. Critical crossing points of the binding warp threads, especially in the areas of the back shots, are distributed over two adjacent warp courses. The intersections of warp yarns crossing each other within a warp course are found in the depth range of the tot poles and the filler chain, respectively. For fixing the weft density, which is achieved during the weft stop, this described binding warp repeat is particularly suitable.

Finally, claim 7 shows a binding variant with a larger Schussrapport. Such bonding results in further material savings and improved ride comfort.

To design the necessary Schussrapportes the thread is presented to the respective gripper by control means of weft scissors or not presented in a conventional manner. On the energetically seemingly cheaper uncoupling and coupling of rapiers from their drive is omitted, since the necessary coupling operations in the significantly increased weaving speed in the time available are no longer reliable controllable. Equipping the weft cutter with a special sensor, you can also reliably check whether a weft thread was registered according to the specified repeat or not.

Fig. 1

einen schematischen Querschnitt eines Doppelflorgewebes, bei dem die Schussfäden im Rhythmus ihrer Eintragsfolge angeordnet wurden, bei dem im rechten Bereich die Polhenkel weggelassen wurden und bei dem die Bindekette einen sich über acht Schusseintragszyklen erstrekkenden Rapport ausführt,

Fig. 2

eine Darstellung analog der Fig. 1, wobei sich der Rapport der Bindekette über sechzehn Schusseintragszyklen erstreckt,

Fig. 3

eine weitere Darstellung analog Fig. 1, wobei die Bindekettfäden in anderer Weise als in Fig. 2 einen Rapport über sechzehn Schusseintragszyklen ausführen,

Fig. 4

eine ähnliche Darstellung wie in Fig. 1, wobei die Polfadenwechsel in ihrer kürzesten Folge dargestellt sind,

Fig. 5

einen etwa realen Querschnitt durch den Teppich einer Oberware eines Doppelteppichgewebes in der Bindungsart nach Fig. 3,

Fig. 6

eine Darstellung analog Fig. 5 mit der Bindungsart nach Fig. 1,

Fig. 7

eine Darstellung analog Fig. 5 mit der Bindungsart nach Fig. 2,

Fig. 8

eine Darstellung analog Fig. 5, die eine Ausführung nach dem Stand der Technik zeigt (prior art),

Fig 9

eine Darstellung analog Fig. 5 mit einem weiteren achttourigen Bindekettfadenrapport und

Fig. 10

eine Darstellung analog Fig. 5 mit einem sechstourigen Schussrapport und einem zwölftourigem Bindekettfadenrapport.

The invention will be explained in more detail below with reference to some examples. In the accompanying drawings show:

Fig. 1

a schematic cross-section of a double pile fabric, in which the weft threads were arranged in the rhythm of their entry sequence, in the right area, the pole legs have been omitted and in which the binding chain executes over eight weft insertion cycles rapport,

Fig. 2

1 shows an illustration analogous to FIG. 1, wherein the repeat of the binding chain extends over sixteen weft insertion cycles,

Fig. 3

1 shows a further illustration analogous to FIG. 1, wherein the binding warp threads execute a repeat over sixteen weft insertion cycles in a different way than in FIG. 2,

Fig. 4

a similar representation as in Fig. 1, wherein the pile yarn changes are shown in their shortest sequence,

Fig. 5

an approximately real cross section through the carpet of a top fabric of a double carpet fabric in the binding manner according to FIG. 3,

Fig. 6

5 shows a representation analogous to the binding type according to FIG. 1, FIG.

Fig. 7

a representation analogous to FIG. 5 with the binding type according to FIG. 2,

Fig. 8

a representation analogous to FIG. 5, which shows an embodiment according to the prior art (prior art),

FIG. 9

a representation analogous to FIG. 5 with another achttourigen Bindekettfadenrapport and

Fig. 10

a representation analogous to FIG. 5 with a six -stroke weft repeat and a twelve-time binder warp repeat.

To prepare the double carpet fabric described below is a double carpet weaving machine with at least two weft insertion, with a - preferably 12-schäftigen - shank arrangement for shedding the binding warp threads and Füllkettfäden and with at least a three-position Jacquard machine to control the drive of the pile warp threads for shedding.

This Doppelteppichwebmaschine is equipped with a clamping and cutting device for the weft threads, which is also able to submit a weft to the Bringergreifer a weft insertion system or not present. It is also equipped with a sensor that monitors whether a weft thread has been registered according to the RS report or not.

In the illustration according to FIG. 1, the shots SR, SI are entered starting from the left in the sequence shown. Superimposed shots are entered simultaneously.

In the first tour, the back weft SR1 is entered into the top fabric WO and the inside weft SI2 into the underware WU. In the following tour, the back weft SR3 is entered individually into the lower ware WU and then also individually the back weft SR2 into the upper WO. In the last tour of the shot repeat RS two shots are registered again at the same time. The At first, the inside weft SI1 in the top fabric WO and secondly the back weft SR4 in the bottom fabric WU. In the following tour, the next shot repeat RS begins in the same way.

Between the back shots SR1, SR2; SR3, SR4 and inner shots SI1 are in each product - lying on the back - the filling chain F and further inside - d. H. further to the pole side, the dead poles PT11 and PT12 are predominantly stretched out and integrated.

The binding warp B are divided into two pairs per group. The first pair B11, B15 is fed in the first warp course K1 and the second pair B12, B16 in the second warp course K2.

The bonding course of each of the binder warps B11, B12, B13 and B14 will be described on the binder warp B11. First, he binds in his goods outside over two adjacent back shots SR1, SR2 in the top product WO. After a trade agreement he binds inside over the inside shot (SI1), before he starts the new rapport RB1 of the binding warp threads five tours later with the binding outside over a back shot SR.

The respective second binding warp thread B15, B16, B17, B18 of a pair starts with a common bond with the first binding warp thread outside over a first back weft. However, he then remains in the outer compartment for three more tours, before switching to the middle compartment in the next tour and then crossing the inside shot. In the next tour he returns to the outer compartment and ends his Rapport RB.

This combination of pairs has the advantage that none of the intersections of the binding warp threads B of a group is positioned between successive back shots SR. As far as the crossing Stelien within the basic goods are their binding warp threads are distributed on two adjacent warp courses K1, K2. For this we can determine that each backshot SR is fixed in the direction of impact by a technical representation of a binding warp B1 of a group.

The relations between the repeat RB of the binding warp threads B and the repeat RS of the weft threads S are always retained in each double-stitched fabric. The size of the repeat RB is always an integer multiple of the repeat RS of the wefts S.

The binding of the top fabric WO produced according to this scheme is shown again in FIG. 6 in an approximately natural section in the plane of the warp course 1. The filling chain F and the group of Totpole PT, which belong to the respective warp course, are in the background and are therefore shown in dashed lines. Directly in front of these warp threads F, PT are the respective observable pole loops PM of the warp course K1, all of which bind via back shots SR1, SR2.

It can clearly be seen that in the two adjacent warp courses K1 and K2 only one of the binding warp threads B11, B15 of a pair actually crosses the legs of the pile loops (PM) between the back wefts SR1 and SR2, the space of the highest pile thread concentration. The legs of the pole legs thus have more room to spread laterally in the available gap.

A binding warp thread section, which changes within a tour from the back weft SR to the inside weft SI, only extends parallel to the pile thread legs between the back wefts SR1 and SR2. Thereby, additional space for the deflection of the pile thread legs in the lateral direction becomes available. The majority of intersections between binding warps B1 (x) of a group are located on the outside of the back shots SR or inside on the inside shots SI. Other crossing points within a K1 Ketting course are located in the Totpole PT area. They do not limit the filament density of the tissue.

Crossing points of binding warp threads, which affect the narrowest area between back shots, regularly consist of binding warp threads of both warp courses K1, K2. This also does not limit the row density. It is also clearly visible from this FIG. 6 that each backshot SR is pulled by a respective binding warp B1 to the previously formed base fabric. This ensures that the density of the fabric produced by the reed will be fixed almost without loss by the expert representation of a binding warp of each group.

Finally, it can be seen from the strong bending of the binding warp thread B11 on the back weft SR2 that the resultant force acting there on the back weft SR2 has a sufficiently large component in the stop direction for securing the density and an approximately equally large component for generating a friction between the weft thread and the weft thread Owns filler chain. The natural expansion endeavor of the pile threads a sufficiently large resistance is opposed after lifting the reed.

Of particular importance is - especially when striking the inner weft SI - that the density between the inner shots SI is significantly lower than the density between the back shots SR. As a result, the inner weft SI against the previously registered back shot SR of the same commodity WO, WU take a more displaced position in the stop direction when striking and pulling the previously registered back shots again additionally and effectively in the direction of attack.

It is apparent from all these facts that this bond allows a high pile row density. In addition, this results in a clear, less ribbed back image of the pile fabric.

In the binding according to FIG. 1, the binding warp threads can also be assigned to the individual warp courses K1 and K2 in a different manner. It is possible that in the same way Binding binders B11 and B12 binding to the weft repeat; B13, B14 a first warp course K1 and the binding warp yarns B15, B16; B17, B18 assign a second warp K2. This eliminates double bindings of the binding chains on the back. On the other hand, crossing areas arise which at least affect the areas of the highest density of the pile thread legs between the back shots.

2 differs from the representation according to FIG. 1 by the reduced number of binding twine B2 in top fabric WO and underware WU and by the size and design of repeat RB2 of binding warp threads B21, B22 of top fabric WO and the binding warp threads B23, B24 of the underware WU. The repeat RB2 of the binding warp threads B2 extends over sixteen weft insertion cycles in each product WO, WU.

For the representation of the binding course of the individual binding warp threads we follow the binding warp thread B21 of the top fabric WO. The binding warp B21 starts on the left outside with a binding inside over the inner weft SI1, then changes in the next tour on the outside of the back shot SR1 of his goods (WO), before after crossing another next backslot SR2 after another three tours inside over the next Inner shot SI1 binds. From there, he switches back to the level of the back shots SR.

After the following binding on the outside over the back shot SR, the binding warp thread is stretched out between further two back shots SR and an inner shank SI inserted therebetween, being arranged in the plane of the filling chain F. This phase serves as a rhythm change W211. As a result, he binds only in plain weave to back shots SR, before he is again led in on the seventh tour on the inside shot SI1 and thus the new Rapport RB2 begins.

The type of binding of the second binding warp B22 of the top fabric WO is - based on the rhythm - identical to the first binding warp B21. However, the binding elements are made eight turns or weft insertion cycles offset from one another. Each binding warp B21, B22 has two change points W212 and W211 or W221 and W222 in its repeat section. In these sections a rhythm change takes place. This rhythm change is necessary in order to carry out the necessary connections of the inner shots SI with only one binding warp thread B21, B22 within a repeat RB and at the same time to keep the length of integration of all binding warp threads B21, B22 within a binding thread repeat RB2 to a uniform size.

The binding warp threads B21, B22, B23, B24, which execute this repeat, can be pulled for the top fabric WO and for the underware WU from the same warp beam. The binder thread repeat RB2 in the lower fabric WU is preferably symmetrical and offset by a tour to the repeat RB2 of the top fabric WO.

The product produced according to this binding scheme is shown in Fig. 7 in a form that closely approximates the real weave. The binding warp B22 is shown in dashed lines. This means that this is assigned to the underlying Kettkurs K2.

It is especially clear in this FIG. 7 in which areas the highest concentration of pile yarns exists between the back shots SR1 and SR2. It can be seen that in the majority of the interspaces per warp course a maximum of one binding warp thread (B) crosses the pole legs. Twice the binding warp B21 is individually rectified with the pole legs, once there are two sections of the binding warp B21 rectified in said alley.

The multiple plain weave with the final binding over the inner weft SI1 ensures a largely lossless fixation of the stop density in the level of the back shots SR. Each backshot is pulled by a specialist of a binding warp B2 of the group to the fabric previously created and the filler chain F. A high pile row density is the result.

Between two inner shots SI, there are regularly the four pole legs of the pole loops binding over the back shots SR. Their density is significantly lower in the plane of the internal shots SI than in the plane of the back shots SR, where the total number of shots is twice as high. These inner shots SI are hardly deflected by the binding warp threads B21 and B22. The pole legs are perpendicular from the basic product WO out. They are flexibly supported by the inner shots SI and thus ensure a high level of comfort and a good recovery ability of the pole layer after loading.

The schematic binding image of a further type is shown in FIG. 3. Here too, apart from the repeat RB3 of the binding warp threads B31, B32, B33, B34, there is a complete match with respect to FIG.

The repeat RB3 of the binding warp threads B31, B32, B33, B34 extends in top fabric WO and underware WU over sixteen weft insertion cycles each. The course of the binding warp threads B31, B32, B33, B34 and their repeat RB3 will be described with reference to the binding warp threads B3 of the top fabric WO. The binding warp threads B31, B32 are arranged in a first warp course K1. The binding warp threads B33, B34 (dash-dot or dash-dot-dot) are located in the underlying Kettkurs K2. The binding program of these two binder warp pairs is offset from each other by four weft insertion cycles. The binding program of the pairs of binding warp threads B31, B32 / B33, B34 is offset from each other by eight weft insertion cycles.

The form of the incorporation is described by the binding warp B31. First, it binds (top left) in the upper compartment without contact over the inside shot SI1 and crossing tangentially the back shot SR1 first. During the two following single shot entries SR4 and SR2 he stays in the upper outer pocket and finally engages the back shots SR1 and SR2 as a pair. The following inner weft SI crosses this binding warp thread without contact outside. He then remains within the plane of the back shots before he crosses the inside shot SI in the fifth tour inside. In the following seven tours, he switches between back shots and inner shots, back into the outer compartment and crosses in the eighth tour the back shots SR1 and begins with the new binder thread repeat RB3.

The binding courses B32 of the same warp course and the binding warp threads B33 and B34, which are arranged in the underlying warp course, follow the same course. The repeats of the binding warp threads of the group are offset from one another in the warp direction in such a way that finally all back shots SR and all inner shots SI are set from outside or inside.

Although the binding warp threads B33 and B34 of the second warp course K2 cross the binding warp threads B31 and B32 of the first warp course K1 in the plane of the back shots. However, with their distribution in different warp courses K1, K2 one avoids an excessive restriction of the space for the pole legs in the plane of the back shots SR, where the highest pile thread concentration is given.

The crossing points of the binding warp threads B3 within a pair of binding warp threads B31 / B32 and B33 / B34 are regularly located in the inner region of the goods WO or WU. They are thus clearly displaced from the zone of highest compression of the poles in the plane of the back shots SR. Pairs of back shots SR, between which binder warp B3 completely absent, are pulled together by a Fachvertritt a binder warp B3 against the previously compressed fabric and fixed in the stopper density.

With this type of binding according to FIG. 3, it is possible, as proven by tests, to achieve up to 150 rows per decimeter (150 / dm) depending on the quality of the thread and its thickness in a carpet fabric. By contrast, the bonds according to FIGS. 1 and 2 permit rows of piles of between 100 / dm and 130 / dm.

The approximately real design of the thread combinations in this fabric according to FIG. 3 is shown in FIG. 5. Although the intersections of the binder warps B31 and B33 and the binder warps B32 and B34 are all in the range of the highest concentration of pile threads between the back shots. However, they are only present individually, since they are in different warp courses K1, K2.

The intersections of the binding warp threads B31 / B32 or B33, B34 from the same warp courses K1 and K2 are without exception clearly outside the plane of the back shots SR and thus do not influence the pile row density.

Of particular importance for a high pile row density in this binding is the almost symmetrical diagonal arrangement of the sections of the binding chains between the back and the inside weft. This ensures a symmetrical loading of the inner weft SI and supports the vertical orientation of the pole legs.

Thus, on the one hand all prerequisites are given that the pole legs protrude vertically from their basic commodity. On the other hand, sufficiently large force components are present in the warp direction and in the direction of the filling chain to maintain the density of the tissue in the plane of the back shots, so that extreme values of the row pile density become possible through the combination of all influencing factors.

For comparison, the closest bond shown in the prior art in Fig. 8 is shown in the prior art. By positioning the back shots SR8 and intermediate shots SZ8 outside and inside the filling chain 8, the highest concentration of the pile threads is achieved between weft threads in the plane of the intermediate shots SZ8 and in the plane of the inner shots SI8. In each of these levels there are four pole legs, the cross section of the intermediate shot SZ8 or of the internal shot SI8 and a crossing point or sections of the binding warp threads B81, B82.

The binding warp threads fixing the intermediate weft SZ8 in the direction of abutment can exert only a limited force in the striking direction, so that the pile thread legs lying between two intermediate wefts and those between the inner wefts can stretch again after the stop. The density reached at the stop of the weft threads can not be obtained in this way. In each weft repeat, the binding warp threads of a group perform only a single trade. The density of the finished carpet fabric is significantly lower than z. B. that of the fabric shown in Fig. 5 or in Fig. 7.

A further disadvantage of the binding according to FIG. 8 is that the tufts between the inner shots leave the binding of the basic product slightly inclined. This inclination results from the fact that the intermediate shot deflects the pole legs under the back of the arch in an arc shape. This tendency increases the closer the double carpet fabric is to the more dense.

The fabric described with reference to FIG. 8 has further significant disadvantages. It is practically not possible to perform a pile thread change between a back shot SR8 and an intermediate shot SZ8. Regularly there would be missing individual pole legs. The already lower Ausziehfestigleit of Polhenkeln an intermediate shot (about 50%) is in this case even less. 21

So that at least one patterned pile thread is visible on the back, the fabric weave manufacturer is advised to do the pile thread change only in the area of a backshot. Thus, each pattern point in the warp direction contains four poles and a Polhenkel, which binds over the back, is visible on the back. This limits the pattern possibilities to a considerable extent, since the pattern resolution is only half that of the two-speed two-shot bindings.

With the present invention, in which each shot carrying a pile loop is a back shot, a pile thread change can be realized in every other tour. Examples show u. a. Fig. 4, in which a large number of variants for such a pile yarn change is shown.

The pile threads PM41 to PM44 are involved in the pattern change shown. Starting from the left, the pile thread PM 41 looks in the usual way in a two-shank weave. In this area, the pile yarn PM42 prepares itself for its pattern by a binding inside via the inner weft SI41, which finally begins at the back weft SR41 in the lower fabric WU. After binding over the backseam SR43 in the upper fabric and over the weft thread SR42 in the lower fabric, it finishes its patterning in Totpolstrang PT of the underware WU.

The pile thread PM42 is detached by the pile thread PM43 from the top fabric WO. He begins his pattern over the backshot SR44, crosses the backshot SR45 of the underware WU and the backshot SR46 of the top fabric WO. He is then returned to the strand of Totpole PT.

During the patterning of this pile PM43, the pile thread PM44 was prepared by a binding inside over the inside weft SI43. The pile thread binds then patterned on the back of the SR46, the back of the SR47 and finally on the back of the SR48 back of the fabric. Because the back shot SR48 follows an inside shot SI44, the binding of this pile thread PM44 can be "stopped". Finally, he is then returned to the Totpolstrang.

As we can see from the Totpolstrang each commodity, the upper fabric and the lower fabric, detach a pile thread and set without mixed contours as musterernder pile thread. The manner of guiding the binding warp threads plays no special role for this process. It is important that every pile-wearing shot is a back shot.

With FIG. 9, a further binding variant for the binding warp threads B91 B92 is shown. The shot repeat RS9 extends over four weft insertion cycles. The repeat RB9 of the binding warp threads B91, B92 is repeated after every eight turns. The two binding warp threads B91, B92 of a group are distributed on two warp courses K1 and K2. The binding warp B91 coming from an inside shot SI intersects the first back shot SR one by one, then passes under the following back shots, before crossing another back shot on the outside and finally ending the rapport inside over the inside shot. The binding warp B92 performs the same binding by four turns offset.

The invention is not limited to the use of a four-speed Schussrapportes SR. It is quite possible to increase this rapport by adding more single-shot pairs. This further differentiates the relationship between the number of back shots SR and the number of inside shots SI. A limit is set only by the need for supporting inner shots SI.

An example of such an enlarged shot repeat is shown in FIG. 10. The shot repeat RS10 extends over six weft insertion cycles. The repeat RB 10 of the binding warp threads B101, B102 is repeated after every twelve turns. The two binding warp threads B101, B102 of a group are distributed on two warp courses K1 and K2. The binding warp B101 coming from an inside weft SI crosses outside a pair of back shots SR, then under the following three back shots, before he crosses another back shot outside and finally inside over the inside weft binding terminates the rapport RB10. The binding warp B102 performs the same binding by six turns offset.

LIST OF REFERENCE NUMBERS

B

Binding chain, (general)

B1, B2, B3, B8, B9, B10

Binding chains of Figures 1, 2, 3, 8, 9, 10 (the following numbers are consecutive numbers of the binding chains of the same Figure)

F

filling warp

K1

Kettkurs (front) also attachment to B-reference

K2

Kettkurs (back) also attachment to B-reference

P

Pile thread (general)

PT, PT8

Totpole

PM, PM8

Pol, eyeing, Polhenkel

PM4

Pole threads, patterning, of Fig. 4 (subsequent numbers indicate the order within the figure)

RB

Repeat, binding warp threads (the following numbers indicate the figure, the following numbers indicate an order within the figure)

RS

Repeat of the weft threads (four weft insertion cycles)

RS10

Repeat of the weft threads (six weft insertion cycles)

SR

Back shot, general (attached numbers indicate an order in Figures 1 to 3 and 5 to 7)

SR4

Back shots of Figure 4 (subsequent numbers indicate the order within the figure)

SI, SI1, SI2

Inner shots (general -> 1 upper fabric, 2 lower fabric)

SI4

Inner shots of Figure 4 (subsequent figures indicate the order within the figure)

SR8

Back shot, Figure 8

SZ8

Interim Shot, Figure 8

SI8

Inner shot, Figure 8

W

Rhythm change (general)

W2

Rhythm change of Figure 2 (in the attached digit pair, the first digit means the assignment to the binding chain and the second digit a running digit)

WHERE

top web

WU

under goods

Claims (8)

1. A method of manufacturing a face to face pile fabric on a double plush loom with at least two weft insertion planes,
   using weft threads (SR and SI) of filler warp threads (FK) and groups of binding warp threads (B) for forming an upper and a lower base cloth (WO, WU)
   as well as strands of pile threads (PM, PT) per warp course

   - for forming a figured pile layer made of figuring pile threads (PM) that can be separated between the upper and lower base cloths, and

   - for filling the base cloths by the non-figuring pile threads (buried piles, PT) incorporated between back wefts and inner wefts,

   with the weft threads (SR) being inserted in an at least four-cycle pattern repeat

   - at least twice in pairs as back wefts (SR3, SR1) into a first base cloth (WU, WO) and as inner wefts (SI1,SI2) into a second base cloth (WO, WU), and

   - two, four, or six times as single back wefts (SR4, SR2) alternately into one of the two base cloths (WU, WO),

   with the figuring pile threads (PM) being exclusively guided between the back wefts (SR1, SR2) of the face cloth (WO) and the back wefts of the backing cloth (WU) tentering pile loops, and
   with the intersecting binding warp threads (B) of a group that intersect in the area of the highest pile thread concentration between subsequent back wefts (SR1, SR2; SR3, SR4) being distributed over two adjacent warp courses (K1, K2), and
   with the binding warp threads (B) of a group performing a shed change at least twice - distributed over adjacent warp courses (K1, K2) - within one weft pattern repeat (RS).
2. The method according to Claim 1, characterized
   in that the pile threads beginning and ending the pattern (PM41, PM42, PM43, PM44) bind for the first and last time around back wefts (SR) of their respective cloth (WO, WU) during a pile thread change according to the pattern.
3. The method according to Claim 1, characterized
   in that, with a four-cycle weft pattern repeat (RS), the complete pattern repeat (RB1) of binding warp threads (B11, B12) stretches over eight weft insertion cycles, and
   in that the group of binding warp threads (B1) of each cloth (WO, WU) consists of two binding warp threads (B11, B12) which - offset by four cycles - each encompass a pair of adjacent back wefts (SR1, SR2) on the outside and immediately thereafter a single inner weft (SI1) on the inside.
4. The method according to Claim 1, characterized
   in that, with a four-cycle weft pattern repeat (RS), the complete pattern repeat (RB1) of binding warp threads (B11, B12) stretches over eight weft insertion cycles, and
   in that the group of binding warp threads (B1) of each cloth (WO, WU) consists of two pairs of binding warp threads (B11, B15; B12, B16) which binding warp threads (B11, B15, B12, B16) - offset by two cycles - each encompass a pair of adjacent back wefts (SR1, SR2) on the outside and thereafter a single inner weft (S11) on the inside.
5. The method according to Claim 1, characterized
   in that, with four-cycle weft pattern repeat (RS), the complete pattern repeat (RB9) of binding warp threads (B91, B92) stretches over eight weft insertion cycles, and
   in that each binding warp thread (B91, B92) of each cloth (WO, WU) in each pattern repeat (RB9) encompasses one back weft (SR) on the outside, two back wefts (SR) on the inside, another back weft (SR) on the outside and finally an inner weft (SI) on the inside.
6. The method according to Claim 1, characterized
   in that, with a four-cycle weft pattern repeat (RS), the complete pattern repeat (RB2) of binding warp threads (B) stretches over sixteen weft insertion cycles, and
   in that each binding warp thread (B21, B22; B23, B24) of a cloth (WO, WU) encompasses per pattern repeat (RB2) first a back weft (SR) on the outside, a back weft (SR) on the inside, an inner weft (SI) on the inside, another back weft (SR) on the outside, two back wefts (SR) on the inside, then three back wefts (SR) on the outside, inside, and outside again, and finally the next inner weft (SI) on the inside.
7. The method according to Claim 1, characterized
   in that, with a four-cycle weft pattern repeat (RS), the complete pattern repeat (RB3) of binding warp threads (B) stretches over sixteen weft insertion cycles, and
   in that the group of binding warp threads (B3) consists of four binding warp threads (B31, B32, B33, B34) that are assigned in pairs (B31, B32 /B33, B34) to two adjacent warp courses (K1, K2), and
   in that the binding warp threads (B31, B32, B33, B34) of a cloth (WO, WU) within one pattern repeat (RB3) each encompass a pair of back wefts (SR1, SR2) on the outside and - at a spacing - a single inner weft (SI) on the inside.
8. The method according to Claim 1, characterized
   in that, with a six-cycle weft pattern repeat (RS10), the complete pattern repeat (RB10) of binding warp threads (B10) stretches over twelve weft insertion cycles, and
   in that each binding warp thread (B101, B102) of each cloth (WO, WU) in each pattern repeat (RB10) encompasses one pair of back wefts (SR) on the outside, three back wefts (SR) on the inside, another back weft (SR) on the outside and finally an inner weft (SI) on the inside.

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