US-12618178-B2 - Weaving machine and method for manufacturing pile fabrics with knotted pile yarns

Abstract

A method and a weaving machine for weaving pile fabrics with knotted pile yarns, configured so that, for sequences (I), (II), (III) of two warp yarn systems, the order of the warp yarn systems in the weft insertion mechanism (X) is changed and a pile yarn (P 1 )-(P 4 ) is brought between the warp yarn systems, at least one warp yarn ( 1 ) of the first warp yarn system and at least one warp yarn ( 2 ) of the second warp yarn system are brought back into the original order on either side of a gap (T 3 ), and finally an end part (L 1 a )-(L 4 a ) of the pile yarn (P 1 )-(P 4 ) is brought through this gap (T 3 ) from the one edge ( 20 ) to the other edge ( 30 ) of the warp yarns ( 1 ), ( 2 ), so that a knot (PK 1 ), (PK 2 ), (PK 3 ), (JK 1 ), (JK 2 ) is formed.

Inventors

• Francois T'SAS

Assignees

• MOVINT

Dates

Publication Date

20260505

Application Date

20230720

Priority Date

20220722

Claims (20)

1. 1 . Weaving machine for weaving pile fabrics, comprising: yarn providers for providing a row of warp yarns running next to each other, a shedding device for forming a shed between the warp yarns in each case in several weft insertion cycles, a weft insertion mechanism for inserting, in the weft insertion cycles, in each case at least one weft yarn in the shed in a weft direction in order to weave a ground fabric, and binders for binding pile yarns to the ground fabric to form the pile, wherein the weaving machine is configured so that, in several pile forming cycles, for several sequences of a first and of a second warp yarn system each comprising at least one warp yarn in the row of warp yarns and located in an original order seen in the weft direction on either side of a first gap: (a) the warp yarns of at least one of the first and the second warp yarn systems in the weft insertion mechanism are moved until the warp yarn systems are located, at least over a portion of their length, in a reversed order on either side of a second gap, (b) a pile yarn in the pile yarns is brought into a pull-through position where the pile yarn extends through the second gap between the first and the second warp yarn system and projects with respective end parts on both sides of the warp yarns, (c) the warp yarns of at least one of the first and second warp yarn systems are moved in the weft direction until at least one warp yarn of the first warp yarn system and at least one warp yarn of the second warp yarn system are back again in the original order on either side of a third gap, and (d) the end part of the pile yarn located on one edge of the warp yarns is pulled through the third gap so that the end part of the pile yarn extends via the third gap up to the other side of the warp yarns and projects on the other edge of the warp yarns.
2. 2 . Weaving machine according to claim 1 , wherein the weaving machine is configured so that, in step (c), the warp yarns of at least one of the warp yarn systems are moved in the weft direction until all warp yarns of the first warp yarn system and all warp yarns of the second warp yarn system are back in the original order on either side of the third gap.
3. 3 . Weaving machine according to claim 1 , further comprising a warp yarn positioning device that is configured to move the warp yarns of the first warp yarn system and/or the warp yarns of the second warp yarn system at least over a portion of their length in a transverse direction that is approximately transverse to the warp yarn plane in which the warp yarns mainly extend, so that the warp yarns of the first warp yarn system and the warp yarns of the second warp yarn system of each sequence in the several sequences are displaced, at least over a portion of their length in the transverse direction, relative to each other, and then move the warp yarns of the first warp yarn system and/or the warp yarns of the second warp yarn system of each sequence in the weft direction relative to each other in order to reverse the order of the warp yarn systems, as seen in the weft direction.
4. 4 . Weaving machine according to claim 3 , wherein the warp yarn positioning device further comprises at least one first positioning body that is configured: to be moved in the transverse direction and thereby also move the warp yarns of the first warp yarn system of each sequence in the several sequences in order to bring the warp yarns of the first warp yarn system at least over a portion of their length outside the warp yarn plane, and to be moved in the weft direction and thereby also move the warp yarns of the first warp yarn system of each sequence in the several sequences in order to reverse the order of the warp yarn systems, as seen in the weft direction.
5. 5 . Weaving machine according to claim 4 , wherein the warp yarn positioning device further comprises at least one second positioning body that is configured: to be moved in the transverse direction and thereby also move the warp yarns of the second warp yarn system of each sequence in the several sequences in order to bring the warp yarns of the second warp yarn system at least over a portion of their length outside the warp yarn plane, and to be moved in the weft direction and thereby also move the warp yarns of the second warp yarn system of each sequence in the several sequences in order to reverse the order of the warp yarn systems, as seen in the weft direction.
6. 6 . Weaving machine according to claim 5 , wherein the at least one first positioning body is provided on the one side of the warp yarns and is configured to move the warp yarns of the first warp yarn system at least over a portion of their length in the transverse direction so that they are brought on the one side of the warp yarns outside the warp yarn plane, and wherein the at least one second positioning body is provided on the other side of the warp yarns and is configured to move the warp yarns of the second warp yarn system at least over a portion of their length in the transverse direction so that they are brought on the other side of the warp yarns outside the warp yarn plane.
7. 7 . Weaving machine according to claim 6 , wherein the at least one first positioning body and/or the at least one second positioning body comprise a row of warp yarn passages.
8. 8 . Weaving machine according to claim 7 , wherein the at least one first positioning body and/or at least one second positioning body comprise a number of fingers that are provided next to each other with spacing, in which at least one warp yarn passage in the row of warp yarn passages is provided.
9. 9 . Weaving machine according to claim 8 , wherein, in each pile forming cycle, at least one pile yarn in the pile yarns is joined to a number of the warp yarns by forming a plurality of knots, wherein each knot in the plurality of knots is located between the edge of the ground fabric in the process of formation and at least one positioning body in the at least one first positioning body and/or the at least one second positioning body, and wherein the at least one positioning body is configured, in a direction in which the warp yarns extend next to each other, to be moved towards the edge in order to move each knot in the plurality of knots in this direction until the at least one positioning body is almost up against the edge.
10. 10 . Weaving machine according to claim 9 , wherein the weft insertion mechanism inserts, in each weft insertion cycle, in each case at least one weft yarn in a weft direction into a shed formed between warp yarns, between the edge of the ground fabric in the process of formation and the at least one positioning body, and wherein the at least one positioning body is configured to be moved in the direction in which the warp yarns extend next to each other towards the edge in order to move each inserted weft yarn in the direction until the at least one positioning body is almost up against the edge.
11. 11 . Weaving machine according to claim 10 , wherein the at least one positioning body is also configured to move, in several weft insertion cycles, the warp yarns of the first warp yarn system of each sequence in the several sequences and/or the warp yarns of the second warp yarn system of each sequence in the several sequences at least over a portion of their length in the transverse direction, to form in each case a shed between the respective warp yarns.
12. 12 . Weaving machine according to claim 1 , further comprising a cutting device that is configured for cutting off, in several pile forming cycles, each pile yarn in the pile yarns to be bound to the ground fabric from a pile yarn supply.
13. 13 . Weaving machine according to claim 1 , further comprising at least one set of (i) a pile yarn feeder, and (ii) an associated pile yarn receiver, wherein the pile yarn feeder is configured so that, in several pile forming cycles, a pile yarn in the pile yarns is held in a first feed position on the one side of the warp yarns, wherein the associated pile yarn receiver is configured so that, in several pile forming cycles, the pile yarn held in the first feed position on the other side of the warp yarns is pulled through a respective second gap between two warp yarn systems in reversed order and is brought into the pull-through position, and then, after at least one warp yarn of the first warp yarn system and at least one warp yarn of the second warp yarn system are put back again in the original order, the end part of the pile yarn located on the one side of the warp yarns is brought through the first gap so that the end part extends via the third gap up to the other side of the warp yarns and projects on the other side, and so that each pile yarn in the pile yarns is joined by formation of a plurality of knots to the warp yarns, and wherein the associated pile yarn receiver comprises two pile legs projecting on the other edge of the warp yarns.
14. 14 . Weaving machine according to claim 1 , further comprising at least one set of (i) a pile yarn feeder, and (ii) an associated pile yarn receiver, wherein the pile yarn feeder is configured so that, in several pile forming cycles, a pile yarn in the pile yarns is held in a second feed position where the pile yarn extends from the one side of the warp yarns through a second gap between two warp yarn systems in reversed order up to the other side of the warp yarns, wherein the associated pile yarn receiver is configured so that, in several pile forming cycles, the associated pile yarn receiver grips the pile yarn held in the second feed position on the other side of the warp yarns and is brought into, or held in, the pull-through position, and then, after the warp yarn systems are put back in the original order, the end part of the pile yarn located on the one side of the warp yarns is pulled through the third gap so that the end part extends via the third gap up to the other side of the warp yarns and projects on the other side, and so that each pile yarn in the pile yarns is joined by formation of a plurality of knots to the warp yarns, and wherein the associated pile yarn receiver comprises two pile legs projecting on the other edge of the warp yarns.
15. 15 . Weaving machine according to claim 14 , wherein the pile yarn feeder comprises an elongated hollow feed-through body that forms a passage for the pile yarn extending in its longitudinal direction, wherein the pile yarn feeder is configured to be placed in a first position where the feed-through body extends from the one side of the warp yarns through the second gap up to the other side of the warp yarns, in that the pile yarn extending through the passage of the feed-through body is held in the second feed position, wherein the associated pile yarn receiver is configured to retain the pile yarn held in the second feed position, and wherein the pile yarn feeder is configured so that, during retention of the pile yarn, the pile yarn feeder is moved from the first position to a second position wherein the feed-through body no longer extends through the second gap and is located completely on the one side of the warp yarns.
16. 16 . Weaving machine according to claim 13 , wherein the pile yarn receiver is configured to be moved between a first and a second position in a transverse direction that is approximately transverse to the warp yarn plane in which the warp yarns mainly extend, in order to take, in the first position, a yarn end of a pile yarn brought into the first or the second feed position and bring the pile yarn, through the movement of the pile yarn receiver to the second position, into the pull-through position.
17. 17 . Weaving machine according to claim 13 , wherein, for the at least one set of the pile yarn feeder and the associated pile yarn receiver, a row of the pile yarns with mutually different appearance-determining properties is provided, and wherein the pile yarn feeder is configured so that, in several pile forming cycles, the pile yarn feeder selectively brings a predetermined pile yarn in the pile yarns of the row into the first or the second feed position.
18. 18 . Weaving machine according to claim 13 , wherein the pile yarn receiver comprises: a first pile yarn rapier that is configured to grip the pile yarn brought into the first or the second feed position, and a second pile yarn rapier that is configured to grip in each case the end part of the pile yarn located on the one side of the warp yarns and pull the end part through the first gap.
19. 19 . Weaving machine according to claim 1 , further comprising a row of warp yarns running next to each other, wherein the row of warp yarns extends mainly in a warp yarn plane (K), wherein the row of warp yarns comprises the several sequences of the first and second warp yarn systems, wherein each warp yarn system in the first and second warp yarn systems comprises at least one warp yarn, and wherein the first and second warp yarn systems are located in an original order, as seen in the weft direction, on either side of the first gap.
20. 20 . Weaving machine according to claim 18 , further comprising: at least one first positioning body that is placed on the one side of the warp yarns and is movable in a transverse direction that is approximately transverse to the warp yarn plane, in order to bring the warp yarns of the first warp yarn systems over a portion of their length on the one side outside the warp yarn plane, and is movable in the weft direction in order to move the warp yarns of the first warp yarn systems over a portion of their length in the weft direction in order to reverse the order of the warp yarn systems, at least one second positioning body that is placed on the other side of the warp yarns and is movable in the transverse direction to bring the warp yarns of the second warp yarn systems over a portion of their length on the other side outside the warp yarn plane, and is movable in the weft direction in order to move the warp yarns of the second warp yarn systems over a portion of their length in the weft direction in order to reverse the order of the warp yarn systems, wherein the weaving machine is configured so that, during several pile forming cycles, the following steps are carried out automatically: (d) the first and the second positioning bodies are moved away from each other in the transverse direction in order to bring the first and the second warp yarns respectively on the one side and on the other side of the warp yarn plane outside the warp yarn plane, (e) the first and the second positioning bodies are moved relative to each other in the weft direction so that the order of the warp yarn systems is reversed, (f) the first pile yarn rapier is operated to grip the yarn end of the pile yarn placed in the first or the second feed position and is brought into, or held in, the pull-through position, (g) the first and the second positioning bodies are moved relative to each other in the weft direction so that at least one warp yarn of the first warp yarn system and at least one warp yarn of the second warp yarn system are back in the original order, on either side of the third gap, and (h) the second pile rapier is operated to pull the end part of the pile yarn located on the one side of the warp yarns through the third gap so that the end part extends via the third gap up to the other side of the warp yarns and projects on the other edge.

Description

This application is a National Phase entry of International Application No. PCT/IB2023/057397 under § 371 and claims the benefit of Belgian Patent Application No. BE2022/5588, filed Jul. 22, 2022, which is hereby incorporated by reference in its entirety. FIELD OF THE DISCLOSURE The present disclosure relates on the one hand to a weaving machine for weaving pile fabrics, comprising yarn providers for providing a number of warp yarns running next to each other, a shedding device for forming a shed between the warp yarns in each case in several weft insertion cycles, a weft insertion mechanism for inserting, in the weft insertion cycles, in each case at least one weft yarn in a weft direction in the shed in order to weave a ground fabric, and yarn binders for binding pile yarns to the ground fabric to form pile on the ground fabric. The present disclosure also relates to a weaving machine with the features indicated in the preceding paragraph, which is ready for weaving a pile fabric and which thus comprises a number of warp yarns running next to each other. The present disclosure also relates on the other hand to a method for manufacturing pile fabrics, wherein a number of warp yarns running next to each other are provided, and wherein in several weft insertion cycles in each case a shed is formed between the warp yarns, and at least one weft yarn is inserted in a weft direction into the shed so that a ground fabric is woven, and pile yarns are bound to the ground fabric to form pile on the ground fabric. The present disclosure relates in particular to a method of this kind and a weaving machine of this kind for manufacturing pile fabrics with pile-forming pile yarns which respectively form a closed loop round at least one warp yarn of the ground fabric, and are also called knotted pile yarns, as will be explained later on in this description. The present disclosure relates to, among other things, a weaving machine and a method for manufacturing a hand-knotted carpet, for example such as a Persian carpet. BACKGROUND A hand-knotted carpet, for example such as a Persian carpet, consists of warp yarns and weft yarns, which together form a ground fabric, and of a large number of pile yarns that are joined to the warp yarns in such a way that each pile yarn comprises two end parts that project on one side of the ground fabric. This side is called the pile side and the other side is called the back of the carpet. All projecting end parts of the various pile yarns together form the pile of the carpet. The projecting end parts of the pile yarns are also called pile legs. It is known to bind a pile yarn to the warp yarns by knotting the pile yarn manually, allowing a set of two or more warp yarns to run around a path such that the pile yarn is held sufficiently in the ground fabric, and in other words can only be pulled out of the ground fabric with great difficulty, for example by pulling on one of the pile legs. Thus, the pile yarn for example forms a closed loop round at least one of the warp yarns so that the pile yarn is sturdily anchored and is retained in the ground fabric. The path that the pile yarn follows is called “the knot path” in this patent application. The operation wherein a pile yarn is bound following a said knot path to a warp yarn is also called “knotting” and takes place manually in the known methods of weaving. The pile yarns that are bound to the ground fabric in this way are also called “knots”. Thus, a carpet of this kind is called “a hand-knotted carpet”. In the manufacture of a hand-knotted carpet of this kind, alternately first a number of weft yarns are inserted manually in a weft direction into a shed formed between the warp yarns, and then a row of knots extending in the weft direction is formed manually by binding pile yarns to respective sets of warp yarns. The aforementioned “number of weft yarns” is usually one, two or three weft yarns. The knots in each row, the knot path of which will be described in detail hereunder, are also pushed manually firmly against the last weft yarn inserted, and each weft yarn is in each case also pushed firmly against the previously formed row of knots or the previously inserted weft yarn, so that weft yarns and rows of knots butt properly against each other. The knot path depends on the knot selected. In the case of a so-called asymmetric knot, also called a Persian knot, the knot path of a pile yarn-comprising a first and a second pile yarn end part that extends respectively from one end and from the other end of the pile yarn-, relative to a set of two adjacent warp yarns (called the first and the second warp yarn hereinafter), may be defined as follows: from the first pile yarn end part that projects above the ground fabric on the pile side and forms a first pile leg, the pile yarn runs firstly between the first and the second warp yarn towards the back of the carpet, is then turned round the first warp yarn, then runs on the side directed away f