CN1113974A - Method and apparatus for the manufacture of carpet - Google Patents

Abstract

A kind of carpet consists of weft yarn filler (18c) which fills in the pile loop formed in the pile of warps 14a and 14b with the result that exposed partially and contributing to the final carpet design and appearance and through supporting the internal side of pile loop formed by warps 14a and 14b to contribute the durability of carpet. The binding chains 17a and 17b and weft yarns 18a and 18b combine the warp yarns 14a and 14b of pile in the base cloth of the carpet to fix the insertion 16 realiably between weft yarns 18a and 18b. At some other implementing examples, the binding chains 17a and 17b may be saved partially or completely and the warp yarns 14a and 14b are fed to the top and bottom of the insertion 16. Said invention also describes the device used to form said carpet.

Description

Method and apparatus for the manufacture of carpet

The present invention relates to be used to improve the method and apparatus of making carpet, and the carpet of making therefrom.Up to the present, various types of carpets, for example Wilton in producing typical products in mass production, can produce by various technology.

In whole specification, term " carpet " is to be used to cover all types of fabric face coverings.

The prior art that is used to make woven carpet at present has many shortcomings, it comprises complicated loom, the requirement of Wilden wire loom, for example, some play the pile steel wire and are embedded into, and extract out and to leave its pile as an air core coil or cutting a mao steel wire by one is cut open, these air core coils also have the combustible shortcoming of the carpet of helping, and just provide oxygen source for various burnings in pile.Existing these production technologies also might often have the shortcoming that lacks certain flexibility, and these shortcomings change its carpet style easily.

The purpose of this invention is to provide method and/or equipment that improve to make carpet, and/or a kind of carpet of improvement, overcome or eliminate at least the shortcoming of currently used method, equipment and/or its carpet.Or provide a kind of useful selection scheme to the public at least.

Other purpose of the present invention will become clearer from following description.

According to an aspect of the present invention, it provides a kind of method that is used to produce carpet, it comprises warp thread and weft material is woven together, and an additional weft material that comprises is held by the pile warp material, and its additional weft material passes the pile warp material, and part exposes.

According to another aspect of the present invention, it provides a kind of equipment that is used to produce carpet, it comprises and is used for weft yarn and is fed into the device of a knit unit through yarn material, this knit unit is used for a longitude and latitude yarn weaving together, and said yarn feeding device comprises the device that is used for feeding to an additional weft material, its additional weft material is to be held by the pile warp material, and additional weft material passes the pile warp material, and part exposes.

According to a further aspect in the invention, it provides the described method that is used to produce carpet in conjunction with arbitrary embodiment of the present invention.

According to a further aspect in the invention, it provides the described device that is used to produce carpet in conjunction with arbitrary embodiment of the present invention.

According to a further aspect in the invention, it provides a kind of carpet of producing by four sections arbitrary section described method above this section and/or device.

According to a further aspect in the invention, it provides a kind of carpet, this carpet is formed by weft yarn with through yarn material and the additional weft material institute that is woven together, its additional weft material is held by the pile warp material, and its additional weft material passes the pile warp material, and part exposes.

According to a further aspect in the invention, it provides the described carpet in conjunction with arbitrary embodiment of the present invention.

Some other aspect that the present invention is considered from every side is by following description, for example some preferred embodiments and will become apparent clear with reference to accompanying drawing.

Figure 1A, 1B and 1C only utilize schematic diagram to represent some examples that the carpet of " prior art " is made

Fig. 2 A and 2B are profile and the perspective views that carpet has only been represented in a preferred embodiment according to the present invention;

Fig. 3 is the side perspective view that a preferred embodiments according to the present invention only shows a kind of carpet loom;

Fig. 4 has only schematically illustrated a plane of Fig. 3 loom;

Fig. 5 has only schematically illustrated the carpet suede opening portion of the loom of Fig. 3 and Fig. 4;

Fig. 6 is shown according to another embodiment of the invention another carpet pile opening details;

Fig. 7 is shown according to another embodiment of the invention another carpet pile opening details.

In order to understand the present invention, be a glossary below, they use together with the meaning of its appointment.

Flammable-as to be meant the degree that a kind of material is flammable.

Arrow shaft-a kind of Metallic rod, it carries through yarn material and its certain-length and is incorporated in the open shedding, then its cut-out.

The distance of splits-between last two the vertical reed wires of reed (a similar coxcomb).

Warp thread-be used for the thread material of base fabric or pile, and on rectilinear direction, move.

The thread material of the operation of weft yarn-in a lateral direction.

Shed open-, be created in the distance at intermittence between the thread material, the arrow shaft of carrying weft yarn with introducing weaving cycle period.

Play pile steel wire-kind of metallic steel silk ribbon, be generally 0.200 " * 0.050 " (high * thick), be used to form pile loop, in weaving Wilden fleece fabric, its pile loop can keep hollow and maybe can be cut open.

Lay sword-have the mechanism of reed, reed is patted material closely together.

Weft yarn filler-help the additional weft material of napping, and be by additional weft material provided by the present invention.

Heald-a kind of wire, approximately half distance has an eye on its vertical length.

The flat board of brest beams baffle plate-a kind of supporting fabrics point.

Weave a little-focus of all warp thread and weft material, this some expression material becomes carpet.

Yarn-one or more synthetic or thread or fibers comprise different fiber millings together.

Pile-common vertical material on base fabric.

Base fabric-be used for pile provides the structure of stability and tissue of a kind of end.

What liner-warp was straight is placed on the base fabric, is woven under heavy duty, and straight line stability and intensity are provided.

Binding chains-warp thread is woven with a kind of form of chain-like, and its all parts are closely connected.

Weft feeder-send latitude mechanism by what arrow shaft was throwed a spear.

The single introducing of the weft yarn number-weft yarn of every row looped pile.

Through axle-the be used for support of metal " bobbin " type of base fabric material.

Cheese-material webs is (this spool is a kind of bobbin that does not have the limit) on a spool.

Dobbies-be used for activate in groups through yarn material to produce the mechanism of simple decorative pattern and image effect.

Jacquard-be used for activating through yarn material to produce the more complicated decorative pattern and the mechanism of image effect with any program of being compiled.

The support of the cheese of bobbin cradle-a kind of fixing many pile yarns materials.

At first referring to accompanying drawing 1A, 1B and 1C, they schematically show some examples of the carpet backing and installation system of prior art.

Constructed profile among Figure 1A has represented that coupling chain 1a and 1b form a connection chain, and this chain and weft yarn 3 are attached to pile warp 4 on the base fabric.The center that is placed on base fabric that liner 2 is straight, connection chain 1a and 1b alternately contact with weft yarn 3, and they are in turn in conjunction with pile warp 4a, 4b.

In Figure 1B, coupling chain 1a and 1b and weft yarn 3 alternately are attached to pile warp 4a and 4b on the base fabric, allow the liner 2 straight base fabric centers that are placed on again.The carpet of Figure 1B is a kind of Wilden type carpet, and pile warp 4a that it had and the air core coil of 4b play the pile steel wire by pile and form, and it plays the pile steel wire and sequentially is introduced into and is removed during the carpet manufacturing.

In Fig. 1 C, coupling chain 1a and 1b and latitude are attached to pile warp 4 on the base fabric second 3, and liner 2 is positioned at the base fabric center of passing as the crow flies with rectilinear direction.The carpet of Fig. 1 C is a kind of Wilden type carpet, and the air core coil of the pile warp 4 that it had plays the pile steel wire by pile and forms, and it plays the pile steel wire and sequentially is introduced into and is removed during the carpet manufacturing.

Term " Wilden " relates generally to a kind of loop pile or velvet carpet, and is that versatility by the Wilden loom is caused, and term can be considered to a kind of generic term that comprises the numerous species product, for example product shown in Figure 1A, 1B and the 1C.

In the Wilden Pile loom, bear building-up closes in traditional braid method of warp thread and weft material, and the base fabric material is collected at the base fabric that is used for pile material together with manufacturing.

When forming with base fabric, pile is formed by a series of metal napping steel wires are introduced under the pile yarns material, and its pile yarns material is thus lifted to a feasible pile steel wire that received in the plane more higher than base fabric material.

According to weaving process, playing first of one group about 30 of the pile steel wire from these plays pile steel wire (the most close operator) and is removed, make it on the base fabric of carpet, stay an emptying wire-core coil, steel wire just is removed and introduces in sequential mode if the constant pile steel wire that provides, these suedes are started.In every winding displacement circle of crossing over product width forms, the circulation of all necessary operations for loom operation want two of the cambered axles of centering and more under more situation.

Wilden loom and its requirement have the result of relative slow processing number of times inevitably in the complexity of sequential introducing of many length pile steel wires and taking-up.

On the contrary, the present invention exempts this pile steel wire of use, and make and a single cycle to be different from a multicycle operation, thereby further quicken productivity ratio, the carpet of Huo Deing is compared with having more distinctive advantages as the carpet that type is arranged earlier by the production of Wilden blanket machine in this case.

At length playing the pile loom referring to Wilden is of great use.Such loom is weaved a kind of structure of weft yarn of two row looped piles usually.Because its special character, the weft yarn of every row looped pile must be introduced into respectively, the looped pile weft yarn at the back side is introduced simultaneously with playing a pile steel wire, and second looped pile weft yarn play the pile steel wire with some and extract out simultaneously, the base fabric that is attached to carpet at the pile yarns that play firm employing on the pile steel wire.

The open shedding that shed open provided is as the usefulness that is suitable for receiving the looped pile weft yarn of weft yarn and plays the pile steel wire, but two looped pile weft yarns and a pile steel wire can not side by side be admitted.

This situation result forms the productivity ratio of paper, for example, a kind of typical 1.5 meters wide Wilden carpet pile loom is to throw a spear from the about 70-75 of per minute or the speed of opening is weaved, each row's looped pile requires the weft yarn of two row looped piles, so that the thread density of woven carpet be every meter 315 row, the Wilden carpet plays the pile loom will be with 100% efficient production, the result be 75 * 60=4500 time picking ÷ 630=7.14 line rice/hour.But the present invention weaves a kind of 1.5 meters wide carpets in an embodiment of some tests, the operation of this embodiment is so that 73 introducing/per minutes=73 * 60=4380 time opening is operated, yet, each introduce to produce row's looped pile, like this this total amount only divided by 315 equal 13.9 line rice/hour.Can expect that compare with the loom of any width, the productivity ratio of this increase all will be suitable for.

A kind of loom according to a preferred embodiment of the present invention can provide open shedding to admit three fill yarn component, last looped pile weft yarn, the weft yarn filler of following looped pile weft yarn and replacement napping steel wire, thereby finish every row circulates at every turn, and do not need two circulations, play the pile loom as above-mentioned Wilden.

Certainly above-mentioned 100% efficient realizes till the ass ascends the ladder, and Wilden pile carpet loom is estimated to operate with the efficient of approximate 65-70% usually.Conceivable is because loom simplified design the number of components less with it and not having can account for the mechanism of a pile steel wire introducing/extraction of complexity that many Wildens play total down time of pile carpet loom according to the present invention, probably obtains for 70-86% believes to do for its efficient of the present invention.

Referring to Fig. 2 A and 2B, marked by arrow 10 usually according to a kind of carpet of a preferred embodiment of the present invention, and only schematically marked profile and perspective view.Fig. 2 A or 2B represent one group of warp yarn, in the one splits, on the transverse width of product, generally include 270-360 one thread/rice, but a wide cut scope have bulky yarn at least 120 usually to 480, or have thinner yarn.

In Fig. 2 A and 2B, binding chains 17a and 17b form a kind of coupling chain, and it and weft yarn 18a and 18b are attached to pile warp line 14a and 14b on the base fabric, and liner 16 is firmly held between weft yarn 18a and the 18b.Yet can find out that the additional weft material 18c filling that is provided is formed in the pile loop of pile warp 14a and 14b.Therefore this " weft yarn filling " 18c partly exposes, and will help the design and the outward appearance of the carpet that forms with this.Have now found that, because fill design and the outward appearance that 18c helps its carpet by weft yarn, exactly by the tone of two or three regulations, adopt solid and choice refreshments completely, some pile yarns 14a and 14b and weft yarn are filled 18c and can be combined, and they can be made into the many arrangements into given different colours.

The applicant believes, various other advantages can realize from the introducing that weft yarn is filled 18c, comprising:

ⅰ) improved appearance stability;

ⅱ) increase durability and/or reduced weight for identical durability for identical weight;

ⅲ) improved flame resistance;

ⅳ) improved anti-fiber loss;

ⅴ) easy to clean;

ⅵ) the anti-contamination;

ⅶ) carpet of lower weight consequently is easier to carrying and assembling; With

ⅷ) reduced the friction of device when carpet moves.

Aspect flammability, can know its typical Wilden pile carpet product, as the product of above-mentioned Fig. 1, the hollow defending party to the application who forms in the pile looped pile be sure of, it provides a kind of oxygen source, this oxygen source with support to be present within the carpet or on any burning.And by comparison, weft yarn is filled 18c and has then been occupied the space that oxygen comprised, and has reduced thus and be applicable to the amount of oxygen that its any burning is provided.Be sure of that weft yarn is filled 18c also provides an intermediate layer to support and to absorb the pressure that is applied on warp yarn 14a and the 14b, so that improved above-mentioned durability and appearance stability.

According to Fig. 2 A and 2B, some other embodiment of the present invention can provide some different carpet backing and installation systems, for example pile yarns material 14a and 14b save use binding chains 17a and 17b to rely on friction that structure is kept together and before base sloth coating is applied in, can be fed on the liner 16 and under.Production about this structure of Fig. 6 will be described below.

Any suitable material can be used for carpet of the present invention, and for example the base fabric material can be polyester and glass fibre or polypropylene, and pile warp and weft yarn filling are woolen yarns.Above-mentioned the weaving for the technical staff of technical field of carpet manufacture of carrying out of change material and variation technology will be to understand easily.

Referring now to Fig. 3 to 5, a kind of loom according to an embodiment of the invention is illustrated by arrow 100 usually, and the woven product of being produced that schematically illustrates is fed on the roller 113, a shown workbench 112 is that the operating personnel for its equipment are provided with, shown loom 100 has a brest beams baffle plate 102, this baffle plate is fed pile yarns 104, inlay thread 106 and binding chains yarn 107 by a reed 103.Breast roll 130 is drawing through yarn material, and woven carpet passes through loom with a set rate with respect to the line density of carpet.Arrow shaft 108 is incorporated in the open shedding lay sword 109 to weft material and carries reed 103 and pat material and make it closely together.

118 expression heald transmission devices operate in heald 105(and see Fig. 4).

In Fig. 5, shed open (space) is represented as to be opened, and is taking weft yarn and fills and can be introduced into simultaneously so that arrow shaft 108b and 108c are taking weft yarn and arrow shaft 108a.Weave in the circulation whole, it is motionless that the liner warp thread keeps.

Weaving cycle period, binding chains warp thread 107 is side by side mutual switch along with pile yarns 104 mutual switches.Binding chains warp thread 107 and pile yarns 104 are driven up and down by heald 105.Each shown heald 105 provides a harness eye 120, and binding chains warp thread 107 and pile yarns 104 can pass its harness eye.When 4 healds 105 are when being illustrated among Fig. 5, can imagine, additional or less heald will use at some among other possible embodiment.Its heald 105 is connected on a cam disc device or the multi-arm, to be used for controlling desired pattern.Heald 105 is connected to a kind of carrying will be convenient to finer pattern and can produce on machine.

In use, lay sword 109 is carrying reed 103 and is driving forwards just in time a position not far from the forward position of brest beams baffle plate 102, as shown in Figure 5 and Figure 6. Warp thread 104 and 107 on this woven position is the approximately half paths through their vertical motion path, and their warp thread 106 with stretching always from brest beams baffle plate 102 more or less on a horizontal line combines.Reed 103 is by arrow shaft 108a, and to weave circulation ready for following thereupon for 108b and 108c and three weft yarns being introduced in advance are driven on the carpet, the exchange warp thread of finishing all warp thread positions then.

Fig. 3 and Fig. 4 ordinary representation pile yarns cheese 116 liners through through axle 110, the position of access node chain rivet 111 and tension weight 119.Shown pile yarns cheese 116 is provided on the creel 115 with corresponding creel weight 17.

Return the schematic diagram 5 of amplification, can see employed three arrow shafts 108, wherein arrow shaft 108b and 108c are used to carry two weft yarns; And the arrow shaft 108a on top is used for carrying weft yarn filling (Fig. 2 A and 2B are 18c).

In another embodiment of the Fig. 6 that illustrates, as can be seen, the arrow shaft that is provided that illustrates is, that be used for that weft yarn fills only is an arrow shaft 108a, and that be used for weft yarn is an arrow shaft 108b.And, also having lacked binding chains warp yarn 107 in this embodiment, the bottom and upper segment of liner warp thread 106 is feasible to combine weft yarn filling and weft material but velvet head line line 104 is fed into.

Be illustrated among Fig. 7 and the embodiment at one, can see and adopt two arrow shaft 108a and 108b or guarantee the same degree that the weft yarn filling is combined closely and be used to combine binding chains 107 desired the reducing to approximately of 2 of common every reeds or any selection with such pile warp.

With accessible be that each arrow shaft 108 comprises that a pair of center of working together transmits the arrow shaft member, correspondingly to feed and to receive weft material.Even some other type that weft yarn is introduced also can be used.

This shows that method and apparatus of the present invention finished the introducing that a kind of weft yarn is filled the pile yarns material, this material is closely kept motionless, to form the part pile, has so just avoided playing the hollow pile loop that the pile steel wire is kept by Wilden.Because mechanical component negligible amounts of the present invention, and for operation and maintenance especially very fast and being easier to, it is simpler and operation is faster therefore to play the operation of pile wire weaver compared with common Wilden.Because final resulting product adopts a kind of weft yarn packing material, this product also has intrinsic advantage as described above.

According to the above, of the present invention concrete element or integral body with known equivalents have been made explanation, and these equivalents are combined in together at this like that like an elephant the front is described respectively like this.

Although the present invention has made description by example with in conjunction with preferred embodiment, what will be understood that thus is can not break away from the present invention as being limited to the category of dependent claims for variation of the present invention and improvement.

Claims (15)

1, a kind of method that is used to produce carpet product, it comprise warp thread with weft material weaving be in the same place, and an additional weft material that comprises is held by the pile warp material, and its additional weft material passes the pile warp material, and part exposes.

2, method according to claim 1, included step are a pair of pile warp yarn to be formed in the pile loop and described additional weft material be arranged in the pile loop.

3, method according to claim 2, included step are that described warp thread is fed in the bottom and upper segment of the hot warp yarns of a lining.

4, method according to claim 2 provides some binding chains warp yarn there, and its warp yarn is fed into the bottom and upper segment of more described weft materials and a liner warp yarn.

5, a kind of method that is used to produce carpet product has comprised in fact as the content of described arbitrary embodiment of the present invention in conjunction with the accompanying drawings.

6, a kind of equipment that is used to produce carpet, it comprises and is used for weft yarn and is fed into the device of a knit unit through yarn material, this knit unit is used for a longitude and latitude yarn weaving together, and feed unit described herein comprises the device that is used for feeding to an additional weft material, its additional weft material is to be held by the pile warp material, and additional weft material passes the pile warp material, and part exposes.

7, device according to claim 6, the described feed unit that is used for weft material comprises some arrow shafts, these arrow shafts carry described weft material and the described additional weft material of one of them respectively, and described additional weft material is provided at by in the described pile loop that forms through yarn material.

8, device according to claim 7 wherein saidly comprises binding chains through yarn material, and these binding chains are arranged on more described weft materials and liner bottom and upper segment through yarn material.

9, device according to claim 6, each feed unit that wherein is used for described weft material and described additional weft material comprises a corresponding arrow shaft, be fed into a liner through yarn material and make through the bottom and upper segment of yarn material and combine that described additional weft material is to be provided at by described in the formed pile loop of yarn material with weft material and additional weft material.

10, a kind of device that is used to produce carpet, it has comprised 3-5 with reference to the accompanying drawings in fact, the described content of Fig. 6 or Fig. 7.

11, a kind of carpet, it is formed by weft yarn with through yarn material and the additional weft material institute that is woven together, and its additional weft material is held by the pile warp material, and its additional weft material passes the pile warp material, and partly exposes.

12, carpet according to claim 11 wherein comprises some pile loops that warp yarn limits through yarn material, in its pile loop, is provided with described additional weft material.

13, carpet according to claim 12, wherein said weft material comprise a liner warp yarn and some binding chains, and these described binding chains are arranged on the bottom and upper segment of described liner warp yarn.

14, carpet according to claim 12 wherein saidly provides bottom and upper segment in a liner warp yarn through yarn material.

15, a kind of carpet, it has comprised according to Fig. 2 and/or when the described content of being made by each the device of each method of claim 1-5 and/or claim 6-10 in fact.

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