Europäisches Patentamt *EP001347087A2* (19) European Patent Office

Office européen des brevets (11) EP 1 347 087 A2

(12) EUROPEAN PATENT APPLICATION

(43) Date of publication: (51) Int Cl.7: D03D 39/16, D03D 39/10 24.09.2003 Bulletin 2003/39

(21) Application number: 03075833.8

(22) Date of filing: 21.03.2003

(84) Designated Contracting States: (72) Inventors: AT BE BG CH CY CZ DE DK EE ES FI FR GB GR • Debaes, John HU IE IT LI LU MC NL PT RO SE SI SK TR 8890 Moorslede (BE) Designated Extension States: • Moulin, Gilbert AL LT LV MK 8930 Rekkem (BE)

(30) Priority: 22.03.2002 BE 200200210 (74) Representative: Ostyn, Frans et al K.O.B. NV, (71) Applicant: NV Michel van de Wiele Kennedypark 31 c 8510 Kortrijk/Marke (BE) 8500 Kortrijk (BE)

(54) machine and method for weaving fabrics with pile loops

(57) This invention relates to a face-to-face weaving pile loop fabrics, in which at least three weft (14, machine comprising upper (5) and lower spacers (6) for 15, 22) are inserted above one another during succes- extending in the warp direction between two fabrics (12), sive weft insertion cycles on a face-to-face weaving ma- (13) and a weft insertion device (2), (3), (4) for inserting chine, in which an upper (12) and a lower backing fabric weft yarns (22) between the spacers (5), (6), said spac- (13) are woven, and loop weft yarns (22) are inserted ers being carried out as a regid element with a first (5c), between the two fabrics (12), (13) and are kept at a dis- (6c) and a second part (5B), (6B), the vertical interme- tance of the backing fabrics (12), (13), and in which pile diate distance between the first parts (5c), (6c) of the warp yarns (23-28) form pile loops over loop weft yarns spacers (6) being shorter than said distance between (22), so that two pile loop fabrics are woven, whereas the second parts (5B), (6B) such that the weft yarns (22) pile warp yarns (23-28) are interlaced in the upper (12) can be inserted between said second parts (5B), (6B). and the lower backing fabric (13) alternately and are cut This invention also relates to a method for weaving through between the two fabrics (12), (13), so that zones with a cut pile are obtained on the fabrics. EP 1 347 087 A2

Printed by Jouve, 75001 PARIS (FR) 1 EP 1 347 087 A2 2

Description upper and lower lancets in order to keep the loop weft yarns at a distance from the backing fabrics. During [0001] This invention relates to a face-to-face weav- each weft insertion, a weft is inserted between the ing machine provided to form a shed between warp two lancets. yarns during successive weft insertion cycles and each 5 [0008] With this type of machines, however, the weft time to insert one or more weft yarns into this shed, so insertion is carried out by a set of rapiers moving be- that two backing fabrics may be woven simultaneously tween the lancets. Then the vertical distance between above one another, this weaving machine comprising the upper and the lower lancets should be sufficiently upper and lower spacers, which are provided in order to long to allow the rapiers to pass freely. The distance be- extend between the said backing fabrics in the warp di- 10 tween the lancets and the respective backing fabrics de- rection during weaving and this weaving machine com- termines the loop height. With these weaving machines, prising a weft insertion device provided in order to insert the loop height should be kept limited, so that sufficient weft yarns between the upper and lower spacers. space should be available for the rapiers to move. It is [0002] More particularly, the present invention relates a purpose of this invention to remedy this drawback. to a face-to-face weaving machine, which has been de- 15 [0009] This purpose will be attained by providing a signed for weaving simultaneously two fabrics with pile face-to-face weaving machine designed to form a shed loops. More particularly, it deals with a face-to-face between the warp yarns during the successive weft in- weaving machine equipped with a four-position jac- sertion cycles and each time to insert one or more weft quard machine. yarns into this shed, so that two backing fabrics may be [0003] The present invention likewise relates to a 20 woven simultaneously one above the other, this weav- method for weaving fabrics with pile loops, in which each ing machine comprising upper and lower spacers, de- time at least three weft yarns are inserted above one signed to extend between the said backing fabrics in the another at a respective insertion level during successive warp direction during weaving, this machine comprising weft insertion cycles on a face-to-face weaving ma- a weft insertion device designed to insert weft yarns be- chine, an upper and a lower backing fabric being woven 25 tween the upper and lower spacers, and the weaving from respective backing warp yarns and backing weft machine according to the present invention comprising yarns, first and second loop weft yarns being inserted spacers carried out in such a manner that they have a between the two backing fabrics and being kept at a dis- first part to form loops and a second part linking up with tance from the two backing fabrics, first pile warp yarns it, and shaped such that the vertical intermediate dis- being alternately interlaced in the upper backing fabric 30 tance between the first parts of the upper and the lower and forming a pile loop over at least one first loop weft spacers is shorter than the vertical intermediate dis- yarn, second pile warp yarns alternately being inter- tance between the second parts of the upper and lower laced in the lower backing fabric forming a pile loop over spacers, and further also comprising a weft insertion de- at least one second loop weft yarn and the first and sec- vice designed to insert weft yarns between the said sec- ond loop weft yarns being subsequently removed, so 35 ond parts of this rigid elements. that two fabrics with pile loops are being woven at the [0010] Preferably, the longer vertical intermediate dis- same time. tance between the said second parts is obtained be- [0004] More particularly, the present invention relates cause the spacers are carried out with a bend. Then the to a method for weaving having one or more first parts (preferably the end parts) are situated be- zones with pile loops at the face being used as well as 40 tween the rulers of the weaving machine, while the said one or more zones with a cut pile and/or one or more second parts are situated where the shed is formed and zones having a ribbed structure (false bouclé fabric) and where the weft yarns are inserted. /or one or more zones with a pile-free effect (where the [0011] In such an embodiment, sufficient space is backing weave is visible) and/or one or more zones with available between the second parts of the spacers to pile warp yarns floating on the pile face (flat weave), the 45 allow a weft insertion means, such as for instance a ra- zones with different effects together forming a pre-de- pier, to pass freely. The loop height is determined by the termined figure or pattern. first parts of the spacers. Even when the vertical dis- [0005] More particularly the present invention relates tance between these first parts is rather short, the ver- to a method carried out by means of a face-to-face tical distance between the second parts may be suffi- weaving machine according to the present invention de- 50 cient to allow the weft insertion means to pass freely. scribed in this patent application. Because of this, greater loop heights may be realized. [0006] Of course, the present invention also relates to [0012] As clearly appears from the preceding pages, the fabrics and more particularly to the multicoloured such a face-to-face weaving machine is particularly suit- carpets manufactured according to a similar method. able for weaving fabrics with pile loops according to the [0007] In the European patent application with publi- 55 present invention. Because of this, fabrics with pile cation number EP 0 974 690 a face-to-face weaving ma- loops can be produced at a high productivity and at a chine is described having the characteristics indicated great weaving speed. Moreover, it is possible, within a in the first section of this description. This machine has same method and on the same weaving machine, to ob-

2 3 EP 1 347 087 A2 4 tain fabrics with a large number of different effects, al- ing a greater variety than the pile loop fabrics known. lowing fabrics to be produced, the pile face of which will [0021] According to the present invention, this pur- show a wide variety. pose is attained by providing for a method for weaving [0013] Preferably, the spacers are designed to keep fabrics with pile loops, where on a face-to-face weaving the weft yarns, inserted between them, at a distance 5 machine, during successive weft insertion cycles, each from the respective backing fabrics, while the said first time at least three weft yarns are inserted at a respective parts for forming loops comprise at least two parts of a insertion level above one another, an upper and a lower different height, so that the said distance may be mod- backing fabric being woven from respective backing ified. By shifting the spacers (in the warp direction) an- warp yarns and backing weft yarns, first and second other part of the spacers may be used and in doing so, 10 loop weft yarns being inserted between the backing fab- the height of the pile loops may be modified. rics and being kept at a distance from the two backing [0014] In order to support the upper spacers the fabrics, first pile warp yarns being interlaced in in the weaving machine may be equipped with a stationary upper backing fabric and forming a pile loop over at least weaving frame. one first loop weft yarn alternately, second pile warp [0015] If the weft insertion device of this weaving ma- 15 yarns being interlaced in in the lower backing fabric and chine is designed to insert at least three weft yarns at forming a pile loop over at least one second loop weft the different insertion levels during successive weft in- yarn alternately, the first and second loop weft yarns be- sertion cycles, during each cycle, a loop weft yarn and ing subsequently removed, so that two fabrics with pile a backing weft yarn for each backing fabric are inserted. loops are woven simultaneously, and where, according In this manner, fabrics with pile loops may be manufac- 20 to the present invention, a number of pile warp yarns tured in a very productive manner. are interlaced in in the upper and the lower backing fab- [0016] In a particular embodiment, at least one upper ric alternately and afterwards being cut between the two and/or at least one lower spacer comprises a cutting de- backing fabrics, so that on both fabrics also at least one vice in order to cut through weft yarns inserted between zone with a cut pile is obtained. the upper and lower spacers. 25 [0022] Because of the combination of two different [0017] In a very preferred embodiment, this face-to- structures in the pile - pile loops and a cut pile - fabrics face weaving machine is designed to weave two fabrics are obtained with an aspect which shows much more with pile loops and a cut pile simultaneously. Preferably, variety than the fabrics woven according to the methods this occurs according to a method according to the known. Because, weaving is carried out according to a present invention, as described hereafter in the patent 30 face-to-face weaving method, a high productivity is at- application. tained. For instance, with a threefold weft insertion, a [0018] In a most preferred embodiment, this weaving weft yarn is inserted between the spacers, each time at machine is provided with a four-position jacquard ma- the middlemost insertion level, while a backing weft yarn chine, preferably an open-shed-four-position jacquard is inserted at the upper and lower insertion level for the machine. 35 upper and the lower fabric respectively. [0019] In the European patent publication EP 0 974 [0023] An additional advantage of this method is that 690 a method is also described, according to which two it allows for pile loops as well as for a cut pile to be loop pile fabrics are woven simultaneously on a face-to- formed in a fabric with the same weaving machine with- face weaving machine where each time three weft yarns out any shifting or modification of the adjustments. are inserted above one another per weft insertion cycle. 40 [0024] Preferably, one or several zones with a cut pile Two backing fabrics are woven above one another from and one or several zones with pile loops being deter- warp yarns and weft yarns, while loop weft yarns, by mined thus that a certain figure or pattern in the fabric means of upper and lower lancets, are kept at a distance is obtained. Therefore, also texts and logograms can be from these backing fabrics. Pile warp yarns are inter- obtained in the fabric, for example, and this both on the laced in alternately in a backing fabric and bent over a 45 face to be used and on the back of the fabric. loop weft yarn. Afterwards, the loop weft yarns are re- [0025] When applying this method, preferably use is moved, so that two fabrics with loop forming pile warp made of a four-position-jacquard machine and more yarns are formed. This method has the characteristics, particularly of such a machine enabling to function ac- which were mentioned, in the third section of this de- cording to the open-shed principle. If a threefold weft scription. 50 insertion (with three weft insertion means functioning The fabrics realized according to this method have a pile above one another) is applied, it should be possible to exclusively consisting of pile loops. In other words, the insert the pile warp yarns in the following four positions: structure of the pile shows no variation at all. [0020] It is likewise a purpose of the present invention - above the upper insertion means, to provide for such a method, by means of which the 55 - between the upper and the middlemost insertion said drawback can be remedied and by means of which means, therefore two pile loop fabrics can be woven simultane- - between the middlemost and the lower insertion ously at a high productivity having a pile structure show- means, and

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- below the lower insertion means. intermediate distance between the second parts of the upper and the lower spacers, while the said weft inser- [0026] When carrying out this method, both a cut pile tion device is designed to insert weft yarns between the and pile loops can be formed by means of a number of said second parts of these rigid elements. pile warp yarns (this is shown in figure 6 for pile warp 5 [0032] In the method according to the present inven- yarns (24) and (26). tion preferably, each time a backing weft yarn for the [0027] With the method according to the present in- upper backing fabric, a backing weft yarn for the lower vention, it is likewise possible in a number of warp yarn backing fabric and a first and a second loop weft yarn systems to make a first and a second pile warp yarn to- alternately will be inserted during successive weft inser- gether form a cut pile over the same weft yarns in order 10 tion cycles. to create pile points with a double pile, while for at least [0033] Further, according to this method, a number of one zone of the fabrics the proportion between the warp thread systems with a first and/or a second loop number of pile points with a double pile and the number forming pile warp yarn, also a third pile warp yarn may of pile points with one single pile is determined as a func- be provided, which is interlaced in the upper and the low- tion of the pile density desired. 15 er backing fabric alternately and thereafter will be cut [0028] When pile warp yarns of a particular colour are through between the two backing fabrics, so that at least used to form pile loops and to form a cut pile, it is nec- in one fabric a zone with both a cut pile and pile loops essary to provide two pile warp yarns of that particular is obtained. Because of this, an additional variety of as- colour if the possibility of forming pile loops of that colour pect of the fabric can be created during the same weav- in the upper and in the lower backing fabric simultane- 20 ing process. ously is required. For instance, these two pile warp [0034] When carrying out the method according to the yarns of the same colour running together may be used present invention, in at least one fabric, with respect to in a number of warp yarn systems in order to form a cut weft yarns inserted during successive weft insertion cy- pile over the same weft yarns. Thus, pile points with a cles, also a third pile warp yarn can be interlaced over double pile are obtained in a zone with a cut pile. Now, 25 a backing weft yarn alternately in order to form cut pile by not always carrying through these double pile points legs, and a first or a second pile warp yarn can form a in a cut pile zone, but only for a fraction of the pile points, pile loop over a loop weft yarn, so that in at least one it is possible to realize a pile density that will be between fabric, a zone is obtained with a pile loop and a two cut 100% (all pile point single pile) and 200% (all pile points pile legs alternately. This is yet another possibility double pile). All intermediate values (between 100% 30 (called "cut-loop" weaving) which may be used during and 200%) of pile density are possible by choosing a the same method in order to bring variety to the aspect suitable proportion between the number of pile points of the fabric. with a double pile and the number of pile points with one [0035] Yet another effect which may be applied when single pile. carrying out this method, is the pile-free effect. For that [0029] According to a preferred embodiment, accord- 35 purpose, in at least one zone of at least one fabric all ing to the present invention, the upper and lower spac- pile warp yarns are woven in, so that the backing fabric ers are carried out as rigid elements and extending in is visible from the pile face of the fabric. the warp direction, are provided between the said back- [0036] Yet another effect is obtained when in at least ing fabrics, and the said first and second loop weft yarns one of the fabrics a number of pile warp yarns is inter- are inserted between upper and lower spacers, because 40 laced alternately in the backing fabric and bent on the of which they are kept at a distance from the upper and pile face over at least one backing weft yarn, so that at lower backing fabric respectively. least also one zone with a ribbed structure, more partic- [0030] Preferably, these spacers are carried out as ularly with false bouclé, is obtained. flat lancets of a limited thickness, the flanks of which [0037] Further, in at least one of the fabrics, also a extend between the upper and the lower fabric, almost 45 number of pile warp yarns may be interlaced alternately vertically next to one another, and in their longitudinal in the backing fabric and made to run floatingly on the direction according to the warp direction. The distance pile face over several backing weft yarns (floating), so between the lower edge of the upper lancets and the that also at least one zone with a flat fabric surface ("flat upper backing fabric determining the height of the ") is obtained. loops being formed on the upper fabric. The distance 50 [0038] Preferably, tension warp yarns are provided in between the upper edge of the lower lancets and the the backing fabrics, and dead pile warp yarns are inter- lower backing fabric determining the height of the pile laced in one the two backing fabrics either running along loops being formed on the lower backing fabric. with the tension warp yarns or floatingly on the pile face, [0031] Preferably, the said spacers are carried out in over one or more backing weft yarns. such a manner that they have a first part for forming 55 [0039] In a number of warp yarn systems, also two loops and a second part linking up with it, that the vertical pile warp yarns may be interlaced in opposite phase in intermediate distance between the first parts of the up- the upper and the lower backing fabric alternately and per and the lower spacers is shorter than the vertical thereafter be cut through between the two backing fab-

4 7 EP 1 347 087 A2 8 rics, so that at least one zone with a cut pile is obtained. warp yarns is represented; By applying this so-called "pile weaving in opposite - in figure 4 the production of fabrics with alter- phase", a fabric is obtained with at least one zone where nating pile loop and two cut pile legs and float- the cut pile has a great pile density. ing dead pile warp yarns is represented; [0040] If tension warp yarns are provided in the back- 5 - in figure 5 the production of fabrics with pile ing fabrics, the pile warp yarns can be interlaced over loops and cut pile, with pile warp yarns forming at least one backing weft yarn inserted on the back with pile in opposite phase, and dead pile warp respect to the tension warp yarns (so called: woven yarns woven in is represented; through the back). In that manner a good pile retention - in figure 6 the production of fabrics with pile is obtained. 10 loops and cut pile, with pile warp yarns forming [0041] The pile warp yarns can also be interlaced over pile in opposite phase, with pile loops formed at least one backing weft yarn, which is inserted, on the over several loop weft yarns, with a pile-free ef- pile face with respect to these tension warp yarns. Be- fect and dead pile warp yarns woven in is - cause of this, the pile yarn consumption can be reduced. resented; [0042] According to a particular method according to 15 - in figure 7 the production of fabrics with pile the present invention, pile warp yarns are used which loops, not woven through the back and dead will shrink after they have been cut through. Therefore pile warp yarns woven in is represented; it is possible to obtain a pile height for the cut pile which - in figure 8 the production of fabrics with pile is smaller than half the distance between the two back- loops woven through the back, with pile loops ing fabrics, so that, for instance, for the cut pile and the 20 formed over several pile weft yarns and with pile loops the same pile height can be obtained. dead pile warp yarns woven in is represented; [0043] It is obvious that the present invention also re- - in figure 9 the production of fabrics with pile lates to fabrics with pile loops, which are manufactured loops, not woven through the back and both by means of a method according to the present inven- floating pile warp yarns and pile warp yarns wo- tion and therefore will comprise also at least one zone 25 ven in is represented; with a cut pile. - in figure 10 the production of fabrics with pile [0044] In the following detailed description, a number loops, not woven through the back, with pile of weaves according to the present invention and a part loops formed over several pile weft yarns, with of a face-to-face weaving machine are described in a cut pile not woven through the back and with more detailed manner. Its only purpose is to further clar- 30 both floating dead pile warp yarns and dead pile ify the principles and the said characteristics and advan- warp yarns woven in is represented; tages of the invention by means of a number of concrete - in figure 11 the production of fabrics with pile examples. It may be clear that nothing in this description loops woven through the back, with pile loops may be interpreted as a restriction of the scope of the formed over several pile weft yarns, with cut pile patent rights claimed for in the claims, nor as a restric- 35 woven through, with pile-free effect and with tion of the field of application of the present invention. both floating dead pile warp yarns and dead pile [0045] In the following description reference is made warp yarns woven in is represented; by means of reference numbers to the attached draw- ings, of which: figure 12 represents a schematic side view of a 40 face-to-face weaving machine with an upper and a the figures 1 to 11 each time represent a schematic lower series of lancets for weaving according to the cross-section in the warp direction of two fabrics method of the present invention; during their being produced according to the present invention on a face-to-face weaving ma- figure 13 represents part of the side view represent- chine equipped with upper and lower lancets, the 45 ed in figure 12, at an enlarged scale; and warp yarns of one warp yarn system, the weft yarns and one upper and one lower lancet being repre- figure 14 represents part of the side view represent- sented in each cross-section, and where, ed in figure 13 at an enlarged scale.

- in figure 1 the production of fabrics with pile 50 [0046] The method according to the present invention loops and cut pile and dead pile warp yarns wo- is best carried out with the help of a three-rapier-face- ven in is represented; to-face weaving machine (see figures 12 to 14). With - in figure 2 the production of fabrics with pile the help of a shed-forming device not represented in the loops and cut pile and floating dead pile warp figures (for instance, a jacquard machine) each time a yarns is represented; 55 shed is formed between a series of warp yarns (1) during - in figure 3 the production of fabrics with pile successive operational cycles and each time three weft loops formed over several loop weft yarns and yarns are inserted into this shed above one another by cut pile and short and long floating dead pile means of rapiers (2),(3),(4) movable above one another.

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The upper (2) and lower rapier (4) inserting a respective cets (5) the upper edge is carried out step-like and with backing weft yarn, while each time the middlemost ra- the lower lancets (6) this is the lower edge. Because of pier inserts a loop weft yarn. The warp yarns (1) are po- this the vertical intermediate distance between the lan- sitioned in such a manner in the shed with respect to the cets (5),(6) stays independent of the lancet height, respective insertion levels that an upper and a lower fab- 5 which is being used. The front part (6C) of the lower lan- ric are woven from respective backing warp yarns and cets (6) rests on the lower ruler (10) of the weaving ma- backing weft yarns, while in both backing fabrics loop chine. The upper lancets (6) are supported by the weav- warp yarns are interlaced and are bent over a loop weft ing frame (8). yarn alternately, so that two fabrics with pile loops are [0051] In each layer, a series of lancets (5),(6) is in- obtained. 10 stalled next to each other. Near the middlemost lancets [0047] In order to obtain these pile loops, the loop weft (5),(6) - in the middle of the weaving machine, seen yarns must be kept at a distance from the backing fab- widthwise - an upper (5) and a lower lancet (6) are pro- rics. This happens by means of upper (5) and lower lan- vided with a device (30) for cutting through the loop weft cets (6). These lancets (5),(6) are carried out as small yarns inserted between the lancets (5),(6). In this man- flat plates of a limited thickness. 15 ner, the loop weft yarns cut through may be easily with- [0048] The upper lancets (5) and the lower lancets (6) drawn from the fabric. are situated in respective layers above one another and [0052] In the figures 1 to 11, each time, a schematic extend according to the direction of the warp yarns (1). cross-section of a face-to-face fabric according to the Each lancet (5),(6) being in a position in which the flat present invention is represented during its being pro- flanks extend almost in a vertical plane. The lancets (5), 20 duced on a face-to-face weaving machine. Each time, (6) have a back part (5A),(6A) inserted in a holder (7), a shed being formed between a series of warp yarns a central part (5B),(6B) supported by a non-moving (16-19, 23-28) during successive weft insertion cycles weaving frame (8) and extend further through the weav- and each time, three weft yarns (14), (15), (22) being ing reed (11), and a front part (5C),(6C) which extends inserted, above one another, between these warp yarns. between the upper ruler (9) and the lower ruler (10) of 25 [0053] Thus, an upper backing fabric (12) is woven the weaving machine. The shape of the lancets (5),(6) from backing weft yarns (14) and several warp yarn sys- is such that the vertical intermediate distance between tems in which two binding warp yarns (16),(17) and a the central parts (5B),(6B) is longer than the vertical in- tension warp yarn (20) are provided each time, and a termediate distances between the back parts (5A),(6A) lower backing fabric (13) is woven from backing weft and the vertical intermediate distance between the front 30 yarns (15) and several warp yarn systems, in which two parts (5C),(6C). The transition between the central parts binding warp yarns (18),(19) and a tension warp yarn (5B),(6B) and the front parts (5C),(6C) of the lancets (5), (21) are provided each time. During each insertion cycle (6) on the one hand and the back parts (5A),(6A) on the a backing weft yarn (14) for the upper backing fabric other hand, occurs via a respective bend, a change in (12), a loop weft yarn (22) and a backing weft yarn (15) height of the lancets (5),(6), and parts of the lancets (5), 35 for the lower backing fabric (13) are inserted. (6) slanting towards each other. Because of this shape, [0054] In these backing fabrics (12),(13) the backing sufficient space is available between the central parts weft yarns (14),(15) are inserted on the pile face and on (5B),(6B) of the lancets for the central rapier (3) to move. the back of the tension warp yarns (20),(21) by means [0049] In the figures 12 to 14 the weaving reed (11) is of systems of two binding warp yarns (16),(17); (18),(19) also represented, and in the figures 12 and 13 this weav- 40 the two binding warp yarns of which are running in op- ing reed (11) was represented both in the retired position posite phase above and below alternately two succes- (at the moment the weft yarns are inserted by the rapiers sive backing warp yarns (14),(15) alternately. (2),(3),(4)) and in the beating up position (in which the [0055] The front parts (5C) of he upper lancets (5) and inserted weft yarns are pushed against the edge of the the front parts (6C) of the lower lancets (6) are situated fabrics already constituted). 45 above one another between the upper (12) and the low- [0050] The front parts (5C),(6C) of the lancets (5),(6) er backing fabric (13). Between these front parts (5C), will keep the loop weft yarns inserted between the lan- (6C) a loop weft yarn (22) is inserted during each weft cets (5),(6) at a distance away from the backing fabrics. insertion cycle. To that purpose, these front parts (5C),(6C) are situated [0056] According to the method illustrated in figure 1, between the upper ruler (9) and the lower ruler (10) of 50 two fabrics with pile loops an cut pile are woven. In order the weaving machine. The lancets (5),(6) have a height to form a cut pile, the pile warp yarns (23),(24),(25) are which decreases step by step in the direction of their interlaced over a backing weft yarn (14) of the upper front extremity. By shifting the lancet in the warp direc- backing fabric (12) and over a backing weft yarn (15) of tion (away from the weaver, i.e. to the right in the fig- the lower backing fabric (13) alternately. Afterwards, ures), a less high part of the lancets is used to form pile 55 these pile warp yarns (23),(24),(25) are cut through be- loops, so that the said distance between the loop weft tween the two backing fabrics (12),(13). In order to form yarns and backing fabrics will decrease and therefore, pile loops on the upper backing fabric (12), a pile warp a shorter pile height will be obtained. With the upper lan- yarn (26) is interlaced and bent in a loop-forming man-

6 11 EP 1 347 087 A2 12 ner over a loop weft yarn (22) alternately. In order to form - in order to be interlaced over the lower backing pile loops on the lower backing fabric (13) a pile warp weft yarn (15) in the lower fabric. yarn (27) is interlaced and bent in a loop-forming man- ner over a loop weft yarn (22) alternately. Interlacing pile [0060] At a weft insertion (for example the second warp yarns (both for forming a cut pile and for forming 5 weft insertion from the left in figure 1) where the upper pile loops) occurs over backing weft yarns (14),(15) be- backing weft yarn (14) should be inserted along the back ing situated on the back of the fabric with respect to the of the upper fabric, the loop weft yarn (22) should be tension warp yarns (20),(21). The loop weft yarns (22) used to form a loop on the lower fabric, and the lower inserted during successive insertion cycles are used for backing weft yarn (15) should be inserted along the pile forming loops on the upper backing fabric (12) and for 10 face of the lower fabric, the pile warp yarns should forming pile loops on the lower backing fabric (13) alter- nately. * take up a first position, above the upper weft inser- [0057] The (parts of) pile warp yarns (23-28) which tion means are not used for creating surface effects (the dead pile warp yarns) are woven in in the backing fabrics (12),(13) 15 - in order to be interlaced over the upper backing running along with the tension warp yarns (20),(21). weft yarn (14) in the upper fabric; [0058] This method requires the use of a four-position jacquard machine. * take up a second position between the upper and [0059] At each weft insertion an upper backing weft the middlemost weft insertion means yarn (14), a loop weft yarn (22) and a lower backing weft 20 yarn (15) are inserted simultaneously above one anoth- - in order to form a loop over the loop weft yarn er. At a weft insertion (for example, the first weft insertion (22) of the lower fabric, in figure 1 on the left) where the upper backing weft yarn - in order to be woven in as dead pile in the upper (14) should be inserted on the pile face of the upper fab- fabric, and ric, the loop weft yarn (22) should be used to form a loop 25 - in order to be woven in in the upper fabric, run- on the upper fabric and the lower backing weft yarn (15) ning floatingly along the pile face; should be inserted along the back of the lower fabric, the pile warp yarns should: * take up a third position between the middlemost and the lower weft insertion means * take up a first position, above the upper weft inser- 30 tion means - in order to form pattern over the lower backing weft yarn (15) in the lower fabric, and - in order to be woven in as a dead pile in the - in order to be woven in in the lower fabric, run- upper fabric, and ning floatingly along the pile face; and - in order to be interlaced over the upper backing 35 weft yarn (14); * take up a fourth position, below the lower weft in- sertion means * take up a second position, between the upper and the middlemost weft insertion means, - in order to be woven in as dead pile in the lower 40 fabric, and - in order to form pattern over the upper backing - in order to be interlaced over the lower backing weft yarn (14) in the upper fabric, and weft yarn (15) in the lower fabric. - in order to be woven in in the upper fabric, run- ning floatingly along the pile face (see figure 2 [0061] In figure 2 is shown how fabrics with pile loops among others); 45 and cut pile and floating dead pile warp yarns (22-28) are woven. This method is different from the method ac- * take up a third position, between the middlemost cording to figure 1 because the dead pile warp yarns and the lower weft insertion means (23-28) are interlaced over one backing weft yarn (14), (15) and are floating along the pile face of the backing - in order to form a loop over the loop weft yarn 50 fabric (12),(13) over several backing weft yarns (14), (22) of the upper fabric, (15) alternately. These dead pile warp yarns (23-28) are - in order to be woven in as a dead pile in the interlaced over a backing warp yarn (14),(15) situated lower fabric, and along the pile face of the tension warp yarns (20),(21). - in order to be woven in in the lower fabric, run- [0062] The method according to figure 3 is different ning floatingly along the pile face; and 55 from that according to figure 2 because now, addition- ally, also pile warp yarns (26),(27) are bent over several * take up a fourth position, below the lower weft in- loop weft yarns (22) in order to form also longer pile sertion means loops in addition to the cut pile and the ordinary pile

7 13 EP 1 347 087 A2 14 loops (formed over one loop weft yarn). Here also the from that of figure 7, only in that the pile warp yarns dead pile warp yarns are woven in floatingly and the pile (23-28) are now interlaced over backing weft yarns (14), warp yarns which form the cut pile and pile loops are (15) running along the back of the tension warp yarns interlaced over backing weft yarns (14),(15) running (20),(21). along the back of the tension warp yarns (20),(21). 5 [0068] In figure 9 illustrates the production of fabrics [0063] The method according to figure 4 produces with pile loops not woven through and with dead pile fabrics with a part with pile loops and a part with a pile warp yarns (23-28) woven in, running along with the ten- loop and two cut pile legs alternately. For that purpose, sion warp yarns (20),(21). In the fabrics, an additional three identical pile warp yarns (23), (24), (25) are made effect is created, because, in certain places, the aspect to form a pile in the same manner according to a W- 10 of the pile face is determined by a pile warp yarn (23), weave, while these pile warp yarns each are dephased (27) floating along the pile face over several backing with respect to one another over two weft insertion cy- weft yarns (14),(15) (flat weave). Now and then, this pile cles. The pile warp yarn being bent over a loop weft yarn warp yarn (23),(27) is interlaced over one backing weft (22), each time in the middle of the W. The dead pile yarn (14),(15) in the backing fabrics (12),(13). warp yarns are interlaced over a backing weft yarn (14), 15 [0069] In the method according to figure 10 in each (15) running along the pile face of the tension warp yarns fabric, a pile warp yarn (24),(27) is made to form pile (20),(21) and brought in a position floating over several loops which are not woven through the back, both short backing weft yarns (14),(15) alternately. and long (formed over several loop weft yarns) being [0064] In figure 5, two pile warp yarns (23),(28) of the formed, another pile warp yarn (23) is made to form a same warp yarn system are made to simultaneously 20 cut pile not woven through the back and yet other pile form a cut pile by interlacing them in opposite phase in warp yarns (25),(28) are made to determine the aspect the upper (12) and the lower backing fabric (13) alter- of the fabric floating along the pile face. Now and then, nately. One pile warp yarn (28) each time being inter- this floating pile warp yarn (25),(28) is interlaced over a laced over a backing weft yarn (14),(15) on the pile face, backing weft yarn (14),(15) running along the pile face while the other pile warp yarn (23), is interlaced, each 25 of the tension warp yarn (20),(21). The dead pile warp time over a backing weft yarn (14), (15) on the back. In yarns (23-28) are woven in in the backing fabrics (12), the same warp yarn system the other pile warp yarns (13) together with the tension warp yarns (20),(21). (26),(27) are made to form pile loops and together with [0070] The method according to figure 11 is different yet other pile warp yarns (24),(25) a cut pile is formed from that according to figure 10 in that the loop forming with a lower pile density. The dead pile warp yarns 30 pile warp yarns (23),(26) and the pile warp yarns (24), (23-28) are woven in, running along with the tension forming a cut pile are now interlaced over backing weft warp yarns (20),(21). yarns (14),(15) running along the back of the tension [0065] The method according to figure 6 is different warp yarns (20),(21) (being woven through the back) from that of figure 5 because here, pile loops are formed and in that a pile-free effect is obtained by making the over two loop weft yarns (22), because of which longer 35 backing weave visible in the lower fabric (13). pile loops are obtained in addition to the cut pile with a [0071] The combinations of effects represented in the high pile density and the short pile loops, because the figures 1 to 11 may be combined infinitely. fabrics show places where the backing weave is visible, [0072] As far as the backing weave is concerned (the so that a pile-free effect is created, and because the two weave of backing warp yarns (16,17);(18,19) and back- pile warp yarns (23),(28) forming a cut pile in opposite 40 ing weft yarns (14),(15) we note, that all possible back- phase, now are interlaced alternately over a backing ing weaves may be applied in the method and in the weft yarn (14),(15) on the pile face and over a backing fabrics according to the present invention and that the weft yarn (14),(15) on the back, this occurring synchron- 2/2-backing weave represented in the figures was given ically for the upper (12) and the lower backing fabric only by way of example. (13). Here, the dead pile warp yarns (23-28) are likewise 45 woven in, running along with the tension warp yarns (20),(21). Claims [0066] According to figure 7 short pile loops are formed by making pile warp yarns (23-28) run over one 1. Face-to-face weaving machine provided to form a loop weft yarn (22), and long pile loops are formed by 50 shed between warp yarns during successive weft making pile warp yarns (24),(27) run over two loop weft insertion cycles and each time to insert one or more yarns (22). Here, no cut pile is formed. The pile warp weft yarns into this shed, so that two backing fabrics yarns (23-28) are interlaced over backing weft yarns (12),(13) may be woven simultaneously above one (14),(15) running along the pile face of the tension warp another, comprising upper (5) and lower spacers yarn (20),(21). The dead pile warp yarns (23-28) are wo- 55 (6), which are provided in order to extend between ven in, running along with the tension warp yarns (20), the said backing fabrics (12),(13) in the warp direc- (21). tion during weaving and a weft insertion device (2), [0067] The method according to figure 8 is different (3),(4) designed to insert weft yarns (22) between

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the upper (5) and the lower spacers (6), character- (18),(19) and backing weft yarns (14),(15), first and ized in that the spacers (5),(6) are carried out as a second loop weft yarns (22) being inserted between rigid element with a first part (5c),(6c) to form loops the two backing fabrics (12),(13) and kept at a dis- and with a second part (5B),(6B) linking up with it, tance of the two backing fabrics (12),(13), the first in that the vertical intermediate distance between 5 pile warp yarns (23-28) being interlaced in the upper the first parts (5c),(6c) of the upper (5) and the lower backing fabric (12) and forming a pile loop over at spacers (6) is shorter than the vertical intermediate least one first loop weft yarn (22) alternately, second distance between the two second parts (5B),(6B) of pile warp yarns (23-28) being interlaced in the lower the upper (5) and the lower spacers (6), and in that backing fabric (13) and forming a pile loop over at the said weft insertion device (2),(3),(4) is designed 10 least one second loop weft yarn (22) alternately, and to insert weft yarns (22) between the said second the first and the second loop weft yarns (22) being parts (5B),(6B) of these rigid elements. removed thereafter, so that two fabrics with pile loops are woven simultaneously, characterized in 2. Face-to-face weaving machine according to claim that a number of pile warp yarns (23-28) are inter- 1, characterized in that the spacers (5),(6) are pro- 15 laced in the upper (12) and in the lower backing fab- vided in order to keep at a distance the weft yarns ric (13) alternately and thereafter are cut through (22) inserted between them, and in that the first between the two backing fabrics (12),(13), so that parts (5c),(6c) to form loops comprise at least two on both fabrics also at least one zone with a cut pile parts of a different height, so that the said distance is obtained. may be modified. 20 9. Method for weaving fabrics with pile loops accord- 3. Face-to-face weaving machine according to claim ing to claim 8, characterized in that it is carried out 1or2,characterized in that the weaving machine with the help of a four-position jacquard device. comprises a stationary weaving frame (8) to support the upper spacers (5). 25 10. Method for weaving fabrics with pile loops accord- ing to claim 8 or 9, characterized in that with a 4. Face-to-face weaving machine according to any- number of pile warp yarns (24),(25) both cut pile and one of the preceding claims, characterized in that pile loops are formed. the weaving machine comprises a weft insertion de- vice (2),(3),(4) designed to insert each time at least 30 11. Method for weaving fabrics with pile loops accord- three weft yarns (14),(15),(22) at different insertion ing to anyone of the claims 8 to 10, characterized levels during the successive weft insertion cycles. in that in a number of warp yarn systems a first and a second pile warp yarn are made to form together 5. Face-to-face weaving machine according to any- a cut pile over the same weft yarns in order to create one of the preceding claims, characterized in that 35 pile points with a double pile, and in that for at least at least one upper (5) and/or at least one lower one zone of the fabrics the proportion between the spacer (6) comprises a cutting device (30) in order number of pile points with a double pile and the to cut through the weft yarns (22) inserted between number of pile points with only one single pile is de- the upper (5) and the lower spacers (6). termined as a function of the pile density desired. 40 6. Face-to-face weaving machine according to any- 12. Method for weaving fabrics with pile loops accord- one of the preceding claims, characterized in that ing to anyone of the claims 8 to 11, characterized the weaving machine is designed for weaving si- in that upper (5) and lower spacers (6) are carried multaneously two fabrics with pile loops and a cut out as a rigid element and, extending in the warp pile. 45 direction, are provided between the said backing fabrics (12),(13), and in that the first and the second 7. Face-to-face weaving machine according to any- loop weft yarns (22) are inserted between the said one of the preceding claims, characterized in that upper (5) and lower spacers (6), because of which the weaving machine is provided with a four-posi- they are kept at a distance from the upper (12) and tion jacquard machine. 50 the lower (13) backing fabric respectively.

8. Method for weaving fabrics with pile loops, by 13. Method for weaving fabrics with pile loops accord- means of which each time at least three weft yarns ing to claim 12, characterized in that the said spac- (14),(15),(22) are inserted above one another at a ers (5),(6) are carried out as a rigid element with a respective insertion level on a face-to-face weaving 55 first part (5c),(6c) to form loops and a second part machine during successive weft insertion cycles, an (5B),(6B) linking up with it, in that the vertical inter- upper (12) and a lower backing fabric (13) being wo- mediate distance between the first parts (5c),(6c) of ven from respective backing warp yarns (16),(17), the upper (5) and the lower spacers (6) is shorter

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than the vertical intermediate distance of the sec- over several backing weft yarns (14),(15), so that ond parts (5B),(6B) of the upper (5) and the lower also at least one zone with a flat fabric surface is spacers (6), and in that during weaving, the said obtained. weft insertion device (2),(3),(4) inserts weft yarns (22) between the said second parts (5B),(6B) of 5 20. Method for weaving fabrics with pile loops accord- these rigid elements. ing to anyone of the claims 8 to 19, characterized in that in the backing fabrics tension warp yarns 14. Method for weaving fabrics with pile loops accord- (20),(21) are provided and in that dead pile warp ing to anyone of the claims 8 to 13, characterized yarns (23-28) are woven in in one or both backing in that during successive weft insertion cycles each 10 fabrics (12),(13), either running along with the ten- time a backing weft yarn (14) for the upper backing sion warp yarns (20),(21) or floating along the pile fabric (12), a backing weft yarn (15) for the lower face over one or more backing weft yarns (14),(15). backing fabric (13), and a first and a second loop weft yarn (22) are inserted alternately. 21. Method for weaving fabrics with pile loops accord- 15 ing to anyone of the claims 8 to 20, characterized 15. Method for weaving fabrics with pile loops accord- in that in a number of warp yarn systems two pile ing to anyone of the claims 8 to 14, characterized warp yarns (23),(28) are interlaced in opposite in that in a number of warp yarn systems with a first phase in the upper (12) and the lower backing fabric and/or a second loop forming pile warp yarn (13) alternately and thereafter are cut through be- (23-28), also a third pile warp yarn (23-28) is pro- 20 tween the two backing fabrics (12),(13), so that also vided, which is interlaced in the upper (12) and the at least one zone with a cut pile is obtained. lower backing fabric (13) alternately and thereafter is cut through between the two backing fabrics (12), 22. Method for weaving fabrics with pile loops accord- (13), so that in at least one fabric, both a cut pile ing to anyone of the claims 8 to 21, characterized and pile loops are obtained. 25 in that tension warp yarns (20),(21) are provided in the backing fabrics, and in that the pile warp yarns 16. Method for weaving fabrics with pile loops accord- (23-28) are interlaced over at least one backing weft ing to claim 15, characterized in that in at least one yarn (14),(15), which has been woven in on the back fabric, with respect to weft yarns (14),(15) inserted with respect to the tension warp yarns (20),(21). during successive weft insertion cycles, a third pile 30 warp yarn (23),(24),(25) is interlaced over a backing 23. Method for weaving fabrics with pile loops accord- weft yarn (14),(15) alternately to form cut pile legs ing to anyone of the claims 8 to 22, characterized and a first or a second pile warp yarn (23),(24),(25) in that tension warp yarns (20),(21) are provided in forms a pile loop over a loop weft yarn (22), so that the backing fabrics, and in that the pile warp yarns in at least one fabric a zone with a pile loop and two 35 (23-28) are interlaced over at least one backing weft cut pile legs is obtained. yarn (14),(15), which has been inserted on the pile face with respect to the tension warp yarns (20), 17. Method for weaving fabrics with pile loops accord- (21). ing to anyone of the claims 8 to 16, characterized in that in at least one zone of at least one fabric all 40 24. Method for weaving fabrics with pile loops accord- pile warp yarns (23-28) are woven in, so that the ing to anyone of the claims 8 to 23, characterized backing fabric (12),(13) is visible from the pile face in that pile warp yarns are used which shrink after of the fabric. having been cut through.

18. Method for weaving fabrics with pile loops accord- 45 25. Fabric with pile loops, characterized in that it com- ing to anyone of the claims 8 to 17, characterized prises at least one zone with a cut pile and is man- in that in at least one of the fabrics a number of pile ufactured according to a method according to any- warp yarns (23-28) is interlaced in the backing fab- one of the claims 8 to 24. ric (12),(13) and bent on the pile face over at least one backing weft yarn (14),(15) alternately, so that 50 also at least one zone with a ribbed structure, more particularly a false boucle, is obtained.

19. Method for weaving fabrics with pile loops accord- ing to anyone of the claims 8 to 18, characterized 55 in that in at least one of the fabrics a number of pile warp yarns (23-28) is interlaced in the backing fab- ric (12),(13) and floating along the pile face, runs

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