Terry Fabric Weave and Resulting Terry Fabric
Field of the Invention
[0001) The present invention relates to terry fabric weaves, methods for weaving terry fabrics
comprising such weaves, and resulting terry fabrics. In particular, the invention relates to terry
fabrics having improved material efficiencies, pull resistance, absorbency, softness and
uniformity of texture.
Background
[0002] Terry fabrics are manufactured for several different end uses, including as towels,
bathrobes, blankets, cleaning products, carpets and the like. Terry fabrics are considered
advantageous in view of the fast drying, softness, ability to pick up particles, and ability to
absorb moisture.
[0003] Terry fabrics typically comprise a woven ground fabric comprising a plurality of
substantially parallel ground warp yarns and a plurality of substantially parallel ground weft
yams (or picks) -wherein the plurality of ground weft yarns intersect the plurality of ground
warp yarns substantially perpendicularly. Additionally, a plurality of pile warp yarns are
interwoven into the ground fabric in a direction substantially parallel to the ground warp yams
- and the pile weave forms a plurality of pile loops or terry loops above and below the woven
ground fabric.
[0004] Ground warp yarns are interwoven with ground weft yarns at a relatively high tension
and forms the base or substrate of the terry fabric. The pile warp yarns are interwoven at a
lower tension and are advanced or "let off'' from the loom beam at a higher rate than the
ground warp yarns. During weaving, a series of adjacent ground weft yarns are subjected to a
partial beat-up or "loose beat-up", where the weft yarn(s) may be pushed partially together
using a comb (or "reed'') or where the fell of the cloth is moved forward to enable a partial
beat-up, while the pile warp yams are permitted to "float" over two or more adjacent ground
weft yarns. On an ensuing ground weft yarn (at the conclusion of a weaving repeat), the
previously partially beat up ground weft yarns as well as the ensuing ground weft yarn are
subjected to a "fast beat up", where all ground weft yarns are pushed fully up to the fell of
the woven fabric - resulting in the floating pile threads forming loops that extend away from
the ground substrate. A common terry pattern comprises a 3 pick sequence, wherein pile
loops are interwoven into the ground fabric in a repeating pattern such that pile loops are
fanned using (and repeated every) 3 ground weft yarns. Less commonly known are 4, 5, 6 and
7 pick sequences -where interweaving a pile yarn into the ground fabric comprises repeating
a pile loop every 4, 5, 6, or 7 ground weft yams.
[0005) Figures 1 and 2 respectively provide transverse and perspective views of a terry weave
sequence 100 comprising a 3 pick sequence. Terry weave sequence 100 comprises a pair of
ground warp yarns 102a and 102b interwoven with a plurality of ground weft yams in a
repeating sequence such that first and second ground weft yams 104a and 104b are placed
within a first shed 106a formed by the pair of ground warp yarns, and a third ground weft
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yarn 104c is placed within a second shed 106b formed by the pair of ground warp yarns. Said
repeating sequence forms a ground fabric on ground substrate terry weave sequence 100
additionally comprises pile yarns 108a and 108b wherein each of said pile yarns are interwoven
into the ground substrate in a sequence that repeats every 3 ground weft yarns. The 3 pick
sequence can be observed in case of pile loop 110a which is formed over the sequence of
ground weft yarns 104a, 104b and 104c, and in case of pile loop 110b which is also formed
over the sequence of ground weft yarns 104a, 104b and 104c. It would be understood from
Figures 1 and 2 that in forming pile loop 11 Oa,pile yarn 1 08a passes between ground weft
yarns 104a and 104b and thereafter forms a pile loop over ground weft yarns 104b and 104c
(i.e. on the top surface I face surface of the ground substrate), before the next 3 pick sequence
is commenced. Likewise, in forming pile loop 110b, pile yarn 108b passes between ground
weft yarns 104a and 104b and thereafter forms a pile loop over ground weft yarns 104b and
104c (i.e. on the bottom surface I back surface of the ground substrate), before the next 3
pick sequence is commenced.
[0006] While prior art weave sequences have been widely used in the past, it is desired to
increase pick density of terry fabrics beyond the pick densities permitted by prior art weave
sequences, as well as to improve pull resistance, absorbency, softness and uniformity of
texture of the terry fabrics.
Summary
[0007] The invention provides a terry fabric comprising a plurality of longitudinally oriented
ground warp yarns pairs, a plurality of longitudinally oriented pile warp yarns, and a plurality
of weft yarns oriented substantially perpendicular to the ground warp yarn pairs. The terry
fabric comprises a repeated weave sequence, said repeated weave sequence comprising a first
interlacing arrangement comprising a first ground warp yarn pair and a first pile warp yarn
interlaced adjacent to and in contact with at least one yarn within the first ground warp yarn
pair, the first interlacing arrangement comprising (a) first, second and third weft yarns
positioned within a first shed formed by the first ground warp yam pair, (b) a fourth weft yarn
positioned within a second shed formed by the first ground warp yarn pair, wherein the
second and third weft yarns are positioned between the first and fourth weft yams, (c) fifth,
sixth and seventh weft yarns positioned within a third shed formed by the first ground warp
yarn pair, (d) an eighth weft yarn positioned within a fourth shed formed by the first ground
warp yarn pair, wherein the sixth and seventh weft yarns are positioned between the fifth and
eighth weft yams, (f) a first pile loop formed by the first pile yam, wherein said first pile loop
is formed over the first, second, third and fourth weft yarns on one of a face surface or a back
surface of a ground substrate, (g) a first region on a surface of the ground substrate that is
opposite to the surface on which the first pile loop is formed, said first region having
boundaries defined by (I) the first ground warp yarn pair, (II) a second ground warp yam pair
adjacent to the first ground warp yam pair, (III) the first weft yarn and (IV) the fourth weft
yarn, wherein said first region is free of pile loop formation, (h) a second pile loop formed by
the first pile yarn, wherein said second pile loop is formed over the fifth, sixth, seventh and
eighth weft yarns on one of the face surface or the back ;urface of the ground substrate, (i) a
second region on a surface of the ground substrate that is opposite to the surface on which
the second pile loop is formed, said second region having boundaries defined by (I) the first
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ground warp yam pair, (II) the second ground warp yam pair, (III) the fifth weft yam and
(IV) the eighth weft yarn, wherein said second region is free of pile loop formation;
[0008] The repeated weave sequence additionally comprises a second interlacing arrangement
comprising the second ground warp yam pair and a second pile warp yarn interlaced adjacent
to and in contact with at least one yam within the second ground warp yam pair. The second
interlacing arrangement additionally comprises (a) the first, second and third weft yams
positioned within a fifth shed formed by the second ground warp yam pair, (b) the fourth
weft yam positioned within a sixth shed formed by the second ground warp yam pair, (c) the
fifth, sixth and seventh weft yams positioned within a seventh shed formed by the second
ground warp yam pair, (d) the eighth weft yam positioned within an eighth shed formed by
the second ground warp yam pair, (e) a third pile loop formed by the second pile yarn, wherein
said third pile loop is formed over the first, second, third and fourth weft yams on one of the
face surface or the back surface of the ground substrate, (f) a third region on a surface of the
ground substrate that is opposite to the surface on which the third pile loop is formed, said
third region having boundaries defined by (I) the second ground warp yam pair, (II) a third
ground warp yam pair adjacent to the second ground warp yam pair and positioned such that
the second ground warp yarn pair is interposed between the third ground warp yam pair and
the first ground warp yam pair, (III) the first weft yam and (IV) the fourth weft yam, wherein
said third region is free of pile loop formation, (g) a fourth pile loop formed by the second
pile yam, wherein said fourth pile loop is formed over the fifth, sixth, seventh and eighth weft
yams on one of the face surface or the back surface of the ground substrate, and (h) a fourth
region on a surface of the ground substrate that is opposite to the surface on which the fourth
pile loop is formed, said fourth region having boundaries defined by (I) the second ground
warp yam pair, (II) the third ground warp yarn pair, (III) the fifth weft yam and (IV) the
eighth weft yam, wherein said fourth region is free of pile loop formation.
[0009] Further, in the repeated weave sequence, one of the first pile loop and the third pile
loop is formed on the face surface of the ground substrate, and the other of the first pile loop
and the third pile loop is formed on the back surface of the ground substrate. Additionally,
one of the second pile loop and the fourth pile loop is formed on the face surface of the
ground substrate, and the other of the second pile loop and the fourth pile loop is formed on
the back surface of the ground substrate.
[0010] In an embodiment of the terry fabric, the repeated weave sequence may ensure one
or more of, positioning the second shed adjacent to the first shed, positioning the third shed
adjacent to the second shed, positioning the fourth shed adjacent to the third shed, positioning
the sixth shed adjacent to the fifth shed, positioning the seventh shed adjacent to the sixth
shed, and positioning the eighth shed adjacent to the seventh shed.
[0011] The repeated weave sequence may also ensures that at least one additional weft yam
is positioned between any of the second shed and the first shed, the third shed and the second
shed, the fourth shed and the third shed, the sixth shed and the fifth shed, the seventh shed
and the sixth shed, or the eighth shed and the seventh shed.
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[0012) Any of the first shed, third shed, fifth shed or seventh shed may have more than three
weft yarns positioned therewithin. Any one of the second shed, fourth shed, sixth shed or
eighth shed may have more than one weft yarn positioned therewithin.
[0013) In an embodiment, in the flrst interlacing arrangement, the flrst pile loop and the
second pile loop may be formed on opposite surfaces of the ground substrate, while in the
second interlacing arrangement, the third pile loop and the fourth pile loop may be formed
on opposite surfaces of the ground substrate.
[0014] In an embodiment, in the flrst interlacing arrangement, the flrst pile loop and the
second pile loop may be formed on one of the face surface or the back surface of the ground
substrate, while in the second interlacing arrangement, the third pile loop and the fourth pile
loop may be formed on the other of the face surface or the back surface of the ground
substrate.
[0015] The flrst ground warp yarn pair and the second ground warp yarn pair may be adjacent
yarn pairs, having only a single pile yarn interposed therebetween. Alternately, the flrst ground
warp yarn pair and the second ground warp yarn pair may have at least one additional ground
warp yarn pair interposed therebetween.
[0016] In an embodiment of the terry fabric, a plurality of instances of the repeated weave
sequences may be implemented within the terry fabric. In a specific embodiment, a flrst
instance of the repeated weave sequence may be located immediately adjacent to a second
instance of the repeated weave sequence.
[0017] In an embodiment of the terry fabric, the flrst pile warp yam and the second pile warp
yarn may be adjacent pile warp yarns.
[0018] The first pile yarn or the second pile yarn may be interlaced into the ground substrate
in a repeating sequence that forms each pile loop over 4 or more weft yarns. In a more specific
embodiment, the flrst pile yarn or the second pile yarn may be interlaced into the ground
substrate in a repeating sequence that forms each pile loop over 4 to 6 weft yarns.
[0019] The invention additionally provides a method of manufacturing a terry fabric
comprising a plurality of longitudinally oriented ground warp yarns pairs, a plurality of
longitudinally oriented pile warp yarns, and a plurality of weft yams oriented substantially
perpendicular to the ground warp yarn pairs. The method comprises weaving a terry fabric
using a plurality of instances of a repeated weave sequence.
[0020) Weaving each repeated weave sequence comprises weaving a flrst interlacing
arrangement comprising a flrst ground warp yarn pair and a flrst pile warp yam interlaced
adjacent to and in contact with at least one yarn within the first ground warp yarn pair,
comprising the steps of (a) placement of first, second and third weft yarns within a flrst shed
formed by the first ground warp yarn pair, (b) placement of a fourth weft yarn within a second
shed formed by the first ground warp yam pair, wherein the second and third weft yarns are
positioned between the first and fourth weft yams, (c) placement of fifth, sixth and seventh
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weft yams within a third shed formed by the first ground warp yam pair, (d) placement of an
eighth weft yarn within a fourth shed formed by the first ground warp yarn pair, wherein the
sixth and seventh weft yarns are positioned between the fifth and eighth weft yams, (e)
forming a first pile loop, wherein said first pile loop is formed with the first pile yarn, and
wherein said first pile loop is formed over the first, second, third and fourth weft yarns, on
one of a face surface or a back surface of a ground substrate (f) forming a first region on a
surface of the ground substrate that is opposite to the surface on which the first pile loop is
formed, said first region having boundaries defined by (I) the first ground warp yam pair, (II)
a second ground warp yarn pair adjacent to the first ground warp yarn pair, (III) the first weft
yam and (IV) the fourth weft yam, wherein said first region is free of pile loop formation, (g)
forming a second pile loop, wherein said second pile loop is formed by the first pile yarn, and
wherein said second pile loop is formed over the fifth, sixth, seventh and eighth weft yams,
on one of the face surface or the back surface of the ground substrate, (h) forming a second
region on a surface of the ground substrate that is opposite to the surface on which the second
pile loop is formed, said second region having boundaries defined by (I) the first ground warp
yam pair, (II) the second ground warp yam pair, (III) the fifth weft yam and (IV) the eighth
weft yam, wherein said second region is free of pile loop formation.
[0021] Weaving each repeated weave sequence additionally comprises weaving a second
interlacing arrangement comprising the second ground warp yarn pair and a second pile warp
yam interlaced adjacent to and in contact with at least one yarn within the second ground
warp yarn pair, comprising the steps of (a) placement of the first, second and third weft yams
within a fifth shed formed by the second ground warp yarn pair, (b) placement of the fourth
weft yam within a sixth shed formed by the second ground warp yam pair, (c) placement of
the fifth, sixth and seventh weft yams within a seventh shed formed by the second ground
warp yam pair, (d) the eighth weft yam positioned within an eighth shed formed by the second
ground warp yam pair, (e) forming a third pile loop, wherein said third pile loop is formed by
the second pile yam, and wherein said third pile loop is formed over the first, second, third
and fourth weft yams, on one of the face surface or the back surface of the ground substrate,
(f) forming a third region on a surface of the ground substrate that is opposite to the surface
on which the third pile loop is formed, said third region having boundaries defined by (I) the
second ground warp yam pair, (II) a third ground warp yarn pair adjacent to the second
ground warp yam pair and positioned such that the second ground warp yam pair is
interposed between the third ground warp yam pair and the first ground warp yam pair, (III)
the first weft yam and (IV) the fourth weft yam, wherein said third region is free of pile loop
formation, (g) forming a fourth pile loop, wherein said fourth pile loop formed by the second
pile yam, and wherein said fourth pile loop is formed over the fifth, sixth, seventh and eighth
weft yams on one of the face surface or the back surface of the ground substrate, (h) forming
a fourth region on a surface of the ground substrate that is opposite to the surface on which
the fourth pile loop is formed, said fourth region having boundaries defined by (I) the second
ground warp yam pair, (II) the third ground warp yam pair, (III) the fifth weft yam and (IV)
the eighth weft yam, wherein said fourth region is free of pile loop formation.
[0022] The method of weaving each repeated sequence may additionally ensure that (a) one
of the first pile loop and the third pile loop is formed on the face surface of the ground
substrate, and the other of the first pile loop and the third pile loop is formed on the back
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surface of the ground substrate, and (b) one of the second pile loop and the fourth pile loop
is formed on the face surface of the ground substrate, and the other of the second pile loop
and the fourth pile loop is formed on the back surface of the ground substrate.
[0023] In an embodiment of the invention, the method of manufacturing the terry fabric
additionally comprises shearing one or more of the first pile loop, second pile loop, third pile
loop and / or fourth pile loop, to generate cut tufted pile tuft on at least one surface of the
ground substrate.
Brief Description of the Accompanying Drawings
[0024] Figures 1 and 2 respectively provide transverse and perspective views of prior art 3
pick repeating terry weave sequences.
[0025] Figures 3, 4 and 5 illustrate a terry weave having a 4 pick repeating sequence in
accordance with the present invention.
[0026] Figures 6, 7 and 8 illustrate perspective and transverse views of another terry weave
having a 4 pick repeating sequence in accordance with the present invention.
[0027] Figures 9, 10 and 11 illustrate perspective and transverse views of a terry weave having
a 5 pick repeating sequence in accordance with the present invention.
[0028] Figures 12, 13 and 14 illustrate perspective and transverse views of a terry weave
having a 5 pick repeating sequence in accordance with the present invention.
[0029] Figure 15A is a photograph of a terry fabric manufactured in accordance with the terry
weave sequence illustrated in Figures 1 and 2.
[0030] Figure 15B is a photograph of a terry fabric manufactured in accordance with the terry
weave sequence of Figures 3, 4 and 5.
[0031] Figure 16 is a table setting out the results of a comparative analysis of fabrics
manufactured in accordance with the present invention against fabrics manufactured in
accordance with terry weave sequences previously known in the art.
Detailed Description
[0032] The present invention comprises a terry fabric weave sequence, resulting terry fabric
and a method for manufacturing a terry fabric implementing the specific terry fabric weave
sequence. In particular the terry fabric weave sequence of the present invention comprises a
repeating weave sequence that has been found to be significantly advantageous in comparison
with prior art terry weaves.
[0033] For the purposes of the present invention each terry fabric weave sequence comprises
a plurality of longitudinally oriented ground warp yarn pairs, a plurality of pile warp yarns
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interwoven in parallel with the ground warp yarn pairs, and a plurality of weft yarns oriented
substantially perpendicular to the ground warp yarn pairs. The terry weave sequence is a
repeating weave sequence, wherein each repeated weave sequence comprises of first and
second interlacing arrangement.
[0034) An embodiment of the terry weave sequence of the present invention is explained in
detail below with reference to Figures 3, 4 and 5.
[0035) Figures 3 and 4 respectively illustrate first and second interlacing arrangements that
are incorporated within a terry weave sequence in accordance with the present invention.
Figure 3 illustrates a first interlacing arrangement, Figure 4 illustrates a second interlacing
arrangement. Figure 5 illustrates the terry weave sequence incorporating both the first
interlacing arrangement and the second interlacing arrangement.
[0036) Figure 3 illustrates a first interlacing arrangement 300A comprising a first ground warp
yarn pair 302a, 302b, a fust pile warp yarn 308a, and a plurality of ground weft yarns 304a to
304h. The first ground warp yarn pair comprises warp yarns 302a and 302b that are interlaced
and positioned adjacent to first pile warp yarn 308a. The fust ground warp yarn pair 302a,
302b is interlaced with ground weft yarns such that first weft yarn 304a, second weft yarn
304b and third weft yarn 304c are positioned within a first shed 306a formed by first ground
warp yarn pair 302a and 302b. Additionally, a fourth weft yarn 304d is positioned within a
second shed 306b formed by first ground warp yarn pair 302a and 302b. A fifth weft yarn
304e, sixth weft yarn 304f and seventh weft yarn 304g are positioned within a third shed 306c
formed by ftrst ground warp yarn pair 302a and 302b. Additionally, an eighth weft yarn 304h
is positioned within a fourth shed 306d formed by first ground warp yarn pair 302a and 302b.
Eighth weft yarn 304h is followed by immediately adjacent weft yarn 304i (adjacent weft yarn
304i forms part of a next instance of the ftrst interlacing arrangement within a repeating
sequence).
[0037) First pile warp yarn 308a is interlaced within first interlacing arrangement 300A so as
to form a fust pile loop 310a and a second pile loop 310b. First pile loop 310a is formed over
first weft yarn 304a, second weft yarn 304b, third weft yarn 304c and fourth weft yarn 304d.
More specifically fust pile loop 31 Oa is formed by passing first pile warp yarn 308a (i) between
first weft yarn 304a and second weft yarn 304b, (ii) over second weft yarn 304b and third weft
yarn 304c in a loop (formed on a top surface I face surface of the ground substrate), (iii)
between third weft yarn 304c and fourth weft yam 304d, and (iv) between fourth weft yarn
304d and fifth weft yarn 304e. Likewise, second pile loop 310b is formed over fifth weft yarn
304e, sixth weft yarn 304f, seventh weft yarn 304g and eighth weft yarn 304h. Specifically,
second pile loop 310b is formed by passing first pile warp yarn 308a (i) between fifth weft
yam 304e and sixth weft yarn 304f, (ii) over sixth weft yarn 304f and seventh weft yarn 304g
in a loop (formed on a bottom surface I back surface of the ground substrate), (iii) between
seventh weft yarn 304g and eighth weft yarn 304h, and (iv) between eighth weft yam 304h
and ninth weft yarn 304i.
[0038) Figure 4 illustrates a second interlacing arrangement 300B compnstng a second
ground warp yarn pair 302c, 302d, and a second pile warp yarn 308b, respectively interlaced
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through ground weft yarns 304a to 304h. The second ground warp yam pair comprises warp
yams 302c and 302d that are interlaced and positioned adjacent to second pile warp yam 308b.
The second ground warp yam pair 302c, 302d is interlaced with ground weft yams such that
first weft yam 304a, second weft yam 304b and third weft yam 304c are positioned within a
fifth shed 306e formed by second ground warp yam pair 302c and 302d. Fourth weft yam
304d is positioned within a sixth shed 306f formed by second ground warp yarn pair 302c and
302d. Fifth weft yarn 304e, sixth weft yarn 304f and seventh weft yarn 304g are positioned
within a seventh shed 306g formed by second ground warp yarn pair 302c and 302d. Eighth
weft yarn 304h is positioned within an eighth shed 306h formed by second ground warp yam
pair 302c and 302d.
[0039] Second pile warp yam 308b is interlaced within second interlacing arrangement 300B
so as to form a third pile loop 31 Oc and a fourth pile loop 31 Od. Third pile loop 31 Oc is formed
over first weft yarn 304a, second weft yarn 304b, third weft yarn 304c and fourth weft yam
304d. More specifically, third pile loop 310c is formed by passing second pile warp yam 308b
(i) between first weft yam 304a and second weft yarn 304b, (ii) over second weft yam 304b
and third weft yarn 304c in a loop (formed on a bottom surface I back surface of the ground
substrate), (iii) between third weft yarn 304c and fourth weft yam 304d and (iv) between
fourth weft yarn 304d and fifth weft yam 304e. Likewise, fourth pile loop 31 Od is formed over
fifth weft yam 304e, sixth weft yarn 304f, seventh weft yam 304g and eighth weft yam 304h.
Specifically, fourth pile loop 31 Od is formed by passing second pile warp yarn 308b (i) between
fifth weft yam 304e and sixth weft yam 304f, (ii) over sixth weft yarn 304f and seventh weft
yam 304g in a loop (formed on a top surface I face surface of the ground substrate), (iii)
between seventh weft yam 304g and eighth weft yarn 304h and (iv) between eighth weft yarn
304h and a ninth weft yarn 304i.
[0040] Figure 5 illustrates a terry weave sequence 500 in accordance with the present
invention, wherein, first interlacing arrangement 300A (as illustrated in Figure 3) and second
interlacing arrangement 300B (as illustrated in Figure 4) are incorporated within terry weave
sequence 500.
[0041] As illustrated in Figure 5, first pile loop 31 Oa is formed on a face surface of the ground
substrate (i.e. the ground fabric comprising interwoven warp and weft yams). Simultaneously
the opposite surface (i.e. the back surface) of the ground substrate comprises a first region
having boundaries defined by (a) first ground warp yam pair 302a, 302b, (b) second ground
warp yarn pair 302c, 302d, (c) first weft yarn 304a and (d) fourth weft yarn 304d- which first
region is devoid or free of pile loop formation (i.e. no pile loop is formed over this region on
said back surface of the ground substrate).
[0042] Likewise, second pile loop 310b is formed on a back surface of the ground substrate.
Simultaneously an opposite surface (i.e. the face surface) of the ground substrate comprises a
second region having boundaries defined by (a) first ground warp yarn pair 302a, 302b, (b)
second ground warp yam pair 302c, 302d, (c) fifth weft yarn 304e and (d) eighth weft yam
304h - which second region is devoid or free of pile loop formation (i.e. no pile loop is
provided in this region on said face surface of the ground substrate).
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[0043] Additionally, as illustrated in Figure 5, third pile loop 31 Oc is formed on a back surface
of the ground substrate. Simultaneously an opposite surface of the ground substrate (i.e. the
face surface) comprises a third region having boundaries defined by (a) second ground warp
yarn pair 302c, 302d, (b) a third ground warp yarn pair (not shown in Figure 5) that is adjacent
to second ground warp yarn pair 302c, 302d, and which is positioned such that second ground
warp yam pair 302c, 302d is interposed between said third ground warp yarn pair and first
ground warp yarn pair 302a, 302b, (c) first weft yam 304a and (d) fourth weft yarn 304dwhich
third region is devoid or free of pile loop formation (i.e. no pile loop is formed over
this region on the face surface of the ground substrate).
[0044] Likewise, fourth pile loop 310d is formed on a face surface of the ground substrate.
Simultaneously an opposite surface (i.e. the back surface) of the ground substrate comprises
a fourth region having boundaries defined by (a) second ground warp yarn pair 302c, 302d,
(b) the third ground warp yarn pair, (c) fifth weft yarn 304e and (d) eighth weft yarn 304hwhich
fourth region is devoid or free of pile loop formation (i.e. no pile loop is formed over
this region on back surface of the ground substrate).
[0045] Additionally, as is apparent from weave sequence 500 as illustrated in Figure 5, first
pile loop 310a and third pile loop 310c are respectively formed on opposite surfaces of the
ground substrate, while second pile loop 310b and fourth pile loop 310d are respectively
formed on opposite surfaces of the ground substrate.
[0046] The terry weave sequence 500 illustrated in Figure 5 shows flrst ground warp yam pair
302a, 302b positioned adjacent to second ground warp yam pair 302c, 302d with only first
pile yarn 308a interposed therebetween. For the purposes of the present invention however,
one or more additional ground warp yarn pairs may be interposed between first ground warp
yarn pair 302a, 302b and second ground warp yam pair 302c, 302d - provided however that
no other pile yarn (i.e. no pile yarn other than first pile yarn 308a) is interposed between first
ground warp yarn pair 302a, 302b and second ground warp yarn P.air 302c, 302d.
[0047] The illustrations in Figures 3 to 5 illustrate embodiments of the terry weave sequence
where first pile yarn 308a forms pile loops alternately on face and back surfaces of the ground
substrate, while second pile yarn 308b also forms pile loops alternately on face and back
I
surfaces of the ground substrate. In another embodiment of the invention, illustrated in
Figures 6, 7 and 8, the first pile yarn may form pile loops on only one of the face or back
surface of the ground substrate while the second pile yarn may form pile loops on only the
other of the face or back surface of the ground substrate.
[0048] Figures 6 and 7 respectively illustrate first and second interlacing arrangements that
are incorporated within a second embodiment of a terry weave sequence in accordance with
the present invention. Figure 6 illustrates a first interlacing arrangement, Figure 7 illustrates a
second interlacing arrangement. Figure 8 illustrates an embodiment of the terry weave
sequence incorporating both of said first interlacing arrangement and the second interlacing
arrangement.
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[0049) Figure 6 illustrates a ftrst interlacing arrangement 600A comprising a first ground warp
yam pair 602a, 602b, a first pile warp yam 608a, and a plurality of ground weft yams 604a to
604i. The flrst ground warp yam pair comprises warp yams 602a and 602b that are interlaced
and positioned adjacent to ftrst pile warp yam 608a. The ftrst ground warp yam pair 602a,
602b is interlaced with ground weft yams such that flrst weft yam 604a, second weft yam
604b and third weft yam 604c are positioned within a first shed 606a formed by ftrst ground
warp yam pair 602a and 602b. Additionally, a fourth weft yam 604d is positioned within a
second shed 606b formed by first ground warp yam pair 602a and 602b. A ftfth weft yam
604e, sixth weft yam 604f and seventh weft yam 604g are positioned within a third shed 606c
formed by first ground warp yam pair 602a and 602b. Additionally, an eighth weft yam 604h
is positioned within a fourth shed 606d formed by first ground warp yam pair 602a and 602b.
Eighth weft yam 604h is followed by immediately adjacent weft yam 604i.
[0050) First pile warp yam 608a is interlaced within first interlacing arrangement 600A so as
to form a first pile loop 610a and a second pile loop 610b. First pile loop 610a is formed over
first weft yam 604a, second weft yam 604b, third weft yam 604c and fourth weft yam 604d.
More specifically first pile loop 610a is formed by passing first pile warp yam 608a (i) between
first weft yam 604a and second weft yam 604b, (ii) over second weft yam 604b and third weft
yam 604c in a loop (formed on a top surface I face surface of the ground substrate), (iii)
between third weft yam 604c and fourth weft yam 604d, and (iv) beneath fourth weft yarn
604d and ftfth weft yam 604e. Likewise, second pile loop 610b is formed over flfth weft yam
604e, sixth weft yam 604f, seventh weft yam 604g and eighth weft yam 604h. Specifically,
second pile loop 610b is formed by passing ftrst pile warp yam 608a (i) between ftfth weft
yam 604e and sixth weft yarn 604f, (ii) over sixth weft yam 604f and seventh weft yam 604g
in a loop (formed on a top surface I face surface of the ground substrate), (iii) between
seventh weft yam 604g and eighth weft yam 604h, and (iv) thereafter beneath eighth weft
yam 604h and ninth weft yam 604i.
[0051) Figure 7 illustrates a second interlacing arrangement 600B comprising a second
ground warp yam pair 602c, 602d, and a second pile warp yam 608b, respectively interlaced
through ground weft yams 604a to 604i. The second ground warp yam pair comprises warp
yams 602c and 602d that are interlaced and positioned adjacent to second pile warp yam 608b.
The second ground warp yam pair 602c, 602d is interlaced with ground weft yams such that
first weft yam 604a, second weft yam 604b and third weft yam 604c are positioned within a
fifth shed 606e formed by second ground warp yam pair 602c and 602d. Fourth weft yarn
604d is positioned within a sixth shed 606f formed by second ground warp yam pair 602c and
602d. Fifth weft yam 604e, sixth weft yam 604£ and seventh weft yam 604g are positioned
within a seventh shed 606g formed by second ground warp yam pair 602c and 602d. Eighth
weft yam 604h is positioned within an eighth shed 606h formed by second ground warp yam
pair 602c and 602d.
[0052) Second pile warp yam 608b is interlaced within second interlacing arrangement 600B
so as to form a third pile loop 61 Oc and a fourth pile loop 61 Od. Third pile loop 61 Oc is formed
over first weft yam 604a, second weft yam 604b, third weft yam 604c and fourth weft yam
604d. More specifically, third pile loop 610c is formed by passing second pile warp yam 608b
(i) between ftrst weft yam 604a and second weft yarn 604b, (ii) over second weft yam 604b
11
and third weft yam 604c in a loop (fanned on a bottom surface I back surface of the ground
substrate), (iii) between third weft yam 604c and fourth weft yam 604d and (iv) and over
fourth weft yam 604d and fifth weft yarn 604e. Likewise, fourth pile loop 610d is formed over
fifth weft yam 604e, sixth weft yam 604f, seventh weft yam 604g and eighth weft yam 604h.
Specifically, fourth pile loop 61 Od is fanned by passing second pile warp yam 608b (i) between
fifth weft yam 604e and sixth weft yarn 604f, (ii) over sixth weft yam 604f and seventh weft
yam 604g in a loop (fanned on a bottom surface I back surface of the ground substrate), (iii)
between seventh weft yarn 604g and eighth weft yam 604h and (iv) over eighth weft yam
604h and a ninth weft yam 604i.
[0053] Figure 8 illustrates a terry weave sequence 800 in accordance with the present
invention, wherein, first interlacing arrangement 600A (as illustrated in Figure 6) and second
interlacing arrangement 600B (as illustrated in Figure 7) are incorporated within terry weave
sequence 800.
[0054] As illustrated in Figure 8, first pile loop 610a is formed on a face surface of the ground
substrate (i.e. the ground fabric comprising interwoven warp and weft yams). Simultaneously
the opposite surface (i.e. the back surface) of the ground substrate comprises a first region
having boundaries defined by (a) first ground warp yam pair 602a, 602b, (b) second ground
warp yam pair 602c, 602d, (c) first weft yam 604a and (d) fourth weft yam 604d ..... which first
region is devoid or free of pile loop formation (i.e. no pile loop is fanned over this region on
said back surface of the ground substrate).
[0055] Likewise, second pile loop 610b is formed on a face surface of the ground substrate.
Simultaneously an opposite surface (i.e. the back surface) of the ground substrate comprises
a second region having boundaries defined by (a) first ground warp yam pair 602a, 602b, (b)
second ground warp yam pair 602c, 602d, (c) fifth weft yam 604e and (d) eighth weft yarn
604h - which second region is devoid or free of pile loop formation (i.e. no pile loop is
provided in this region on said back surface of the ground substrate).
[0056] Additionally, as illustrated in Figure 8, third pile loop 610c is formed on a back surface
of the ground substrate. Simultaneously an opposite surface of the ground substrate (i.e. the
face surface) comprises a third region having boundaries defined by (a) second ground warp
yam pair 602c, 602d, (b) a third ground warp yam pair (not shown in Figure 8) that is adjacent
to second ground warp yarn pair 602c, 602d, and which is positioned such that second ground
warp yam pair 602c, 602d is interposed between said third ground warp yarn pair and first
ground warp yam pair 602a, 602b, (c) first weft yarn 604a and (d) fourth weft yam 604dwhich
third region is devoid or free of pile loop formation (i.e. no pile loop is formed over
this region on the face surface of the ground substrate).
[0057] Likewise, fourth pile loop 610d is fanned on a back surface of the ground substrate.
Simultaneously an opposite surface (i.e. the face surface) of the ground substrate comprises a
fourth region having boundaries defined by (a) second ground warp yam pair 602c, 602d, (b)
the third ground warp yam pair, (c) fifth weft yam 604e and (d) eighth weft yarn 604h -which
fourth region is devoid or free of pile loop formation (i.e. no pile loop is fanned over this
region on the face surface of the ground substrate).
12
[0058] Additionally, as is apparent from weave sequence 800 as illustrated in Figure 8, first
pile loop 610a and third pile loop 610c are respectively formed on opposite surfaces of the
ground substrate, while second pile loop 610b and fourth pile loop 610d are respectively
formed on opposite surfaces of the ground substrate.
[0059] The terry weave sequence 800 illustrated in Figure 8 shows first ground warp yarn pair
602a, 602b positioned adjacent to second ground warp yam pair 602c, 602d with only first
pile yarn 608a interposed therebetween. For the purposes of the present invention however,
one or more additional ground warp yarn pairs may be interposed between first ground warp
yarn pair 602a, 602b and second ground warp yarn pair 602c, 602d.In an embodiment of the
invention, while one or more additional ground warp yarn pairs may be interposed between
first ground warp yarn pair 602a, 602b and second ground warp yarn pair 602c, 602d,no other
pile yarn (i.e. no pile yarn other than first pile yarn 608a) is interposed between first ground
warp yarn pair 602a, 602b and second ground warp yam pair 602c, 602d.
[0060] The invention embodiments described above relate to terry fabrics having a repeating
ground weave sequence comprising 3 ground weft yarns positioned within a first shed formed
by a ground warp yarn pair, followed by one ground weft yam positioned within a second
shed formed by the ground warp yarn pair, wherein the first shed and second shed may be
adjacent to each other. It would be understood that one or both of the first shed and the
second shed may have a larger number of ground weft yarns positioned therein. Figures 9 to
14 illustrate exemplary embodiments of such type.
[0061] Figures 9 and 10 respectively illustrate first and second interlacing arrangements that
are incorporated within an alternate terry weave sequence, in accordance with the present
invention. Figure 9 illustrates a ftrst interlacing arrangement, Figure 10 illustrates a second
interlacing arrangement. Figure 11 illustrates the terry weave sequence incorporating both the
first interlacing arrangement and the second interlacing arrangement.
[0062] Figure 9 illustrates a first interlacing arrangement 900A comprising a first ground warp
yarn pair 902a, 902b, a first pile warp yarn 908a, and a plurality of ground weft yarns 904a to
904k. The first ground warp yarn pair comprises warp yams 902a and 902b that are interlaced
and positioned adjacent to first pile warp yarn 908a. The first ground warp yarn pair 902a,
902b is interlaced with ground weft yarns such that first weft yarn 904a, second weft yarn
904b and third weft yarn 904c are positioned within a first shed 906a formed by first ground
warp yarn pair 902a and 902b. Additionally, a fourth weft yam 904d is positioned within a
second shed 906b formed by first ground warp yarn pair 902a and 902b. A fifth weft yarn
904e, sixth weft yarn 904f and seventh weft yarn 904g are positioned within a third shed 906c
formed by first ground warp yarn pair 902a and 902b. Additionally, an eighth weft yam 904h
is positioned within a fourth shed 906d formed by first ground warp yam pair 902a and 902b.
Eighth weft yarn 904h is followed by immediately a"djacent weft yarn 904i. Yet further, second
weft yarn 904b and third weft yarn 904c have an additional weft yarn 904j interposed
therebetween, which additional weft yarn 904j is positioned within first shed 906a formed by
first ground warp yarn pair 902a and 902b. Sixth weft yarn 904f and seventh weft yarn 904g
also have an additional weft yarn 904k interposed therebetween, which additional weft yarn
13
904k is positioned within third shed 906c formed by first ground warp yam pair 902a and
902b.
[0063] First pile warp yarn 908a is interlaced within first interlacing arrangement 900A so as
to form a flrst pile loop 910a and a second pile loop 910b. First pile loop 910a is formed over
first weft yam 904a, second weft yam 904b, additional weft yam 904j, third weft yam 904c
and fourth weft yam 904d. More speciflcally first pile loop 910a is formed by passing flrst pile
warp yam 908a (i) between first weft yam 904a and second weft yam 904b, (ii) over second
weft yam 904b, additional weft yam 904j and third weft yarn 904c in a loop (formed on a top
surface I face surface of the ground substrate), (iii) between third weft yam 904c and fourth
weft yam 904d, and (iv) between fourth weft yam 904d and flfth weft yam 904e. Likewise,
second pile loop 91 Ob is formed over fifth weft yam 904e, sixth weft yam 904f, additional
weft yam 904k, seventh weft yam 904g and eighth weft yam 904h. Specifically, second pile
loop 910b is formed by passing first pile warp yam 908a (i) between fifth weft yam 904e and
sixth weft yarn 904f, (ii) over sixth weft yam 904f, additional weft yam 904k, and seventh weft
yam 904g in a loop (formed on a bottom surface I back surface of the ground substrate), (iii)
between seventh weft yarn 904g and eighth weft yam 904h, and (iv) between eighth weft yam
904h and ninth weft yam 904i.
[0064] Figure 10 illustrates a second interlacing arrangement 900B comprising a second
ground warp yam pair 902c, 902d, and a second pile warp yam 908b, respectively interlaced
through ground weft yams 904a to 904k. The second ground warp yam pair comprises warp
yams 902c and 902d that are interlaced and positioned adjacent to second pile warp yam 908b.
The second ground warp yam pair 902c, 902d is interlaced with ground weft yarns such that
first weft yam 904a, second weft yam 904b and third weft yam 904c are positioned within a
fifth shed 906e formed by second ground warp yam pair 902c and 902d. Fourth weft yarn
904d is positioned within a sixth shed 906f formed by second ground warp yam pair 902c and
902d. Fifth weft yam 904e, sixth weft yam 904f and seventh weft yam 904g are positioned
within a seventh shed 906g formed by second ground warp yam pair 902c and 902d. Eighth
weft yam 904h is positioned within an eighth shed 906h formed by second ground warp yam
pair 902c and 902d. Additional weft yam 904j (which is interposed between second weft yam
904b and third weft yam 904c) is positioned within fifth shed 906e formed by second ground
warp yam pair 902c and 902d. Additional weft yam 904k (which is interposed between sixth
weft yam 904f and seventh weft yam 904g) is positioned within seventh shed 906g formed
by second ground warp yam pair 902c and 902d.
[0065] Second pile warp yam 908b is interlaced within second interlacing arrangement 900B
so as to form a third pile loop 910c and a fourth pile loop 910d. Third pile loop 910c is formed
over first weft yam 904a, second weft yam 904b, additional weft yam 904j, third weft yam
904c and fourth weft yam 904d. More specifically, third pile loop 91 Oc is formed by passing
second pile warp yam 908b (i) between first weft yam 904a and second weft yam 904b, (ii)
over second weft yam 904b, additional weft yam 904j, and third weft yam 904c in a loop
(formed on a bottom surface I back surface of the ground substrate), (iii) between third weft
yam 904c and fourth weft yam 904d and (iv) between fourth weft yam 904d and fifth weft
yam 904e. Likewise, fourth pile loop 910d is formed over fifth weft yam 904e, sixth weft yam
904f, additional weft yam 904k, seventh weft yam 904g and eighth weft yarn 904h.
14
Specifically, fourth pile loop 91 Od is formed by passing second pile warp yarn 908b(i) between
fifth weft yarn 904e and sixth weft yarn 904f, (ii) over sixth weft yarn 904f,additional weft
yarn 904k and seventh weft yarn 904g in a loop (formed on a top surface / face surface of the
ground substrate), (ill) between seventh weft yam 904g and eighth weft yarn 904h and (iv)
between eighth weft yarn 904h and a ninth weft yarn 904i.
[0066] Figure 11 illustrates a terry weave sequence 1100 in accordance with the present
invention, wherein, first interlacing arrangement 900A (as illustrated in Figure 9) and second
interlacing arrangement 900B (as illustrated in Figure 10) are incorporated within terry weave
sequence 1100.
[0067] As illustrated in Figure 11, first pile loop 91 Oa is formed on a face surface of the
ground substrate. Simultaneously the opposite surface (i.e. the back surface) of the ground
substrate comprises a first region having boundaries defined by (a) first ground warp yarn pair
902a, 902b, (b) second ground warp yarn pair 902c, 902d, (c) first weft yarn 904a and (d)
fourth weft yarn 904d- which first region is devoid or free of pile loop formation (i.e. no pile
loop is formed over this region on said back surface of the ground substrate).
[0068] Likewise, second pile loop 910b is formed on a back surface of the ground substrate.
Simultaneously an opposite surface (i.e. the face surface) of the ground substrate comprises a
second region having boundaries defined by (a) first ground warp yarn pair 902a, 902b, (b)
second ground warp yarn pair 902c, 902d, (c) fifth weft yarn 904e and (d) eighth weft yarn
904h - which second region is devoid or free of pile loop formation (i.e. no pile loop is
provided in this region on said face surface of the ground substrate).
[0069] Additionally, as illustrated in Figure 11, third pile loop 910c is formed on a back
surface of the ground substrate. Simultaneously an opposite surface of the ground substrate
(i.e. the face surface) comprises a third region having boundaries defined by (a) 'second ground
warp yarn pair 902c, 902d, (b) a third ground warp yam pair (not shown in Figure 11) that is
adjacent to second ground warp yarn pair 902c, 902d, and which is positioned such that
second ground warp yam pair 902c, 902d is interposed between said third ground warp yarn
pair and first ground warp yarn pair 902a, 902b, (c) first weft yam 904a and (d) fourth weft
yarn 904d- which third region is devoid or free of pile loop formation (i.e. no pile loop is
formed over this region on the face surface of the ground substrate).
[0070] Likewise, fourth pile loop 910d is formed on a face surface of the ground substrate.
Simultaneously an opposite surface (i.e. the back surface) of the ground substrate comprises
a fourth region having boundaries defined by (a) second ground warp yarn pair 902c, 902d,
(b) the third ground warp yam pair, (c) fifth weft yam 904e and (d) eighth weft yarn 904hwhich
fourth region is devoid or free of pile loop formation (i.e. no pile loop is formed over
this region on back surface of the ground substrate).
[0071] As is apparent from weave sequence 1100 as illustrated in Figure 11, first pile loop
910a and third pile loop 910c are respectivdy formed on opposite surfaces of the ground
substrate, while second pile loop 910b and fourth pile loop 910d are respectively formed on
opposite surfaces of the ground substrate.
15
[0072] The terry weave sequence 1100 illustrated in Figure 11 shows first ground warp yam
pair 902a, 902b positioned adjacent to second ground warp yarn pair 902c, 902d with only
flrst pile yam 908a interposed therebetween. For the purposes of the embodiment under
discussion however, one or more additional ground warp yam pairs may be interposed
between first ground warp yam pair 902a, 902b and second ground warp yam pair 902c, 902d
-provided however in a specific embodiment, no other pile yam (i.e. no pile yam other than
first pile yam 908a) is interposed between first ground warp yam pair 902a, 902b and second
ground warp yam pair 902c, 902d.
[0073] The illustrations in Figures 9 to 11 illustrate embodiments of the terry weave sequence
where first pile yam 908a forms pile loops altematdy on face and back surfaces of the ground
substrate, while second pile yam 908b also forms pile loops altematdy on face and back
surfaces of the ground substrate. In another embodiment of the invention, illustrated in
Figures 12, 13 and 14, the first pile yam may form pile loops on only one of the face or back
surface of the ground substrate while the second pile yam may form pile loops on only the
other of the face or back surface of the ground substrate.
[0074] Figures 12 and 13 respectively illustrate fl.rst and second interlacing arrangements that
are incorporated within a second embodiment of a terry weave sequence in accordance with
the present invention. Figure 12 illustrates a first interlacing arrangement, Figure 13 illustrates
a second interlacing arrangement. Figure 14 illustrates an embodiment of the terry weave
sequence incorporating both of said first interlacing arrangement and the second interlacing
arrangement.
[0075] Figure 12 illustrates a flrst interlacing arrangement 1200A comprising a first ground
warp yam pair 1202a, 1202b, a fl.rst pile warp yam 1208a, and a plurality of ground weft yams
1204a to 1204k. The first ground warp yam pair comprises warp yams 1202a and 1202b that
are interlaced and positioned adjacent to first pile warp yam 1208a. The flrst ground warp
yam pair 1202a, 1202b is interlaced with ground weft yams such that first weft yam 1204a,
second weft yam 1204b and third weft yam 1204c are positioned within a first shed 1206a
formed by first ground warp yam pair 1202a and 1202b. Additionally, a fourth weft yam
1204d is positioned within a second shed 1206b formed by first ground warp yam pair 1202a
and 1202b. A fifth weft yam 1204e, sixth weft yam 1204f and seventh weft yam 1204g are
positioned within a third shed 1206c formed by first ground warp yam pair 1202a and 1202b.
[0076] Additionally, an eighth weft yam 1204h is positioned within a fourth shed 1206d
formed by first ground warp yam pair 1202a and 1202b. Eighth weft yam 1204h is followed
by immediately adjacent weft yam 1204i. Yet further, second weft yam 1204b and third weft
yam 1204c have an additional weft yarn 1204j interposed therebetween, which additional weft
yam 1204j is positioned within first shed 1206a formed by ground warp yam pair 1202a and
1202b. Sixth weft yam 1204f and seventh weft yam 1204g also have an additional weft yam
1204k interposed therebetween, which additional weft yam 1204k is positioned within third
shed 1206c formed by ground warp yam pair 1202a and 1202b.
[0077] First pile warp yam 1208a is interlaced within first interlacing arrangement 1200A so
as to form a first pile loop 1210a and a second pile loop 1210b. First pile loop 1210a is formed
16
over first weft yarn 1204a, second weft yarn 1204b, additional weft yarn 1204j, third weft yarn
1204c and fourth weft yarn 1204d. More specifically, first pile loop 1210a is formed by passing
first pile warp yarn 1208a (i) between first weft yarn 1204a and second weft yarn 1204b, (ii)
over second weft yarn 1204b, additional weft yarn 1204j, and third weft yarn 1204c in a loop
(formed on a top surface I face surface of the ground substrate), (ill) between third weft yarn
1204c and fourth weft yarn 1204d, and (iv) beneath fourth weft yarn 1204d and fifth weft
yarn 1204e. Likewise, second pile loop 1210b is formed over fifth weft yarn 1204e, sixth weft
yarn 1204f, additional weft yarn 1204k, seventh weft yarn 1204g, and eighth weft yarn 1204h.
Specifically, second pile loop 1210b is formed by passing first pile warp yarn 1208a (i) between
fifth weft yarn 1204e and sixth weft yarn 1204f, (ii) over sixth weft yarn 604f, additional weft
yarn 1204K, and seventh weft yarn 1204g in a loop (formed on a top surface I face surface
of the ground substrate), (ill) between seventh weft yarn 1204g and eighth weft yarn 1204h,
and (iv) thereafter beneath eighth weft yarn 1204h and ninth weft yarn 1204i.
[0078] Figure 13 illustrates a second interlacing arrangement 1200B comprising a second
ground warp yarn pair 1202c, 1202d, and a second pile warp yarn 1208b, respectively
interlaced through ground weft yarns 1204a to 1204k. The second ground warp yarn pair
comprises warp yarns 1202c and 1202d that are interlaced and positioned adjacent to second
pile warp yarn 1208b. The second ground warp yarn pair 1202c, 1202d is interlaced with
ground weft yarns such that first weft yarn 1204a, second weft yarn 1204b and third weft yarn
1204c are positioned within a fifth shed 1206e formed by second ground warp yarn pair 1202c
and 1202d. Fourth weft yarn 1204d is positioned within a sixth shed 1206f formed by second
ground warp yarn pair 1202c and 1202d. Fifth weft yarn 1204e, sixth weft yarn 1204f and
seventh weft yarn 1204g are positioned within a seventh shed 1206g formed by second ground
warp yarn pair 1202c and 1202d. Eighth weft yarn 1204h is positioned within an eighth shed
1206h formed by second ground warp yarn pair 1202c and 1202d. Additional weft yarn 1204j
(which is interposed between second weft yarn 1204b and third weft yarn 1204c) is positioned
within fifth shed 1206e formed by second ground warp yarn pair 1202c and 1202d. Additional
weft yarn 1204k (which is interposed between sixth weft yarn 1204f and seventh weft yarn
1204g) is positioned within seventh shed 1206g formed by second ground warp yarn pair
1202c and 1202d.
[0079] Second pile warp yarn 1208b is interlaced within second interlacing arrangement
1200B so as to form a third pile loop 1210c and a fourth pile loop 1210d. Third pile loop
1210c is formed over flrst weft yarn 1204a, second weft yarn 1204b, additional weft yarn
1204j, third weft yarn 1204c and fourth weft yarn 1204d. More specifically, third pile loop
1210c is formed by passing second pile warp yarn 1208b(i) between first weft yarn 1204a and
second weft yarn 1204b, (ii) over second weft yarn 1204b, additional weft yarn 1204j, and
third weft yarn 1204c in a loop (formed on a bottom surface I back surface of the ground
substrate), (ill) between third weft yarn 1204c and fourth weft yarn 1204d and (iv) and over
fourth weft yarn 1204d and fifth weft yarn 1204e. Likewise, fourth pile loop 1210d is formed
over fifth weft yarn 1204e, sixth weft yarn 1204f, additional weft yarn 1204k, seventh weft
yarn 1204g and eighth weft yarn 1204h. Specifically, fourth pile loop 1210d is formed by
passing second pile warp yarn 1208b(i) between fifth weft yarn 1204e and sixth weft yarn
1204f, (ii) over sixth weft yarn 1204f, additional weft yarn 1204k, and seventh weft yarn 1204g
in a loop (formed on a bottom surface I back surface of the ground substrate), (ill) between
17
seventh weft yam 1204g and eighth weft yam 1204h and (iv) over eighth weft yam 1204h and
a ninth weft yam 1204i.
[0080] Figure 14 illustrates a terry weave sequence 1400 in accordance with the present
invention, wherein, first interlacing arrangement 1200A (as illustrated in Figure 12) and
second interlacing arrangement 1200B (as illustrated in Figure 13) are incorporated within
terry weave sequence 1400.
[0081] As illustrated in Figure 14, f1rst pile loop 1210a is formed on a face surface of the
ground substrate (i.e. the ground fabric comprising interwoven warp and weft yams).
Simultaneously the opposite surface (i.e. the back surface) of the ground substrate comprises
a first region having boundaries defined by (a) first ground warp yam pair 1202a, 1202b, (b)
second ground warp yam pair 1202c, 1202d, (c) first weft yam 1204a and (d) fourth weft yam
1204d- which first region is devoid or free of pile loop formation (i.e. no pile loop is formed
over this region on said back surface of the ground substrate).
[0082] Likewise, second pile loop 1210b is formed on a face surface of the ground substrate.
Simultaneously an opposite surface (i.e. the back surface) of the ground substrate comprises
a second region having boundaries defined by (a) first ground warp yam pair 1202c, 1202d,
(b) second ground warp yam pair 1202c, 1202d, (c) fifth weft yam 1204e and (d) eighth weft
yam 1204h- which second region is devoid or free of pile loop formation (i.e. no pile loop is
provided in this region on said back surface of the ground substrate).
[0083] Additionally, as illustrated in Figure 14, third pile loop 1210c is formed on a back
surface of the ground substrate. Simultaneously an opposite surface of the ground substrate
(i.e. the face surface) comprises a third region having boundaries defmed by (a) second ground
warp yam pair 1202c, 1202d, (b) a third ground warp yam pair (not shown in Figure 14) that
is adjacent to second ground warp yam pair 1202c, 1202d, and which is positioned such that
second ground warp yam pair 1202c, 1202d is interposed between said third ground warp
yam pair and fJ.rst ground warp yam pair 1202a, 1202b, (c) first weft yarn 1204a and (d) fourth
weft yarn 1204d -which third region is devoid or free of pile loop formation (i.e. no pile loop
is formed over this region on the face surface of the ground substrate).
[0084] Likewise, fourth pile loop 1210d is formed on a back surface of the ground substrate.
Simultaneously an opposite surface (i.e. the face surface) of the ground substrate comprises a
fourth region having boundaries defined by (a) second ground warp yam pair 1202a, 1202b,
(b) the third ground warp yam pair, (c) fifth weft yam 1204e and (d) eighth weft yam 1204h
- which fourth region is devoid or free of pile loop formation (i.e. no pile loop is formed over
this region on the face surface of the ground substrate).
[0085] Additionally, as is apparent from weave sequence 1400 as illustrated in Figure 14, first
pile loop 1210a and third pile loop 1210c are respectively formed on opposite surfaces of the
ground substrate, while second pile loop 1210b and fourth pile loop 1210d are respectively
formed on opposite surfaces of the ground substrate.
18
[0086) The terry weave sequence 1400 illustrated in Figure 14 shows first ground warp yarn
pair 1202a, 1202b positioned adjacent to second ground warp yarn pair 1202c, 1202d with
only first pile yarn 1208a interposed therebetween. For the purposes of the present invention
however, one or more additional ground warp yarn pairs may be interposed between first
ground warp yarn pair 1202a, 1202b and second ground warp yarn pair 1202c, 1202d. In an
embodiment of the invention, while one or more additional ground warp yarn pairs may be
interposed between first ground warp yarn pair 1202a, 1202b and second ground warp yarn
pair 1202c, 1202d, no other pile yarn (i.e. no pile yarn other than first pile yarn 1208a) is
interposed between first ground warp yarn pair 1202a, 1202b and second ground warp yarn
pair 1202c, 1202d.
[0087] The present invention additionally provides terry weaves fabrics which comprise one
or more instances of the terry weave sequences described above in connection with Figures 3
to 14. An embodiment of the invention comprises a terry weave fabric having at least two and
preferably more than two instances of the repeating terry weave sequences as described above.
[0088] In an embodiment of the terry fabric of the present invention, the terry weave
sequence ensures positioning the second shed adjacent to the first shed, positioning the third
shed adjacent to the second shed, positioning the fourth shed adjacent to the third shed,
positioning the sixth shed adjacent to the fifth shed, positioning the seventh shed adjacent to
the sixth shed and I or positioning the eighth shed adjacent to the seventh shed.
[0089) The repeated weave sequence may alternately ensure that at least one additional weft
yarn is positioned between any of the second shed and the first shed, the third shed and the
second shed, the fourth shed and the third shed, the sixth shed and the flfth shed, the seventh
shed and the sixth shed and I or the eighth shed and the seventh shed.
[0090) In an embodiment of the invention, any of the first shed, third shed, fifth shed or
seventh shed may have more than three weft yarns positioned therewithin. Likewise, any one
of the second shed, fourth shed, sixth shed or eighth shed may have more than one weft yarn
positioned therewithin.
[0091] It would be understood that the first ground warp yarn pair and the second ground
warp yarn pair may be adjacent yarn pairs, having only a single pile yarn interposed
therebetween. The first ground warp yarn pair and the second ground warp yarn pair may
alternately have at least one additional ground warp yam pair interposed therebetween. In an
embodiment, the first pile warp yarn and the second pile warp yarn may be adjacent pile warp
yarns.
[0092] In weaving a terry fabric, a plurality of instances of the terry weave sequences
described above may be implemented within the terry fabric. In an embodiment, a first
instance of the terry weave sequence may be located immediately adjacent to a second instance
of the terry weave sequence. In another embodiment, the flrst pile yarn or the second pile
yarn may be interlaced into the ground substrate in a repeating sequence that forms each pile
loop over 4 or more weft yarns.
19
[0093] The invention additionally provides methods of weaving a terry fabric, the method
comprising repeating at least one of the terry weave sequences described above in a plurality
of instances while weaving a terry fabric.
[0094] A particular method embodiment of the present invention comprises a method of
manufacturing a terry fabric comprising a plurality of longitudinally oriented ground warp
yarns pairs, a plurality of longitudinally oriented pile warp yams, and a plurality of weft yarns
oriented substantially perpendicular to the ground warp yarn pairs. The method comprises
weaving a terry fabric using a plurality of instances of a repeated weave sequence.
[0095] Weaving each repeated weave sequence includes weaving a first interlacing
arrangement comprising a first ground warp yarn pair and a first pile warp yam interlaced
adjacent to and in contact with at least one yarn within the first ground warp yam pair, and
comprising the steps of (i) placement of first, second and third weft yarns within a first shed
formed by the first ground warp yarn pair, (ii) placement of a fourth weft yarn within a second
shed formed by the first ground warp yarn pair, wherein the second and third weft yarns are
positioned between the first and fourth weft yarns, (ill) placement of fifth, sixth and seventh
weft yams within a third shed formed by the first ground warp yarn pair, (iv) placement of an
eighth weft yarn within a fourth shed formed by the first ground warp yarn pair, wherein the
sixth and seventh weft yarns are positioned between the fifth and eighth weft yams, (v)
forming a first pile loop, wherein said first pile loop is formed with the first pile yarn, and
wherein said first pile loop is formed over the first, second, third and fourth weft yarns, on
one of a face surface or a back surface of a ground substrate, (vi) forming a first region on a
surface of the ground substrate that is opposite to the surface on which the first pile loop is
formed, said first region having boundaries defined by (a) the first ground warp yarn pair, (b)
a second ground warp yarn pair adjacent to the first ground warp yarn pair, (c) the first weft
yarn and (d) the fourth weft yarn, wherein said first region is free of pile loop formation, (vii)
forming a second pile loop, wherein said second pile loop is formed by the first pile yarn, and
wherein said second pile loop is formed over the fifth, sixth, seventh and eighth weft yarns,
on one of the face surface or the back surface of the ground substrate, (viii) forming a second
region on a surface of the ground substrate that is opposite to the surface on which the second
pile loop is formed, said second region having boundaries defined by (a) the first ground warp
yarn pair, (b) the second ground warp yarn pair, (c) the fifth weft yam and (d) the eighth weft
yarn, wherein said second region is free of pile loop formation.
[0096] Weaving each repeated weave sequence additionally includes weaving a second
interlacing arrangement comprising the second ground warp yarn pair and a second pile warp
yarn interlaced adjacent to and in contact with at least one yarn within the second ground
warp yarn pair, and comprising the steps of (i) placement of the first, second and third weft
yarns within a fifth shed formed by the second ground warp yarn pair, (ii) placement of the
fourth weft yarn within a sixth shed formed by the second ground warp yarn pair, (ill)
placement of the fifth, sixth and seventh weft yarns within a seventh shed formed by the
second ground warp yam pair, (iv) the eighth weft yarn positioned within an eighth shed
formed by the second ground warp yarn pair, (v) forming a third pile loop, wherein said third
pile loop is formed by the second pile yarn, and wherein said third pile loop is formed over
the fust, second, third and fourth weft yarns, on one of the face surface or the back surface
20
of the ground substrate, (vi) forming a third region on a surface of the ground substrate that
is opposite to the surface on which the third pile loop is formed, said third region having
boundaries defined by (a) the second ground warp yarn pair, (b) a third ground warp yarn pair
adjacent to the second ground warp yarn pair and positioned such that the second ground
warp yarn pair is interposed between the third ground warp yarn pair and the first ground
warp yarn pair, (c) the first weft yarn and (d) the fourth weft yarn, wherein said third region
is free of pile loop formation, (vii) forming a fourth pile loop, wherein said fourth pile loop
formed by the second pile yarn, and wherein said fourth pile loop is formed over the fifth,
sixth, seventh and eighth weft yarns on one of the face surface or the back surface of the
ground substrate, (viii) forming a fourth region on a surface of the ground substrate that is
opposite to the surface on which the fourth pile loop is formed, said fourth region having
boundaries defined by (a) the second ground warp yarn pair, (b) the third ground warp yarn
pair, (c) the fifth weft yarn and (d) the eighth weft yarn, wherein said fourth region is free of
pile loop formation.
[0097] Weaving each repeated weave sequence includes ensuring that (i) one of the first pile
loop and the third pile loop is formed on the face surface of the ground substrate, and the
other of the first pile loop and the third pile loop is formed on the back surface of the ground
substrate, and (ii) one of the second pile loop and the fourth pile loop is formed on the face
surface of the ground substrate, and the other of the first pile loop and the third pile loop is
formed on the back surface of the ground substrate.
[0098] In an embodiment of the invention, the method of manufacturing the terry fabric
additionally comprises shearing one or more of the first pile loop, second pile loop, third pile
loop and / or fourth pile loop, to generate cut tufted pile tuft on at least one surface of the
ground substrate.
[0099] The terry weave sequences and terry weave fabrics in accordance with the above
embodiments of the invention have been found to present several significant advantages.
[0100] Table A in Figure 16 sets out results of comparative product testing using terry fabrics
manufactured in accordance with embodiments of the present invention, in comparison with
terry fabrics manufactured in accordance with terry weave sequences known in the prior art.
[0101] Terry fabric A corresponds to a fabric of the kind discussed in connection with
Figures 3 to 8, whereas terry fabric E corresponds to a fabric of the kind discussed in
connection with Figures 9 to 14. As will be observed, for a given grams per square meter
(GSM) value, terry fabrics manufactured in accordance with the present invention exhibit
significantly higher pick density, and cover factor (weft). Terry fabric A additionally exhibits
absorbency that is comparable to prior art towels despite having a significantly lower loop
density. Lower loop density has been found to significantly improve fabric softness of the
resulting terry fabric. It would also be observed that terry fabrics A and E use significantly
less pile yam per inch, while offering absorbency that is comparable to prior art terry fabrics
-which in presents significant cost and manufacturing efficiencies, particularly since pile yarn
is typically more expensive that ground warp and weft yams. In cases where pile yarn is
manufactured using soluble fibers such as polyvinyl alcohol (PV A) fibers, lowering the pile
21
per inch value also offers environmental advantages. Yet further, as is apparent from the data
in Table A, terry fabrics manufactured in accordance with the present invention exhibit
significantly improved tensile strength.
[0102) In addition to the above, terry fabrics manufactured in accordance with teachings of
the present invention have been found to have a distinctive and aesthetically appealing
appearance and improved uniformity of texture in comparison with terry fabrics
manufactured in accordance with terry weaves known in the prior art. Figure 15B provides a
photograph depicting appearance of a terry fabric manufactured in accordance with teachings
of the present invention - which appearance is significantly different and aesthetically
improved over the terry fabric photographs in Figure 15A, which corresponds to a terry fabric
manufactured in accordance with prior art methods.
[0103) The terry fabrics in accordance with the present invention may be manufactured using
one or more non-soluble yams and optionally one or more soluble yams. Non-soluble yams
for manufacturing terry fabrics in accordance with teachings of the present invention may
comprise any one or more natural fibers such as cotton, wool, silk, jute, flax, bamboo or ramie,
or one or more regenerated / synthetic fibres such as lyocell, viscose, modal, soya, polyester,
acrylic, rayon, charcoal, linen, com, milk fibre, PLA (poly lactic acid) fibre etc. Soluble yams
for manufacturing ply yams (or for that matter ground yams) may include any of polyvinyl
alcohol (PVA), wool or a yam product that is sold under the trade name "solucell".
[0104) It would be understood that the examples and embodiment discussed anywhere in the
present specification are illustrative only. Those skilled in the art would immediately
appreciate that various modifications in form and detail may be made without departing fr.om
or offending the spirit and scope of the invention as defined by the appended claims.
22
We claim:
1. A terry fabric comprising a plurality of longitudinally oriented ground warp yarns
pairs, a plurality of longitudinally oriented pile warp yarns, and a plurality of weft yarns
oriented substantially perpendicular to the ground warp yam pairs, the terry fabric comprising
a repeated weave sequence, said repeated weave sequence comprising:
a first interlacing arrangement comprising a first ground warp yarn pair and a first pile warp
yarn interlaced adjacent to and in contact with at least one yarn within the first ground warp
yarn pair, the first interlacing arrangement comprising:
first, second and third weft yarns positioned within a first shed formed by the first
ground warp yarn pair;
a fourth weft yarn positioned within a second shed formed by the first ground warp
yarn pair, wherein the second and third weft yarns are positioned between the first
and fourth weft yarns;
fifth, sixth and seventh weft yarns positioned within a third shed formed by the first
ground warp yarn pair;
an eighth weft yarn positioned within a fourth shed formed by the first ground warp
yam pair, wherein the sixth and seventh weft yams are positioned between the fifth
and eighth weft yarns;
a first pile loop formed by the first pile yarn, wherein said first pile loop is formed
over the first, second, third and fourth weft yams on one of a face surface or a back
surface of a ground substrate;
a first region on a surface of the ground substrate that is opposite to the surface on
which the first pile loop is formed, said first region having boundaries defined by (i)
the first ground warp yarn pair, (ii) a second ground warp yarn pair adjacent to the
first ground warp yarn pair, (iii) the first weft yarn and (iv) the fourth weft yarn,
wherein said first region is free of pile loop formation;
a second pile loop formed by the first pile yarn, wherein said second pile loop is
formed over the fifth, sixth, seventh and eighth weft yams on one of the face surface
or the back surface of the ground substrate;
a second region on a surface of the ground substrate that is opposite to the surface
on which the second pile loop is formed, said second region having boundaries
defined by (i) the first ground warp yarn pair, (ii) the second ground warp yarn pair,
(iii) the fifth weft yarn and (iv) the eighth weft yam, wherein said second region is free
of pile loop formation;
23
a second interlacing arrangement comprising the second ground warp yarn pair and a second
pile warp yarn interlaced adjacent to and in contact with at least one yarn within the second
ground warp yarn pair, the second interlacing arrangement comprising:
the first, second and third weft yarns positioned within a fifth shed formed by the
second ground warp yarn pair;
the fourth weft yarn positioned within a sixth shed formed by the second ground warp
yarn pair;
the fifth, sixth and seventh weft yarns positioned within a seventh shed formed by the
second ground warp yarn pair;
the eighth weft yarn positioned within an eighth shed formed by the second ground
warp yarn pair;
a third pile loop formed by the second pile yarn, wherein said third pile loop is formed
over the first, second, third and fourth weft yarns on one of the face surface or the
back surface of the ground substrate;
a third region on a surface of the ground substrate that is opposite to the surface on
which the third pile loop is formed, said third region having boundaries defined by (i)
the second ground warp yarn pair, (ii) a third ground warp yam pair adjacent to the
second ground warp yarn pair and positioned such that the second ground warp yarn
pair is interposed between the third ground warp yarn pair and the first ground warp
yam pair, (iii) the first weft yam and (iv) the fourth weft yam, wherein said third region
is free of pile loop formation;
a fourth pile loop formed by the second pile yam, wherein said fourth pile loop is
formed over the fifth, sixth, seventh and eighth weft yarns on one of the face surface
or the back surface of the ground substrate;
a fourth region on a surface of the ground substrate that is opposite to the surface on
which the fourth pile loop is formed, said fourth region having boundaries defined by
(i) the second ground warp yarn pair, (ii) the third ground warp yarn pair, (iii) the fifth
weft yarn and (iv) the eighth weft yam, wherein said fourth region is free of pile loop
formation;
wherein:
one of the first pile loop and the third pile loop is formed on the face surface of the
ground substrate, and the other of the first pile loop and the third pile loop is formed
on the back surface of the ground substrate; and
24
one of the second pile loop and the fourth pile loop is formed on the face surface of
the ground substrate, and the other of the second pile loop and the fourth pile loop
is formed on the back surface of the ground substrate.
2. The terry fabric as claimed in claim 1, wherein the repeated weave sequence ensures
one or more of:
positioning the second shed adjacent to the first shed;
positioning the third shed adjacent to the second shed;
positioning the fourth shed adjacent to the third shed;
positioning the sixth shed adjacent to the fifth shed;
positioning the seventh shed adjacent to the sixth shed; and
positioning the eighth shed adjacent to the seventh shed.
3. The terry fabric as claimed in claim 1, wherein the repeated weave sequence ensures
that at least one additional weft yam is positioned between any of:
the second shed and the first shed;
the third shed and the second shed;
the fourth shed and the third shed;
the sixth shed and the fifth shed;
the seventh shed and the sixth shed; or
the eighth shed and the seventh shed.
4. The terry fabric as claimed in claim 1, wherein any of the first shed, third shed, fifth
shed or seventh shed includes more than three weft yams positioned therewithin.
5. The terry fabric as claimed in claim 1, wherein any one of the second shed, fourth
shed, sixth shed or eighth shed includes more than one weft yam positioned therewithin.
6. The terry fabric as claimed in claim 1, wherein:
in the first interlacing arrangement, the first pile loop and the second pile loop are
formed on opposite surfaces of the ground substrate; and
in the second interlacing arrangement, the third pile loop and the fourth pile loop are
formed on opposite surfaces of the ground substrate.
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7. The terry fabric as claimed in claim 1, wherein:
in the first interlacing arrangement, the first pile loop and the second pile loop are
formed on one of the face surface or the back surface of the ground substrate; and
in the second interlacing arrangement, the third pile loop and the fourth pile loop are
formed on the other of the face surface or the back surface of the ground substrate.
8. The terry fabric as claimed in claim 1, wherein the first ground warp yarn pair and the
second ground warp yarn pair are adjacent yarn pairs, and having only a single pile yarn
interposed therebetween.
9. The terry fabric as claimed in claim 1, wherein the first ground warp yarn pair and the
second ground warp yam pair have at least one additional ground warp yarn pair interposed
therebetween.
10. The terry fabric as claimed in claim 1, wherein a plurality of instances of the repeated
weave sequences are implemented within the terry fabric.
11. The terry fabric as claimed in claim 1, wherein a first instance of the repeated weave
sequence is located immediately adjacent to a second instance of the repeated weave sequence.
12. The terry fabric as claimed in claim 1, where the first pile warp yam and the second
pile warp yarn are adjacent pile warp yarns.
13. The terry fabric as claimed in claim 1, wherein the first pile yam or the second pile
yarn is interlaced into the ground substrate in a repeating sequence that forms each pile loop
over 4 or more weft yarns.
14. The terry fabric as claimed in claim 1, wherein the first pile yam or the second pile
yarn is interlaced into the ground substrate in a repeating sequence that forms each pile loop
over 4 to 6 weft yarns.
15. A method of manufacturing a terry fabric comprising a plurality of longitudinally
oriented ground warp yarns pairs, a plurality of longitudinally oriented pile warp yarns, and a
plurality of weft yarns oriented substantially perpendicular to the ground warp yarn pairs, the
method comprising weaving a terry fabric using a plurality of instances of a repeated weave
sequence, wherein weaving each repeated weave sequence comprises:
weaving a first interlacing arrangement comprising a first ground warp yarn pair and a first
pile warp yarn interlaced adjacent to and in contact with at least one yarn within the first
ground warp yarn pair, comprising the steps of:
placement of first, second and third weft yarns within a first shed formed by the first
ground warp yarn pair;
26
placement of a fourth weft yam within a second shed formed by the first ground warp
yam pair, wherein the second and third weft yams are positioned between the first
and fourth weft yams;
placement of fifth, sixth and seventh weft yams within a third shed formed by the
first ground warp yam pair;
placement of an eighth weft yam within a fourth shed formed by the first ground
warp yam pair, wherein the sixth and seventh weft yams are positioned between the
fifth and eighth weft yams;
forming a first pile loop, wherein said first pile loop is formed with the first pile yam,
and wherein said first pile loop is formed over the first, second, third and fourth weft
yams, on one of a face surface or a back surface of a ground substrate;
forming a first region on a surface of the ground substrate that is opposite to the
surface on which the first pile loop is formed, said first region having boundaries
defined by (i) the first ground warp yam pair, (ii) a second ground warp yam pair
adjacent to the first ground warp yam pair, (iii) the first weft yam and (iv) the fourth
weft yam, wherein said first region is free of pile loop formation;
forming a second pile loop, wherein said second pile loop is formed by the first pile
yam, and wherein said second pile loop is formed over the fifth, sixth, seventh and
eighth weft yams, on one of the face surface or the back surface of the ground
substrate;
forming a second region on a surface of the ground substrate that is opposite to the
surface on which the second pile loop is formed, said second region having boundaries
defined by (i) the first ground warp yarn pair, (ii) the second ground warp yam pair,
(iii) the fifth weft yam and (iv) the eighth weft yam, wherein said second region is free
of pile loop formation;
weaving a second interlacing arrangement comprising the second ground warp yam pair and
a second pile warp yam interlaced adjacent to and in contact with at least one yam within the
second ground warp yam pair, comprising the steps of:
placement of the first, second and third weft yams within a fifth shed formed by the
second ground warp yam pair;
placement of the fourth weft yam within a sixth shed formed by the second ground
warp yam pair;
placement of the fifth, sixth and seventh weft yams within a seventh shed formed by
the second ground warp yam pair;
27
the eighth weft yarn positioned within an eighth shed fanned by the second ground
warp yarn pair;
fanning a third pile loop, wherein said third pile loop is fanned by the second pile
yam, and wherein said third pile loop is fanned over the first, second, third and fourth
weft yarns, on one of the face surface or the back surface of the ground substrate;
fanning a third region on a surface of the ground substrate that is opposite to the
surface on which the third pile loop is fanned, said third region having boundaries
defined by (i) the second ground warp yarn pair, (ii) a third ground warp yarn pair
adjacent to the second ground warp yarn pair and positioned such that the second
ground warp yarn pair is interposed between the third ground warp yarn pair and the
first ground warp yarn pair, (iii) the first weft yarn and (iv) the fourth weft yarn,
wherein said third region is free of pile loop fonnation;
fanning a fourth pile loop, wherein said fourth pile loop fanned by the second pile
yarn, and wherein said fourth pile loop is fanned over the fifth, sixth, seventh and
eighth weft yarns on one of the face surface or the back surface of the ground
substrate;
fanning a fourth region on a surface of the ground substrate that is opposite to the
surface on which the fourth pile loop is fanned, said fourth region having boundaries
deflned by (i) the second ground warp yarn pair, (ii) thethird ground warp yarn pair,
(iii) the fifth weft yarn and (iv) the eighth weft yam, wherein said fourth region is free
of pile loop fonnation;
wherein:
one of the first pile loop and the third pile loop is fanned on the face surface of the
ground substrate, and the other of the first pile loop and the third pile loop is fanned
on the back surface of the ground substrate; and
one of the second pile loop and the fourth pile loop is fanned on the face surface of
the ground substrate, and the other of the second pile loop and the fourth pile loop
is fanned on the back surface of the ground substrate.
16. The method as claimed in claim 15, comprising shearing one or more of the first pile
loop, second pile loop, third pile loop and fourth pile loop, resulting in one or more cut pile
tufts on at least one surface of the ground substrate.