2007
EasyLeno®
Titel…
EasyLeno® – EasyLeno® 2T New technology for innovative textile fabrics
DORNIER air-jet weaving machine, fitted with leno device EasyLeno ® 2T for “drebfabrics” from mesh-like up to 100 % compressed structures
An innovation with potential Globalization has made the hard-fought market for textile fabrics even tougher. The difference made through innovation is therefore more important than ever for many manufacturers. Bearing our customers in mind, DORNIER has reacted to this challenge with groundbreaking technology for completely new leno fabric structures, the “drebbing“ technique. Leno weaves may be in demand due to their transparency and slip resistance but the classical manufacturing technology with inverted leno heddles shows significant disadvantages regarding productivity, flexibility and wear. DORNIER took the task on and presented a new method: DORNIER EasyLeno®. This means: Weaving without superstructures, with needle bars instead of leno heddles, without separate shedding devices, with speeds to over 700 rpm, less wear and high efficiency during style changes. The terms “drebbing“ and “drebfabric“ characterize this new style of leno weavVarious final products produced
ing. DORNIER‘s EasyLeno® and EasyLeno® 2T technology allows you to create
using the “drebbing” technique
completely new high quality products in “drebbing” technique that cannot easily
on DORNIER air-jet and rapier
be imitated and copied.
weaving machines with EasyLeno ® and EasyLeno ® 2T
... EasyLeno® 2T creates a new textile surface the drebfabric
EasyLeno® makes leno weaving easy ...
Drebbing technique advantages
EasyLeno ® 2T advantages
Filling thread
• Higher weaving machine productivity with
• Innovative double-face fabric
speeds up to 450 rpm on rapier machines
• Reduced structural elongation
and up to 720 rpm on air-jet machines
(filling threads and carrier threads lay straight
• Easy handling and maintenance through
in the drebfabric) • Higher density level and distinctly superior
needle bars without additional shedding
c olor brilliance
device
• Relief-type fabric surfaces through different
• Normal front and rear shed • High warp densities up to 30 threads/cm
yarn counts • Variable density level settings allow mesh-like
possible • Slip resistance is up to 70 % higher than
and compressed stripes
plain weaves
Carrier warp Binder warp
Ground needle bar (blue) and movable needle bar (grey) create the weaving shed for the leno weave. The reed
Drebfabric - universal in use - inherently stable,
EasyLeno ® 2T is suitable to produce
(green) beats up the filling thread into the drebfabric
brilliant colors and tear proof
f abrics with various densities because
EasyLeno 2T processes warp ends in two systems.
no crimping capability is required in
Different warp tensions then create an innovative dreb-
f illing direction independent of the
fabric. Warp ends are crossed on the rear side which
thread density. Temple cylinders with
means a higher filling density can be set and the new
only two needle knurls are sufficient for
Textile fabrics with leno weave are more slip resistant than fabrics with plain, twill or satin weaves.
geometry creates new attractive optical characteristics.
f abric guidance in all density settings
Reason: The number of crossings within a binding unit is higher and the angle of wrap on thread
Substituting finer threads for the binding thread allows
crossings larger. Assuming the same thread density, thread tension and friction coefficient for
new designs with a double-face character. Filling threads
a plain and a drebbing weave (drebfabric), the slip resistance of the drebfabric is up to 70 %
can be impacted so close to each other that a density
higher. This means, for example, plain weaves can be redesigned as drebfabrics so that material
level of 100 % can be attained. The drebfabric thus
usage can be reduced by up to 30 % and productivity increased by up to 40 %. Even more the
shows a mock plain weave on the upper side. An over 20
color brilliance of drebfabrics is impressive: Filling yarn colors dominate and overpower the warp
% increase in breaking strength has been proven thanks
color so that standard warps can be used to produce different styles just through filling changes
to decisive improvements in the stress-strain ratio.
®
DORNIER‘s drebbing technique EasyLeno® - minimum material use, maximum productivity
or filling effects. DORNIER‘s new drebbing technique achieves its advantages through innovative technology, gentle to the yarn, user-friendly, self-cleaning as well as quick in gaining experience and style Stress-strain ratio for fabrics and drebfabrics
Characteristic lines for drebfabric density limits
25
70
ε
ε
H
Plain weave
Leno weave
60
20
RH
EasyLeno® 2T
Thread tension relative to yarn count [cN/tex]
EasyLeno® 2T
H
RH Filling density [1/cm]
changes - it´s easy.
15
10 L 1/1
5
50 conventional leno fabric
40
30
20
0 0 Elongation [%]
5
10
15
20
25
10
0
22 100
200
Filling yarn count
4 interlacings in a weave repeat (small crossing angle)
300
400
500
600
700
800
900
1000
1100
[dtex]
6 interlacings in a weave repeat (large crossing angle)
Titel… Multifunctional and versatile - drebbing technique
High savings potential with excellent product features
Drebbing technology with a future - higher flexibility, new design options
From fabric to drebfabric
Technical Specifications
EasyLeno® is suitable for all leno fabrics and drebfabrics - from very light curtains to the
The following example based on an upholstery fabric
heaviest glass roving. Drebfabrics open up new design options for clothing, household
compares economical aspects as well as product
textiles and technical textiles. Interesting tasks also open up in the carpet industry with clas-
features of drebfabric with a comparable fabric.
sical carpet backings as well as manufacturing textile flooring, DrebCarpet®, that can
This example shows 125 % higher productivity and
be produced in just one process step. Weaving in leno and plain weave techniques will
28 % material savings in favour of the drebbed textile
also become more flexible; curtain weavers can produce leno fabrics and plain styles with
achieving the same or better product features.
the same machine. There are no design limits - drapery and clothing fabrics with warp stripes
Type code DORNIER EasyLeno ® air-jet weaving machine AWS4/ L 540 DORNIER EasyLeno ® rapier weaving machine PTS 4/ L 190 Number of filling colors Leno device (Leno) Nominal width cm
using plain or leno warp ends will be possible. Air-Jet Weaving Machine Machine Machine nominal width width* cm mm
Garments:
Max. fabric reeded width mm
Min. fabric reeded width mm
Plain and satin-like surfaces with definable air per-
190
4810
1880
900
200
4910
1980
1000
meability in differentiated colors and high brilliance.
220
5110
2180
1200
240
5310
2380
1400
280
5710
2780
1800
300
5910
2980
2000
320
6110
3180
2200
340
6310
3380
2400
360
6510
3580
2600
380
6710
3780
2800
390
6810
3880
2900
400
6910
3980
3000
430
7210
4280
3300
460
7510
4580
3600
540
8310
5380
4400
Multiple articles based on standard warps exclusively by color selection and variable settings for filling densities, e.g. for shirt fabrics Fabric with 360 bindings / cm
Drebfabric with 390 bindings / cm
rics as compared to classical satin fabrics with better surface coverage and equal abrasion resistance. The high color brilliance is also suitable for curtain fabrics
Upholstery textiles:
Filling density 36 threads / cm
Reduction in overall material usage for upholstery fab-
Filling density 13 threads / cm
Decorative textiles:
*Width valid for machines with 6 colors
Rapier Weaving Machine Machine ominal n width cm
Relief-type surfaces for better air circulation and antislip behavior thanks to different filling thread fineness. Formability through Elastan yarns in the ground warp Warp density 48 threads / cm
Technical textiles:
Fabric
Constant warp density across the whole fabric width,
Production data
reproducible, different density levels, coarse and fine
Warp end PES
mesh structures, high breaking strength; decisive, for
Warp density threads/cm
example, for coating fabrics, sun screening fabrics
Filling density threads/cm Chenille yarn Nm 4 PES 150 dtex
and all kinds of glass fabrics
Fabric weight g/m²
150 dtex 48
Warp density 20 threads / cm
Drebfabric
150/66 dtex 20
12 24
13 0
552
430
(– 28 % material)
Max. fabric reeded width
Min. fabric reeded width
mm
mm
190
4975
1850
1044
200
5125
1950
1130
210
5275
2050
1230
220
5425
2150
1330
230
5575
2250
1430
240
5725
2350
1530
260
6025
2550
1730
280
6325
2750
1930
300
6625
2950
2130
320
6925
3150
2330
340
7225
3350
2530
360
7525
3550
2730
380
7825
3750
2930
*Add 100 mm for 6 colors *Add 600 mm for 8 colors Additional width on request
Carpets: Ideally stiffened, velours-type surface structure, light,
Production features
e nvironmentally friendly and economically producible
Chenille yarn coverage
Good
Very good
in just one workstep
Slip and seam resistance
Good
Good
Friction resistance
Good
Very good
(+ 125 % productivity)
Machine width* with 4 colors mm
Please contact DORNIER for exact dimensioning of available machine types Subject to modifications
Lindauer DORNIER GmbH 88129 Lindau/Germany Telephone +49 8382 7030 Telefax
+49 8382 703386
American DORNIER Machinery Corp. P.O. Box 668865 Charlotte, N.C. 28266, USA Telephone +1 704 394 6192 Telefax
+1 704 399 2018
DORNIER Machinery (Shanghai) Co. Ltd. Area B G/F Block 45 299 FuTeZhong Road WaiGaoQiao Tax Free Zone Shanghai 200131, China Telephone +86 21 504 62838 Telefax
+86 21 504 62138
Lindauer DORNIER GmbH India Liaison Office 204, Sangeet Plaza Marol Maroshi Road Andheri (East) Mumbai 400 059, India Telephone +91 22 292 50674 Telefax
+91 22 292 08760
www.lindauerdornier.com
23011/RT/07 /07 All rights reserved!
[email protected]
