US3442101A - Pile fabric - Google Patents

Description

May 6, 1969 s. PLOCH ET AL 3,442,101

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May 6, 1969 s, p og ET AL 3,442,101

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FILE FABRIC Filed April 1, 1965 Sheet INVENTO RS IflFQ'FP/[D 200/ United States Patent 3,442,101 PlLE FABRIC Siegfried Ploch, Waiter Scholtis, and Heinz Zschunke,

Karl-Marx-Stadt, Germany, assignors to Forschungsinstitut fiir Textiltechnologie, Karl-Marx-Stadt, Germany Filed Apr. 1, 1965, Ser. No. 444,640 lint. Cl. D041) 7/12, 9/12, 11/08 US. Cl. 66-194 4 Claims The present invention relates to textile webs which have a fiber layer arranged on a base or foundation, as well as to a device and process for joining the base with the fiber layer by means of parallel seams of fiber loops extending in the direction of movement of the Web through the device.

It is known to sew fleeces to a base web with the aid of sewing threads. This results in insufiicient properties for use as the fibers are not anchored firmly enough in the fabric bond. Moreover, because of the sewing threads, an additional thread system is required.

Another known process envisages the needling up of fleeces on a base with the aid of multi-needle machines having needles with small barbs. These needles penetrate from the side of the fleece through the two materials to be joined and on their return take along a number of fibers as, for example, in the form of fiber loops. These loops are put down on the top side of the fleece in a quilting stitch manner and compress the fleece in an unwanted manner. The fleece is connected with the base only by those fibers which have been pulled through to the side opposite the fleece and which form little knots thereat. The connection between the fleece and the base is not very strong.

In another known process, fiber tufts are bound into knit fabrics, simultaneously with the production thereof, by means of circular knitting machines. For this purpose the machine has on its circumference between four and eight miniature cards to which a fiber band is supplied, and which deliver the fibers coming from the band into the needles of the knitting machine. The output of this type of machine is relatively low, and the resulting product has at first the property of a mesh fabric which must subsequently be stabilized by subsequent finishing. Moreover, with such machines only the connection between fiber tufts and a knit fabric is possible, while the sewing in of the fiber tufts, for example, in foam material or fleece fabric webs cannot be accomplished by this method.

Methods are also known for gluing pleated fleeces on a base or between two base webs. The disadvantages of this method are that an adhesive is needed, that the product becomes rather stiff, and that the air permeability and hence the respiratory activity of the product are impaired by the gluing.

Finally, it is known to sew fleeces in the form of longitudinal ribs on a base web by means of nap-forming elements. Sewing threads are again needed, and the fibers are held only by the pressure between sewing threads and base web so that they are not firmly anchored in the base itself.

It is the object of this invention to provide a textile web in which a fiber layer is connected with a base or foundation without sewing threads, providing high strength, without constricting the fiber layer in the manner of a quilting stitch seam; as well as a device and a process for making this novel web.

According to an important feature of the invention, the base and the fiber layer are connected by means of fiber loops which are pulled out of the fiber layer and formed into wales or chain-stitch seams and arranged on the back of the base or foundation. The fibers are ice oriented in the fiber layer, preferably lengthwise or transverse to the direction of movement of the web.

The base is a woven, knitted, fleece, foam material or similar web. Alternatively, it may be formed of a loose layer of longitudinal and/ or transverse threads. The transverse and longitudinal threads are arranged in crossed superposition and are mutually interconnected by means of the fiber loops pulled out of the fiber layer, and finally connected with the fiber layer itself.

In the process for the production of the textile web, according to the invention, the fiber loops are pulled out of the fiber layer by means of slide, latch, or other suitable reciprocating needles of multi-needle machines.

In the inventive device, the fiber layer is pushed into the hooks of the needles by suitable means, e.g. by way of a roller fitted completely or partly with brushes. The roller rotates continuously or synchronously with the needles, by means of a rod or rail executing a swinging movement synchronously with the needle cycle. The roller may be fitted with brushes, or by a similarly functioning pressure rod which may also be designed in the form of a pressure comb.

The tips of the needles enter into the fiber layer from the side of the base, pull the seized fibers through the base on their return, and form from these fibers, a fiber loop held by the needle hooks. As has been mentioned, the base may consist of a woven, knitted, fleece, or foam material, or of a layer of longitudinal or transverse threads or fibers, or of loosely superimposed longitudinal and transverse threads.

When the needles occupy their rearmost position and their hooks are closed, the previously formed fiber loops still present on the needle shanks are cast off over the previously mentioned new fiber loops. In this way a portion of the fiber material is present as wales or chain stitch seams on the side of the base away from the fiber layer, and thus establishes a firm connection between the fiber layer and the base. This connection is much more intimate due to its mesh-like, non-raveling arrangment than can be achieved with the known needling.

The fibers may also be pulled out of the fiber layer in such manner so that separate fiber tufts are formed which are tied into the base-like knitting stitches. The fiber tufts result in a plushor fur-like surface. By increasing the rate of supply of the fiber layer in relation to that of the base web about four to tenfold, the fiber layer can be compressed in transverse direction or even pleated in rib form.

By the use of nap-forming means, e.g. nap sinkers, between the needles of the novel device, an arrangement in the form of longitudinal ribs can be obtained.

The fiber layer of the textile web according to the invention may also consist of two or more fiber layers, the fibers in the layer toward the needles'being, for example, substantially longitudinally oriented, while the fibers in the outer layer are oriented substantially slantwise to the direction of movement of the web. Then substantially only the transversally oriented fibers are seized by the needle hooks and bind the longitudinally oriented fibers in, together with the above-mentioned loose fiber layers.

The textile web according to the invention can be finished in various ways, for example, it is possible to roughen it, shear it, or full it. The base and/or the fiber layer may consist wholly or partly of shrinkable fiber materials, known per se. The textile web thus produced can then be subjected to a shrinkage treatment resulting in a thickening of the fiber layer.

The advantages of the textile web, process and device according to the present invention are the following: The connection of the fiber layer with the base is achieved without sewing thread but with substantial preservation 3 of the voluminosity of the fiber layer, from which a rough, high pile, or similar surfaces can be achieved in a particularly favorable manner. There are no quilting-seam type constrictions. Also, the nap formation itself occurs without the use of spun products or threads, using only the fibers of the fiber layer, so that for this part of the textile web the spinning process and the preparatory operations,

' such as reeling and warping, are also eliminated.

No special machines are necessary, as the device required for carrying out the process, for feeding the fiber layer and for introducing the fibers into needle hooks, is relatively simple and can easily be attached to known multi-needle machines. For the production of the textile Web according to the invention there is used a multineedle machine which in its output is superior to the known looms and knitting machines.

The invention permits the manufacture of a plurality of products, such as velours, padded overcoat materials, blankets, fur imitations, plushes, and carpets.

The products according to the invention have a high voluminosity as the fiber material is not pressed into a spun system. Thereby major air inclusions are obtained, which result in a higher heat holding capacity than with the use of yarns or compressed fleeces. Due to the fact that the proportion of fibers taken along on the side of the base away from the fiber layer can be controlled, a bilateral arrangement of a fiber layer on the base is obtained, the fibers being present on one side in fleece, nap, or tuft form and on the other side in the form of knitted stitches. Depending on the quantity of fibers participating in the stitch formation, the stitch side, too, can be given a plushor blanket-like finish.

The control of the proportion of fibers of the fiber layer formed into stitches can be effected in the inventive process and device, among other things, by the size of the needle hooks, by the timing of the covering of the needle hooks inside or outside the fiber layer, by the regulation of the speed and amount of movement of the means for pressing the fiber layer into the needle hooks, by the height of the nap or plush sinkers, by the mass of the fiber layer, and by the rate of their feed.

Other objects and advantages of the invention will be appreciated and more fully understood with reference to the following detailed description, when considered with the accompanying drawings, wherein:

FIG. 1 is a somewhat schematic, cross-sectional view of a work position of the device according to the invention, forming part of a multi-needle sewing-knitting machine, with slide needle, brush roller and fabric feed;

FIGS. 2a and 2b illustrate a tubular and latch needle, respectively, which can also be used in the inventive device;

FIG. 3 is a view similar to that of FIG. 1 of an alternative device according to the invention, having a brushfitted rod or rail therein;

FIG. 3a is a fragmentary cross-sectional view along line III-III of the sinkers 14 of FIG. 3;

FIGS. 4a and 4b show a pressure rod and a pressure comb, to be used in the inventive device in lieu of brushes as shown in FIG. 3;

FIG. 5 is a plan view of the drive for the needles, the closing wires and also for the brush-fitted rail of FIG. 3;

FIG. 6 is a partial sectional view of the drive shown in FIG. 5, taken along line 66;

FIGS. 7a-7d shows, in longitudinal sectional views, various forms of textile webs made according to the invention, with the devices of FIGS. 1 and 3, and having a woven fabric as a base;

FIG. 7e is a plan view of the textile web according to FIG. 7d;

FIG. 8 is a view similar to that of FIGS. 1 and 3 of another alternative device using an array or layer of longitudinal and transverse threads as a base; and

FIG. 9 is a longitudinal sectional view, similar to those 4 of FIGS. 7a-7d, of a textile web produced with the device of FIG. 8.

FIG. 1 of the drawings shows a first embodiment of the work position of the device according to the invention, forming part of a multi-needle knitting machine also capable of sewing stitches. As shown in the somewhat schematic view, the device comprises a plurality of slide needles 11 arranged on a common bar 21, the needles having hooks (see the enlarged views of FIGS. 2a and 2b). For closing the hooks, wires 12 are provided on a bar 22. The conventional means serving to reciprocate the needles 11 and the closing wires 12 have not been illustrated; reference to an appropriate drive mechanism will be made when describing FIGS. 5 and 6.

This type of device uses a woven fabric as a base, shown at 60, to which is applied a fiber layer 70, as will be explained in more detail. This layer preferably consists of fibers oriented substantially longitudinally or transversally to the direction of advance. The exit of the slide needles 11 from the base 60 is ensured by cast-off sinkers 13, secured to a bar 23. The fiber layer 70 is laid over nap or plush sinkers 14 supported by a bar 24.

The fabric 60, serving as a base, is fed continuously to the device, as is the fiber layer 70. The latter is continuously delivered by means of rotating feed rollers 18, one of them entraining an endless conveyor cloth 28 which also passes over a roller 19 in the region of the work station. The fiber layer 70 may, however, also be fed directly to the sewing-knitting station by a card (not illustrated) working synchronously with the machine.

The slide needles 11 pass through the base 60 and seize with their hooks 11a fiber tufts from the fiber layer 70, when they have reached their foremost position (as illustrated). The fiber layer 70 is brought into the form of nap-like longitudinal ribs by the cooperation of the sinkers 14. The fibers are pushed into the hooks 11a of the needles 11 by a rotating brush roller 20 so that the needles, on their return, take along the fiber tufts from the fiber layer 70, pulling them through the base 60.

In the hooks 11a of the slide needles 11 these fiber tufts forrn fiber loops 75 over which the previously formed fiber loops are cast off in the rearmost position of the needles when their hooks 11a are closed by the wires 12. There are thus formed closed wales or chain-stitched seams, and the reverse side of the textile web according to the invention has the appearance of a mesh fabric, as will be explained further as the description proceeds.

FIG. 3a is a fragmentary cross-sectional view along IIIIII of the sinkers 14 of FIG. 3 looking into the direction of arrows. It is seen that loops 75 are formed around the respective sinkers 14, 14 and 14" with legs passing over the base fabric 60.

Instead of the previously made woven or other type of base fabric as shown at 60, a knit, a fleece, or a foamed web may be used with the device illustrated in FIG. 1.

It should be noted that instead of the slide needles 11 shown in FIGS. 1, 3 and 8, tubular needles 11' or latch needles 11" may be used (see respective FIGS. 2a and 2b). In the former, a closing member 11b may slide back and forth for opening the hook 11a. In the latter, a latch 11c is provided in a known manner for the same purpose. It is understood that the afore-mentioned closing wires 12 are adapted to co-operate with the alternative types of needles as well.

FIG. 3 shows an alternative or second embodiment of the device according to the invention, wherein most elements are identical with those already described for FIG. 1, and have, accordingly, been given identical reference numerals. Instead of the previous rotating brush roller 20, however, this device has a rod or rail 50 which carries a plurality of small brushes 40. The rail 50 is made to carry out an up-and-down swinging movement in unison with the longitudinal reciprocation of the needles 11, as indicated by the appropriate arrows.

Instead of brushes, rail 50 may carry a pressure rod 40' as shown in FIG. 4a or a pressure comb 40", as illustrated in FIG. 4b. The rod 40 is preferably equipped with a foam or rubber covering (not shown). It should be noted that both the rail 50 and the needle bar 21 may be provided with appropriate, conventional holders for releasable attachment of the respective brushes and needles, as has been schematically shown in FIG. 5.

FIGS. 5 and 6 illustrate an exemplar embodiment of the drive mechanism for the needles 11, the wires 12 and particularly for the brush rail 50 of the device of FIG. 3. It should be noted that this drive mechanism has been shown in FIGURES 4 and 5 of US. Patent 3,030,786 to H. Mauersberger, with a reissue Patent Re. 25,749 dated Mar. 23, 1965, entitled Textile Material and Manufacture, and co-assigned with the present application. In the present FIGS. 5 and 6, correlated reference numerals have been used (e.g. 111 instead of 11, or 150 instead of 50 as used in the earlier patent).

The drive mechanism employs, for purposes of rapid machine operation, circular eccentric cams for actuating the needles 11, the closing wires 12 and the brushes 40. As shown in FIG. 5, the needle bar 21 carrying the needles 11 is actuated by a connecting rod 113 extending from an eccentric rod 112 linked to a strap 112a of an eccentric cam 111 which is rotated by a motor-driven shaft 110 supported by a housing 150.

Similarly, the reciprocating movement of the closing wires 12 is obtained by means of an eccentric cam 115 cooperating with a strap 142a actuating, through an eccentric rod 142, a connecting rod 143 that actuates the bar 22 which carries wires 12. The connection between rod 143 and bar 22 has been broken away for the sake of clarity.

The rail 50, carrying brushes 40, is fixedly mounted on a shaft 120 by means of suitably attached lever arms 117. Shaft 120, being rotatably mounted within bearings 119, is adapted to slide longitudinally back and forth, within certain limits, and carries a short lever 121. The latter is connected with a coupling rod 122 linked to an eccentric rod 124. This rod, with its strap 124a, encloses an eccentric cam 125 which, by means of an intermediate connecting rod 123, moves the brushes 40 up and down.

Aside from this reciprocating movement, the brushes must preferably undergo an axially transverse back and forth movement. The brushes 40 and the shaft 120 carrying the rail 50 therefore are preferably operated to perform one complete back and forth movement while the needles 11 are moved twice back and forth. To accomplish this, a pinion 126 keyed to the shaft 110 engages a spur wheel 127 of twice its size. Consequently, the spur wheel rotates at one half of the speed of the shaft.

The spur wheel 127 is fixedly connected with an eccentric cam 128 whose strap member 129a is lined by an eccentric rod 129 to a connecting rod 131, axially slidable in bearing 130. When in operation, the rod 131 and its linkage 131a impart axial reciprocation to the shaft 120 by actuating an angle lever 133 rotatably mounted on a pivot 132. A tension spring 134 positioned around the shaft 120 between one of the bearings 119 and the adjacent lever arm 117 of the rail 50 aids the axially oscillating movement by forcing the shaft against an adjusting screw 135 connecting the free end of angle lever 133 to that of shaft 120.

In carrying out the new textile-web making process according to the present invention, the fibers of layer 70 may be given a much greater length than that consumed in each working cycle, so that they are seized several times in succession by the needles, namely successively by several needles standing side by side, owing to the lateral movement of rail 50, as has been described before. This results in locked chain-stitch seams which solidly connect the fiber layer 70 with the base 60, and which do not unravel.

FIGS. 7a through 7d show various longitudinal sections of textile webs made according to the invention, with FIG. 7e representing a plan view of the web according to FIG. 7d. These variants can be produced with the devices according to FIGS. 1 and 3. In the alternative of FIG. 7a, the base 60 is connected with a closed fiber layer 70a by means of the fiber loops 75. As shown in FIG. 7a the fiber loops 75 are substantially U-shaped in form, and adjacent loops are interconnected together at the side of base 60 disposed away from fiber layer 70a. In this manner fiber layer 70a is firmly secured to base 60.

In the second alternative according to FIG. 7b, separate twistless fiber bundles are pulled out of the plush fiber layer 7011, fed to the working station in closed form. These bundles are anchored in the base 60 by means of the substantially U-shaped fiber loops 75. The leg portions of the loops 75 are passed through a single opening in base 60. Adjacent loops 75 are interconnected to one another to thereby secure the fiber layer 70b to the base 60. The fiber bundles or tufts 90, extending uniformly throughout fiber layer 70b, form a plushor fur-like web surf-ace.

In the form of web shown in FIG. 7c, a crosswise pleated fiber layer 7% is utilized, that is the twistless fibers of layer 70c are folded over one another to achieve a greater thickness of fiber as shown in FIG. 70, the pleating being crosswise to the direction of movement of the web. The layer is connected with the base 60 by means of the loops 75. The pleating has been obtained in that the fiber layer 70 has been fed to the device at a speed increased by about four to tenfold as compared to the fabric base 60.

In the fourth alternative appearing in FIGS 7d and- 72, the fiber layer connected with the base 60 by means of loops 75 consists of two layers, namely 70d and 70d. The fibers in layer 70d are oriented substantially in the direction of movement of the web, while the fibers in layer 70d are oriented substantially perpendicularly thereto. In the plan view of FIG. 7e the stitch lines in course 70d are indicated by broken lines 7 5'.

A modified or third embodiment of the inventive device is illustrated in FIG. 8 wherein, again, identical elements have been designated with the same numerals as in FIGS. 1 and 3. This device permits the use of loose longitudinal and transverse threads or fibers in crossed superposition, instead of woven or knitted fabrics or the like, as a base fabric 60 for the novel textile web. Such a base 60 is illustrated as consisting of cross threads 61, supplied continuously to the device by means of endless needle chains 62. Longitudinal threads 63 are continuously fed, in the manner of a warp-thread group, in a manner to be described somewhat later.

Closing wires 12' have been alternatively illustrated, secured to bar 22, which are somewhat different from the wires 12 of the previous embodiments. Cast-off sinkers 13' are provided on bar 23, somewhat longer than sinkers 13 illustrated and described before. Additionally, the device of FIG. 8 is fitted with counter-holders 15 held by a common bar 25, and a counter-holder rod 16. As clearly shown in the drawing, the fiber layer 70 is guided between these last-named elements. For introducing the warp-wise threads 63, eye needles 65 are provided between the counter-holders 15 and the path of the layer 70; these needles are also held by bar 25.

The device operates as those described before. By means of the feed rollers 18 and the conveyor cloth 28, driven by one of the feed rollers and guided around roller 19, the fiber layer 70 is supplied continuously to the work position of the machine. The feed of the fiber layer may, however, also be effected directly by a card. (not illustrated) working synchronously with the sewing-knitting machine.

When the needles 11 have reached their foremost position, as illustrated, the fibers of layer 70 are pushed, by the rotating brush roller 20, into the hooks 11a of the needles. On their return, the needles take along these fiber tufts.

In the hooks 110, the fiber tufts form fiber loops 75 over which the previously formed fiber loops are cast off by means of sinkers 13 in the rearmost position of the needles 11, in which the hooks are closed by the wires 12'. The cast-off sinkers 13' ensure, moreover, the exit of the needles 11 in their rearmost position from the layer 70 and the base layer 60 (including threads 61 and 63). The counter-holder 15 and the counter-holding rod 16 facilitate the passage of the needles 11 during their forward movement through the threads 61, 63 and fiber layer '70.

It will be understood, of course, that needles 11' and 11" might as well be used in this embodiment of the inventive device, too. Also, alternately, individual brushes 40 on a bar could be incorporated instead of the rotating brush roller 20.

FIG. 9 shows a textile web made with the use of the device of FIG. 8, utilizing threads as a base or foundation. The transverse threads or fibers 61 and the longitudinal threads 63 constitute the base they are connected with the fiber layer by way of fiber loops 75. It should be noted, however, that the connection of the layers can also be effected in the manner shown in FIGS. 717 through 7d.

The foregoing disclosure relates only to preferred, exemplary embodiments of the invention, which are intended to include all changes and modifications of the examples described within the scope of the invention.

We claim:

1. A textile fabric comprising:

(a) a base; and

(b) a pile layer comprising a plurality of rows of fiber bundles extending along one side of said base in at least one direction, each of said rows comprising a plurality of substantially twistless fiber bundles secured to said base by extending portions of said bundles through said base to the other side thereof to form, with portions of adjacent bundles, at least two interconnected rows of knitted loops extending in the same direction as the rows of fiber bundles of which they are a part, each of said bundles comprising fibers of a length sufficient to extend into at least two adjacent rows of said knitted loops.

2. A textile fabric as defined in claim 1, wherein said rows of fiber bundles constitute a pleated layer, the pleats in said pleated layer being at least partly transversal to the longitudinal run of the textile fabric, said portions extending through said base forming chain stitches on said other side of said base.

3. A textile fabric as defined in claim 1, wherein said base consists of a knitted fabric.

4. A textile fabric as defined in claim 1, wherein at least a portion of said base is constituted of a shrinkable material.

References Cited UNITED STATES PATENTS 271,539 1/1883 Straw. 1,314,565 9/1919 Billington 2827.2 1,334,744 3/1920 Farr 16180 2,672,673 3/1954 Shaw 2872.2 X 2,881,505 4/1959 Hofiman 287-2.2 2,978,786 4/1961 Turner 28--72.2 3,174,308 3/1965 Mauersberger 66-192 3,260,640 7/1966 Owen 28--72.2 X 3,274,806 9/1966 Duhl 66192 3,168,883 2/1965 Ploch et a1. 112-411 3,309,901 3/1967 Danhel et al.

FOREIGN PATENTS 236,272 7/ 1925 Great Britain.

853,867 12/1939 France.

900,056 12/1953 Germany.

ROBERT R. MACKEY, Primary Examiner.

US. Cl. X.R.

Claims (1)

1. A TEXTILE FABRIC COMPRISING: (A) A BASE; AND (B) A PILE LAYER COMPRISING A PLURALITY OF ROWS OF FIBER BUNDLES EXTENDING ALONG ONE SIDE OF SAID BASE IN AT LEAST ONE DIRECTION, EACH OF SAID ROWS COMPRISING A PLURALITY OF SUBSTANTIALLY TWISTLESS FIBER BUNDLES SECURED TO SAID BASE BY EXTENDING PORTIONS OF SAID BUNDLES THROUGH SAID BASE TO THE OTHER SIDE THEREOF TO FORM, WITH PORTIONS OF ADJACENT BUNDLES, AT LEAST TWO INTERCONNECTED ROWS OF KNITTED LOOPS EXTENDING IN THE SAME DIRECTION AS THE ROWS OF FIBER BUNDLES OF WHICH THEY ARE A PART, EACH OF SAID BUNDLES COMPRISING FIBERS OF A LENGTH SUFFICIENT TO EXTEND INTO AT LEAST TWO ADJACENT ROWS OF SAID KNITTED LOOPS.

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