CA1089333A - Method and apparatus for forming a narrow weave from bare elastomeric threads - Google Patents
Method and apparatus for forming a narrow weave from bare elastomeric threadsInfo
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- CA1089333A CA1089333A CA327,582A CA327582A CA1089333A CA 1089333 A CA1089333 A CA 1089333A CA 327582 A CA327582 A CA 327582A CA 1089333 A CA1089333 A CA 1089333A
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- threads
- elastomeric
- woven fabric
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- thread
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Abstract
ABSTRACT OF THE DISCLOSURE
A narrow woven fabric comprising a plurality of shrunk non-elastomeric warp threads. A plurality of bare elastomeric warp threads are separated by the shrunk warp threads. A pair of elastomeric threads form the edge warp threads, each of the edge warp threads having a heat set yarn loosely wrapped thereon. A shrunk non-elastomeric weft thread is also provided in the fabric.
A narrow woven fabric comprising a plurality of shrunk non-elastomeric warp threads. A plurality of bare elastomeric warp threads are separated by the shrunk warp threads. A pair of elastomeric threads form the edge warp threads, each of the edge warp threads having a heat set yarn loosely wrapped thereon. A shrunk non-elastomeric weft thread is also provided in the fabric.
Description
BACKGROUND OF THE I~lVENTION
Thi~ invention relate~ generally to narrow weaves and more particularly to a ~heer elastomeric woven fabric.
In the field of narrow bands or tapes containing elastomeric or rubber threads, the elastomeric threads are generally covered so as to retain their position in the final wea~e in use as well as over the lifetime of the fabric. The multiple washings over a lifetime have a tendency to cause the elastomeric threads to move relative to the remainder of the threads and thus provide an unattractive and unuseable element of a piece of apparel. By using wrapped elastomeric thread~, the fabric may be formed by weaving relatively low wefts per ;
inch, such as 30 wefts per inch. This reduction in the weft~
per inch makes the wo~en fabrics co~ercially competitive in ~pite of the increased cost of the covered elastomeric thread.
When forming narrow bando, tapes, or ~trap~ from uncovered elastomeric or rubber threads, the number o$ wefts per inch must be increAsed to hold the bare elastomeric thread~
in plac~ ln the woven fabric. This generally includes weaving 20 at 50-60 weft3 per inch aepending upon the density or number of ; ends. Though b~ing relatively cheaper than the amount of materials being used, the increased we~ts per inch increases the C09t of production.
Wrapped ela3tomeric threads may be single or double wrapped with a second material or yarn. Single and double ,, ~
wrapped elastomeric yarns are generally balanced, but have a tendency when unbalanced or un~table to turn, twist, and form extending loops of the wrapped material. The unstable condition of the wrapped elastomeric yarn also causes narrow tapes formed with the elastomeric band to twist or turn or not to lie flat.
Wrapping operations are expensive since they re~uire separate machinery to wind the thread~, unwind the thread~, wrap the threads, and rewind the threads, as well as space and operating time. The single and double wound elastomeric threads of the prior art are generally bulky since they are tightly wrapped to keep the elastomeric thread under tension and to counteract or restrain any twisting or buckling of the elasto-meric thread. The wrapping yarn is generally twisted so as to bring forces to bear on the elastomeric yarn. It is this twist-ing that sets up the unstable condition of the wrapped elasto-meric thread which produces the undesirable results in the final woven product.
Thus, there exists a need for making a sheer, inexpensive, narrow elastomeric fabric.
SUMM~RY OF THE INVENTION
The pre~ent invention relates to a narrow woven elas-tic fabric. The warp of the fabric includes a plurality of ela3tomeric threads separated fxom each other by a plurality of high shrink non-elastic synthetic threads which are prefer-ably made of nylon or polyester. The two edge warp threads are -elastomeri~ and are loo~ely wrapped with a heat set yarn to increase the hold of these edge elastomeric warp threads. The edge elastomeric threads are under the same tension as the other elastomeric threads to assure the stability of the woven fabric.
A high shrin~ synthetic weft thread is interwoven with the warp threads. The process includes the step~ of providing the warp threads from a plurality o~ supply elements to the loom and wrapping the two edge warp elastomeric threads between the supply and the loom with texturized, heat set synthetic yarn, for example, polyester yarn. The weft is woven at a lcw weft count for example 25-35 wefts per inch. The non-elastic warp threads and the weft thread are preferably continuous multi-filament yarns. The final woven product is heat treated at a temperature sufficient to cause the high shrink weft and warp threads to shrink 80 as to further bind the elastomeric threads.
The temperature i8 not sufficient to heat set the elastomeric threads, but the elastomeric thread assume4 a corrugated shape which increases the hold of the ela~tomeric thread in the final woven product.
The machinery needed to provide the proper tension of the elastomeric thread from the supply elements to the loom as well as the rate of wrapping of the wrap yarn include~ mechanically interconnecting the drive of the loom with the drive of the wrapping device and the positive feed mechanism for the elasto-meric threads. The elastomeric threads are driven or let-off the spool by interconnected or synchronous feed rollers which engage the elastomeric material on the rolls and control or synchronize let-off.
- ,, : ., ~ . . .
.' ~. ' .. . . .
. . .
~08~333 An object of the invention i9 to provide a sheer, long-lasting, narrow elastomeric fabric, tape, or band.
Another object of the invention is to provide a narrow elastomeric fabric requiring low wefts per inch of weaving operation without reducing the life of the fabric.
A further object of the invention is to provide a stable stretch fabric having covered and bare elastomeric threads.
According to the above objects, from a broad aspect, the present invention provides a narrow woven fabric comprising a plurality of shrunk non-elastomeric warp threads. A plurality of bare elastomeric warp threads are separated by the shrunk warp threads. A pair of elastomeric threads form the edge warp threads, each of the edge warp threads having a heat set yarn loosely wrapped thereon. A shrunk non-elastomeric weft thread is also provided in the fabric.
Other objects, advantages, and novel features of the pre~ent invention will become apparent from the following detailed description of the invention when considered in con-junction with the accompanying drawings in which:
Figure 1 is a cro~ ectional view of a narr~w woven fabric incorporating the principles of the pre~ent invention.
Figure 2 i~ a cross-sectional view of the fabric of Figure 1 taken along lines 2-2.
; 25 Figure 3 is a section of elastomeric thread with the polyester loosely wrapped thereon.
Figure 4 i3 a side elevation of the interrelationship - of the thread supply, wrapping device and loom.
10~ 3 Figure 5 i~ a front view of the thread ~upply and wrap~ping device taken along line~ 5-5 of figure 4.
Figure 6 is a diagrammatic perspective of the thread supply, wrapping device and loom drives.
S DESCRIPTION OF THE PREFERRED EMBODIMENTS
Fabric illustrating the concepts of the present invention is illustrated in Figures 1 and 2. The warp is made up of a plurality of warp threads, including high shrink back threads 10, high shrink binder threads 12, bare elastomeric threads 14, and covered elastomeric edge warp threads 16. A
heat set synthetic yarn 18 is loo~ely wrapped around the edge elastomeric warp threads 16 to increase their hold within the woven fabric. A ~igh shrink weft thread 20 is interwoven with the warp threads. The specific fabric illu~trated in Figures ~5 1 and 2 includes eight kack threads 10, sixteen binder threads 12, and nine elastomeric threads 14, 16. The back threads 10, as illu~trated in Figure 2, are interwoven with the weft threads 20 every fourth weft. The non-elastic warp threads 10 and 12 and weft thread 20 may be any high heat shrinkable synthetic '0 yarn, preferably selected from nylon or polyester, and heat set ~ynthetic wrapping yarn 18 i~ preferably polyester.
As will be evident from the detailed analy~is of the method, it i important that the majority of the warp threads 12 and the weit thread5 20 be heat-~hrinkable threads to diminish '5 the weave and increase the bind or holding power on the elasto-meric threads 14 and 16~ Similarly, it is es~ential that the wrapping thread 18 he pre-heat ~et ~o as to not be afiected by .: ' . .
, 10~93;~3 the subsequent heat treatment and that the ela~tomeric threads 14 and 16 be capable of forming corrugationq during ~he heating process. This is also important to increase the holding power of the fabric on the elastomeric thread~.
9 In a specific embodiment of the present invention, the elastomeric threads 14 and 16 were spandex having a 1120 denier; the warp threads 10 and 12 were thirty-four filament 140 denier nylon, the weft thread 20 was a thirty filament 150 denier polyester, and the wrapping yarn 18 was a textured, heat set 150 denier polyester. It i5 considered quite desirable that the high shrink warp and weft threads be continuous filament.
By viewing the structure of Figure 1, it is seen that the interior warp elastomeric threads 14 are bare and the exterior or eage elastomeric warp threads 16 are wrapped. The exterior elastomeric threads must be wrapped since the weft thread wrapping around the edge warp thread 16 produces a tunneling effect ~uch that the weft threads cannot bind or hold the elastomeric edge warp thread 16 sufficiently to hold them from ~lipping in the fabric. A section of the wrapped elasto-meric thread 16 having the heat set polyester yarn 18 loosely wrapped around it i8 illustrated in Figure 3. ~he wrap i~
sufficiently tight to increase the coefficient of friction of the elastomeric thread without reducing or restricting its diameter.
The method of thi~ invention needed to produce the novel fabric includes controlling the let-off of bare elasto-meric threads as warp threads into a loom and 1005ely wrapping lO~g333 heat set yarn onto the edge elastomeric warp threads between the supply and the loom. The loose wrap is possible since the elast:omeric thread is under tension from its supply directly into the loom and onto the take-up roll of the loom whereas with pre-wrapped elastomeric yarn the wrap must be tight to prevent curling, looping, and buckling which is present when the wrapped elastomeric thread is wound on a supply cone and unwound in use on the loom. Also, it is difficult to use pre-wrapped elastomeric threads in combination with bare elastomeric threads becau~e it is necessary to control the tension on the elastomeric threads during wrapping relative to the tension on the bare threads during weaving (preferably the tensions are about equal) in order to obtain a stable fabric which will lie flat. The wrapping yarn is applied without twists and conequently the resulting structure produces an elastomeric yarn which i8 stable and not under any twi~t or tension. The ela3tomeric warp yarns are separated by non-elastomeric heat ~hrinkable synthetic warp yarns, preferably made of nylon or polyester and preferably the weft yarn i~ interwoven t,herewith at a low weft per inch. Generally, a weft count between 25 and 35 wefts per inch i~ sufficient to initially hold the elastomeric yarns in position in the woven fabric on the take-up roll.
The woven fabric is then heat treated at between 140_1soC. to shrink the heat shrinkable warp and weft threads to tighten the weave and to bind the elastomeric warp threads.
With the contraction of the weave pattern, the ela~tomeric thread~ increase their corrugation or buckles. The temperatures io~s;~
are not sufficient to cau~e heat setting of the elastomeric threads. By wrapping the elastomeric threads with a heat set yarn, a further reduction of the denier of the elastomeric thr~_ads i-~ not produced by the heat treatment. In a typical procedure, heat treatment is carried out on a Carroll calender using steam heated drums with a steam pressure of 40-65 pounds per square inch. The fabric may be treated with a wax softener and a resin prior to heat treatment to improve the hand or finish of the final woven product.
Since some of the bare elastomeric threads are being simultaneously wrapped and woven, it i9 essential that the let-off or feed mechanism for the elastomeric thread be syn-chronized with the weave or loom operations so as to provide the proper tension on the elastomeric threads during the combined operations and maintain them equal to the tension on the bare elastomeric threads~ This is even more critical in a needle loom which operates at a greater rate of speed than than the standard gang looms. Although the fabric and method of the present invention has been produced on both looms, it.is prefexably performed on a needle loom. The apparatus as illustrated in F$gures 4, 5, and 6 i9 a needle loom, for example, a Crompton & Knowle~ model NL-7.
Mechanisms illustrated in Figures 4 and 5 include a loom 21, a driven creel 22, a yarn creel 24 and wrapping device 26. The yarn creel 24 include~ a plurality of rolls or cones 28 of non-elastic, heat shrinkable synthetic threads for the warp threads and a cone 30 of heat shrinkable synthetic thread for the weft thread of each fabric woven. The cones are supported on ~pindles 32 connected to uprights 34 which are secured to the frame 36 of the yarn creel. The frame is held above the floor by a pair of uprights 38. A guide 40 5 i8 provided at the front of frame 36 to guide or direct the warp threads into the warp of loom 21. The non-elastic warp and weft thread~ are let-off a~ needed by the ten~ion exerted by the loom take-up roll and the shuttle or needle of the weft re~pectively. Tension devices, not shown, provide the desired ten~ion on the warp thread~ from cones 28.
The driven roller creel 22 includes a plurality of non-slip roller~ 42 including shafts whose outer ends are journalled in supports 44 and are interconnected by sprockets and chains 46. The interconnection of the drive rollers by chain~ synchronizes the rotation 90 as to drive the surface of the ela3tomeric thread~ to control or synchronize the let-off and consequently maintain equal tension on all ela~tomeric thread~ whether to be wrapped or not. A plurality of roll~
of elastomeric yarn 48 are ~hawn resting on their face between two non 81ip rollers 42. The elastomeric threads leave the supply rolls 48 and traverse guide rollers 50 on their way to the loom 21. A main ~haft 52 (Figure 5) i~ mounted to the driven creel 22 and includes a sprocket 54 to receive chain ; drive 56 ~rom the loom and is interconnected to the synchronous chains 46 of the non-~lip roller drives by a chain and ~procket 5~.
Between the driven creel 22 for the elastomeric threads and the loom 21 is a wrapping device 26. Mounted to support 60 are ~pindles 62 having bobbins 64 of the heat -~et wrap mounted thereon. A spring 66 biases a flyer wire 68 into a top 70. The to-be-wrapped elastomeric thread traverses the center of the wrapping device 26 or spindle 62 and has preferably a texturized heat ~et polyester yarn wrapped thereon by flyer wire 68. The wrapping device 26 is driven by belts and gears 72 which are interconnected to the loom drive by chain 74.
Four wrapping devices 26 (without the uprights for support 60) are illu~trated in Figure 5 Rince loom 21 is capable of weaving two fabrics Rimultaneously.
As illustrated in Figure 4, a guide frame 76 receives the non-elastic warp threads from yarn creel 24 and the elasto-meric threads from the driven creel 22 to provide the warp for the loom 21. Ihe weft thread is received by a driven roller 78 and transmitted to the needle or shuttle. Roller 78 is inter-connected by chain 80 to shaft 82 which also drives the chain 74 which drives the wrapping device 26.
~he interconnection of the drive of the loom and the ~unctional element of the loom 21 with the wrapping devices 26 and the driven creel 22 for the elastomeric threads i9 illustrated diagrammatically in Figure 6. The main motor 84 ha~ a drive shaft 86. By appropriate gears the take-up roller 88 is con-nected to shaft 86 by its shaft 90 and chain and sprocket 92.
Shaft 90 i~ also connected to the feed roller drive shaft 52 by chainq 93, gear box 94, and chain 56. The gear box 94 is sufficient to interconnect or synchronize the drive or rotation of the take-up roll 88 and the drive for the rollers 42 for the ela~tomeric threads. Thu~, the tension on the threads can be morle uniformly controlled for wrapping and sub~equent warp structure in the loom. Motor drive shaft 86 is also connected by ~hain and sprockets 96 to a shaft 98 which drives the shed cam mechanism 100. Also driven by shaft 98 through chain and sprockets 102 is shaft 82 which drives through chain 80 the weft roller 78 and drives through chain 74 the wrapping gear 72.
Thus, the low speed take-up reel drive i8 used to drive the let-off for the elastomeric thread feed and the high speed shed cam drive i8 used to drive the high speed weft feed roller and the wrapping device.
Although Figure 6 illustrates a mechanical synchroniza-tion of the respective drives, obviously individual motor drives may be provided using a system of electronic or electrical synchronization. Since the ~hed cam drive is available as well a~ the take-up roll drive, the mechanical implementation is considered inexpensive and provides the performance of control characteristics.
The method and apparatus of the present invention reduces the coqt of manufacture ~y reducing the meahanical work done and the amount of materials used. By the use of synthetic elastomeric threads instead of rubber, needle cutting is eliminated and the fabric formed is sheer. The use of threads of heat shrinkable material such as nylon and polyester al50 provide the heat characteri~tics desired whereby the final heat treatment shrinks these threads to tighten the weave and prevent 31ippage of the elastomeric threads without the use of prewrapped ~0893~;~
ela~tomeric threads except at the edges of the fabric. The pres,ent materials and method provide a sheer elastic band with the ,ability to withstand repeated washings.
From the preceding description of the preferred embodiments, it is evident that the objects of the invention are obtained, and although the invention has been described and illustrated in detail, it i8 to be clear that the details are intended for illustrative purposes only and are not to be taken by way of limitation. If desired for certain end uses, more elastomeric threads than the edge elastomeric thread~ may be wrapped between the Yupply and the loom. The spirit and scope of the invention are to be limited only by the terms of the appended claim~.
This application is a division of application Serial No. 288,296, filed October 7, 1977.
Thi~ invention relate~ generally to narrow weaves and more particularly to a ~heer elastomeric woven fabric.
In the field of narrow bands or tapes containing elastomeric or rubber threads, the elastomeric threads are generally covered so as to retain their position in the final wea~e in use as well as over the lifetime of the fabric. The multiple washings over a lifetime have a tendency to cause the elastomeric threads to move relative to the remainder of the threads and thus provide an unattractive and unuseable element of a piece of apparel. By using wrapped elastomeric thread~, the fabric may be formed by weaving relatively low wefts per ;
inch, such as 30 wefts per inch. This reduction in the weft~
per inch makes the wo~en fabrics co~ercially competitive in ~pite of the increased cost of the covered elastomeric thread.
When forming narrow bando, tapes, or ~trap~ from uncovered elastomeric or rubber threads, the number o$ wefts per inch must be increAsed to hold the bare elastomeric thread~
in plac~ ln the woven fabric. This generally includes weaving 20 at 50-60 weft3 per inch aepending upon the density or number of ; ends. Though b~ing relatively cheaper than the amount of materials being used, the increased we~ts per inch increases the C09t of production.
Wrapped ela3tomeric threads may be single or double wrapped with a second material or yarn. Single and double ,, ~
wrapped elastomeric yarns are generally balanced, but have a tendency when unbalanced or un~table to turn, twist, and form extending loops of the wrapped material. The unstable condition of the wrapped elastomeric yarn also causes narrow tapes formed with the elastomeric band to twist or turn or not to lie flat.
Wrapping operations are expensive since they re~uire separate machinery to wind the thread~, unwind the thread~, wrap the threads, and rewind the threads, as well as space and operating time. The single and double wound elastomeric threads of the prior art are generally bulky since they are tightly wrapped to keep the elastomeric thread under tension and to counteract or restrain any twisting or buckling of the elasto-meric thread. The wrapping yarn is generally twisted so as to bring forces to bear on the elastomeric yarn. It is this twist-ing that sets up the unstable condition of the wrapped elasto-meric thread which produces the undesirable results in the final woven product.
Thus, there exists a need for making a sheer, inexpensive, narrow elastomeric fabric.
SUMM~RY OF THE INVENTION
The pre~ent invention relates to a narrow woven elas-tic fabric. The warp of the fabric includes a plurality of ela3tomeric threads separated fxom each other by a plurality of high shrink non-elastic synthetic threads which are prefer-ably made of nylon or polyester. The two edge warp threads are -elastomeri~ and are loo~ely wrapped with a heat set yarn to increase the hold of these edge elastomeric warp threads. The edge elastomeric threads are under the same tension as the other elastomeric threads to assure the stability of the woven fabric.
A high shrin~ synthetic weft thread is interwoven with the warp threads. The process includes the step~ of providing the warp threads from a plurality o~ supply elements to the loom and wrapping the two edge warp elastomeric threads between the supply and the loom with texturized, heat set synthetic yarn, for example, polyester yarn. The weft is woven at a lcw weft count for example 25-35 wefts per inch. The non-elastic warp threads and the weft thread are preferably continuous multi-filament yarns. The final woven product is heat treated at a temperature sufficient to cause the high shrink weft and warp threads to shrink 80 as to further bind the elastomeric threads.
The temperature i8 not sufficient to heat set the elastomeric threads, but the elastomeric thread assume4 a corrugated shape which increases the hold of the ela~tomeric thread in the final woven product.
The machinery needed to provide the proper tension of the elastomeric thread from the supply elements to the loom as well as the rate of wrapping of the wrap yarn include~ mechanically interconnecting the drive of the loom with the drive of the wrapping device and the positive feed mechanism for the elasto-meric threads. The elastomeric threads are driven or let-off the spool by interconnected or synchronous feed rollers which engage the elastomeric material on the rolls and control or synchronize let-off.
- ,, : ., ~ . . .
.' ~. ' .. . . .
. . .
~08~333 An object of the invention i9 to provide a sheer, long-lasting, narrow elastomeric fabric, tape, or band.
Another object of the invention is to provide a narrow elastomeric fabric requiring low wefts per inch of weaving operation without reducing the life of the fabric.
A further object of the invention is to provide a stable stretch fabric having covered and bare elastomeric threads.
According to the above objects, from a broad aspect, the present invention provides a narrow woven fabric comprising a plurality of shrunk non-elastomeric warp threads. A plurality of bare elastomeric warp threads are separated by the shrunk warp threads. A pair of elastomeric threads form the edge warp threads, each of the edge warp threads having a heat set yarn loosely wrapped thereon. A shrunk non-elastomeric weft thread is also provided in the fabric.
Other objects, advantages, and novel features of the pre~ent invention will become apparent from the following detailed description of the invention when considered in con-junction with the accompanying drawings in which:
Figure 1 is a cro~ ectional view of a narr~w woven fabric incorporating the principles of the pre~ent invention.
Figure 2 i~ a cross-sectional view of the fabric of Figure 1 taken along lines 2-2.
; 25 Figure 3 is a section of elastomeric thread with the polyester loosely wrapped thereon.
Figure 4 i3 a side elevation of the interrelationship - of the thread supply, wrapping device and loom.
10~ 3 Figure 5 i~ a front view of the thread ~upply and wrap~ping device taken along line~ 5-5 of figure 4.
Figure 6 is a diagrammatic perspective of the thread supply, wrapping device and loom drives.
S DESCRIPTION OF THE PREFERRED EMBODIMENTS
Fabric illustrating the concepts of the present invention is illustrated in Figures 1 and 2. The warp is made up of a plurality of warp threads, including high shrink back threads 10, high shrink binder threads 12, bare elastomeric threads 14, and covered elastomeric edge warp threads 16. A
heat set synthetic yarn 18 is loo~ely wrapped around the edge elastomeric warp threads 16 to increase their hold within the woven fabric. A ~igh shrink weft thread 20 is interwoven with the warp threads. The specific fabric illu~trated in Figures ~5 1 and 2 includes eight kack threads 10, sixteen binder threads 12, and nine elastomeric threads 14, 16. The back threads 10, as illu~trated in Figure 2, are interwoven with the weft threads 20 every fourth weft. The non-elastic warp threads 10 and 12 and weft thread 20 may be any high heat shrinkable synthetic '0 yarn, preferably selected from nylon or polyester, and heat set ~ynthetic wrapping yarn 18 i~ preferably polyester.
As will be evident from the detailed analy~is of the method, it i important that the majority of the warp threads 12 and the weit thread5 20 be heat-~hrinkable threads to diminish '5 the weave and increase the bind or holding power on the elasto-meric threads 14 and 16~ Similarly, it is es~ential that the wrapping thread 18 he pre-heat ~et ~o as to not be afiected by .: ' . .
, 10~93;~3 the subsequent heat treatment and that the ela~tomeric threads 14 and 16 be capable of forming corrugationq during ~he heating process. This is also important to increase the holding power of the fabric on the elastomeric thread~.
9 In a specific embodiment of the present invention, the elastomeric threads 14 and 16 were spandex having a 1120 denier; the warp threads 10 and 12 were thirty-four filament 140 denier nylon, the weft thread 20 was a thirty filament 150 denier polyester, and the wrapping yarn 18 was a textured, heat set 150 denier polyester. It i5 considered quite desirable that the high shrink warp and weft threads be continuous filament.
By viewing the structure of Figure 1, it is seen that the interior warp elastomeric threads 14 are bare and the exterior or eage elastomeric warp threads 16 are wrapped. The exterior elastomeric threads must be wrapped since the weft thread wrapping around the edge warp thread 16 produces a tunneling effect ~uch that the weft threads cannot bind or hold the elastomeric edge warp thread 16 sufficiently to hold them from ~lipping in the fabric. A section of the wrapped elasto-meric thread 16 having the heat set polyester yarn 18 loosely wrapped around it i8 illustrated in Figure 3. ~he wrap i~
sufficiently tight to increase the coefficient of friction of the elastomeric thread without reducing or restricting its diameter.
The method of thi~ invention needed to produce the novel fabric includes controlling the let-off of bare elasto-meric threads as warp threads into a loom and 1005ely wrapping lO~g333 heat set yarn onto the edge elastomeric warp threads between the supply and the loom. The loose wrap is possible since the elast:omeric thread is under tension from its supply directly into the loom and onto the take-up roll of the loom whereas with pre-wrapped elastomeric yarn the wrap must be tight to prevent curling, looping, and buckling which is present when the wrapped elastomeric thread is wound on a supply cone and unwound in use on the loom. Also, it is difficult to use pre-wrapped elastomeric threads in combination with bare elastomeric threads becau~e it is necessary to control the tension on the elastomeric threads during wrapping relative to the tension on the bare threads during weaving (preferably the tensions are about equal) in order to obtain a stable fabric which will lie flat. The wrapping yarn is applied without twists and conequently the resulting structure produces an elastomeric yarn which i8 stable and not under any twi~t or tension. The ela3tomeric warp yarns are separated by non-elastomeric heat ~hrinkable synthetic warp yarns, preferably made of nylon or polyester and preferably the weft yarn i~ interwoven t,herewith at a low weft per inch. Generally, a weft count between 25 and 35 wefts per inch i~ sufficient to initially hold the elastomeric yarns in position in the woven fabric on the take-up roll.
The woven fabric is then heat treated at between 140_1soC. to shrink the heat shrinkable warp and weft threads to tighten the weave and to bind the elastomeric warp threads.
With the contraction of the weave pattern, the ela~tomeric thread~ increase their corrugation or buckles. The temperatures io~s;~
are not sufficient to cau~e heat setting of the elastomeric threads. By wrapping the elastomeric threads with a heat set yarn, a further reduction of the denier of the elastomeric thr~_ads i-~ not produced by the heat treatment. In a typical procedure, heat treatment is carried out on a Carroll calender using steam heated drums with a steam pressure of 40-65 pounds per square inch. The fabric may be treated with a wax softener and a resin prior to heat treatment to improve the hand or finish of the final woven product.
Since some of the bare elastomeric threads are being simultaneously wrapped and woven, it i9 essential that the let-off or feed mechanism for the elastomeric thread be syn-chronized with the weave or loom operations so as to provide the proper tension on the elastomeric threads during the combined operations and maintain them equal to the tension on the bare elastomeric threads~ This is even more critical in a needle loom which operates at a greater rate of speed than than the standard gang looms. Although the fabric and method of the present invention has been produced on both looms, it.is prefexably performed on a needle loom. The apparatus as illustrated in F$gures 4, 5, and 6 i9 a needle loom, for example, a Crompton & Knowle~ model NL-7.
Mechanisms illustrated in Figures 4 and 5 include a loom 21, a driven creel 22, a yarn creel 24 and wrapping device 26. The yarn creel 24 include~ a plurality of rolls or cones 28 of non-elastic, heat shrinkable synthetic threads for the warp threads and a cone 30 of heat shrinkable synthetic thread for the weft thread of each fabric woven. The cones are supported on ~pindles 32 connected to uprights 34 which are secured to the frame 36 of the yarn creel. The frame is held above the floor by a pair of uprights 38. A guide 40 5 i8 provided at the front of frame 36 to guide or direct the warp threads into the warp of loom 21. The non-elastic warp and weft thread~ are let-off a~ needed by the ten~ion exerted by the loom take-up roll and the shuttle or needle of the weft re~pectively. Tension devices, not shown, provide the desired ten~ion on the warp thread~ from cones 28.
The driven roller creel 22 includes a plurality of non-slip roller~ 42 including shafts whose outer ends are journalled in supports 44 and are interconnected by sprockets and chains 46. The interconnection of the drive rollers by chain~ synchronizes the rotation 90 as to drive the surface of the ela3tomeric thread~ to control or synchronize the let-off and consequently maintain equal tension on all ela~tomeric thread~ whether to be wrapped or not. A plurality of roll~
of elastomeric yarn 48 are ~hawn resting on their face between two non 81ip rollers 42. The elastomeric threads leave the supply rolls 48 and traverse guide rollers 50 on their way to the loom 21. A main ~haft 52 (Figure 5) i~ mounted to the driven creel 22 and includes a sprocket 54 to receive chain ; drive 56 ~rom the loom and is interconnected to the synchronous chains 46 of the non-~lip roller drives by a chain and ~procket 5~.
Between the driven creel 22 for the elastomeric threads and the loom 21 is a wrapping device 26. Mounted to support 60 are ~pindles 62 having bobbins 64 of the heat -~et wrap mounted thereon. A spring 66 biases a flyer wire 68 into a top 70. The to-be-wrapped elastomeric thread traverses the center of the wrapping device 26 or spindle 62 and has preferably a texturized heat ~et polyester yarn wrapped thereon by flyer wire 68. The wrapping device 26 is driven by belts and gears 72 which are interconnected to the loom drive by chain 74.
Four wrapping devices 26 (without the uprights for support 60) are illu~trated in Figure 5 Rince loom 21 is capable of weaving two fabrics Rimultaneously.
As illustrated in Figure 4, a guide frame 76 receives the non-elastic warp threads from yarn creel 24 and the elasto-meric threads from the driven creel 22 to provide the warp for the loom 21. Ihe weft thread is received by a driven roller 78 and transmitted to the needle or shuttle. Roller 78 is inter-connected by chain 80 to shaft 82 which also drives the chain 74 which drives the wrapping device 26.
~he interconnection of the drive of the loom and the ~unctional element of the loom 21 with the wrapping devices 26 and the driven creel 22 for the elastomeric threads i9 illustrated diagrammatically in Figure 6. The main motor 84 ha~ a drive shaft 86. By appropriate gears the take-up roller 88 is con-nected to shaft 86 by its shaft 90 and chain and sprocket 92.
Shaft 90 i~ also connected to the feed roller drive shaft 52 by chainq 93, gear box 94, and chain 56. The gear box 94 is sufficient to interconnect or synchronize the drive or rotation of the take-up roll 88 and the drive for the rollers 42 for the ela~tomeric threads. Thu~, the tension on the threads can be morle uniformly controlled for wrapping and sub~equent warp structure in the loom. Motor drive shaft 86 is also connected by ~hain and sprockets 96 to a shaft 98 which drives the shed cam mechanism 100. Also driven by shaft 98 through chain and sprockets 102 is shaft 82 which drives through chain 80 the weft roller 78 and drives through chain 74 the wrapping gear 72.
Thus, the low speed take-up reel drive i8 used to drive the let-off for the elastomeric thread feed and the high speed shed cam drive i8 used to drive the high speed weft feed roller and the wrapping device.
Although Figure 6 illustrates a mechanical synchroniza-tion of the respective drives, obviously individual motor drives may be provided using a system of electronic or electrical synchronization. Since the ~hed cam drive is available as well a~ the take-up roll drive, the mechanical implementation is considered inexpensive and provides the performance of control characteristics.
The method and apparatus of the present invention reduces the coqt of manufacture ~y reducing the meahanical work done and the amount of materials used. By the use of synthetic elastomeric threads instead of rubber, needle cutting is eliminated and the fabric formed is sheer. The use of threads of heat shrinkable material such as nylon and polyester al50 provide the heat characteri~tics desired whereby the final heat treatment shrinks these threads to tighten the weave and prevent 31ippage of the elastomeric threads without the use of prewrapped ~0893~;~
ela~tomeric threads except at the edges of the fabric. The pres,ent materials and method provide a sheer elastic band with the ,ability to withstand repeated washings.
From the preceding description of the preferred embodiments, it is evident that the objects of the invention are obtained, and although the invention has been described and illustrated in detail, it i8 to be clear that the details are intended for illustrative purposes only and are not to be taken by way of limitation. If desired for certain end uses, more elastomeric threads than the edge elastomeric thread~ may be wrapped between the Yupply and the loom. The spirit and scope of the invention are to be limited only by the terms of the appended claim~.
This application is a division of application Serial No. 288,296, filed October 7, 1977.
Claims (8)
1. A narrow woven fabric comprising:
a plurality of shrunk non-elastomeric warp threads:
a plurality of bare elastomeric warp threads separated by said shrunk warp threads;
a pair of elastomeric threads forming the edge warp threads, each of said edge warp threads having a heat set yarn loosely wrapped thereon and a shrunk non-elastomeric weft thread.
a plurality of shrunk non-elastomeric warp threads:
a plurality of bare elastomeric warp threads separated by said shrunk warp threads;
a pair of elastomeric threads forming the edge warp threads, each of said edge warp threads having a heat set yarn loosely wrapped thereon and a shrunk non-elastomeric weft thread.
2. The narrow woven fabric according to claim 1 wherein said elastomeric threads have a buckled configuration formed by subjecting the fabric to a heat treatment which shrinks the non-elastomeric warp and weft threads.
3. The narrow woven fabric according to claim 1 wherein said elastomeric threads are spandex.
4. The narrow woven fabric according to claim 1 including rubber warp threads.
5. The narrow woven fabric according to claim 1 wherein said shrunk threads are selected from nylon or polyester.
6. The narrow woven fabric according to claim 1 wherein said weft thread is approximately 150 denier polyester and said wrap yarn is approximately 150 denier, textured heat set polyester.
7. The narrow woven fabric according to claim 1 wherein said wrap yarn is textured, heat set polyester.
8. The narrow woven fabric according to claim 1 wherein said elastomeric threads are not heat set in the woven fabric.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA327,582A CA1089333A (en) | 1977-09-07 | 1979-05-15 | Method and apparatus for forming a narrow weave from bare elastomeric threads |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US831,457 | 1977-09-07 | ||
| US05/831,457 US4164963A (en) | 1977-09-07 | 1977-09-07 | Apparatus for forming a narrow weave from bare elastomeric threads |
| CA288,296A CA1091545A (en) | 1977-09-07 | 1977-10-07 | Method and apparatus for forming a narrow weave from bare elastomeric threads |
| CA327,582A CA1089333A (en) | 1977-09-07 | 1979-05-15 | Method and apparatus for forming a narrow weave from bare elastomeric threads |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1089333A true CA1089333A (en) | 1980-11-11 |
Family
ID=27165309
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA327,582A Expired CA1089333A (en) | 1977-09-07 | 1979-05-15 | Method and apparatus for forming a narrow weave from bare elastomeric threads |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1089333A (en) |
-
1979
- 1979-05-15 CA CA327,582A patent/CA1089333A/en not_active Expired
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