CA1194331A - Single bar lock-stitch lofted fabric construction - Google Patents
Single bar lock-stitch lofted fabric constructionInfo
- Publication number
- CA1194331A CA1194331A CA000432046A CA432046A CA1194331A CA 1194331 A CA1194331 A CA 1194331A CA 000432046 A CA000432046 A CA 000432046A CA 432046 A CA432046 A CA 432046A CA 1194331 A CA1194331 A CA 1194331A
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- fabric
- warp elements
- elements
- knitting thread
- stitch
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Abstract
ABSTRACT OF THE DISCLOSURE
A fabric having a novel lock-stitch construction is made on a stitch-through type machine equipped with a single knitting thread guide bar and comprises a flexible substrate such as a layer of textile yarn filling elements, a plurality of warp elements laid on the substrate in the longitudinal or warpwise direction, and knitting thread forming a multiplicity of warpwise stitches in a lock-stitch configuration. The knitting thread lock-stitch configuration comprises a sequence of three-needle atlas stitch courses on a given knitting thread wale to bind together into an integrated structure the substrate and warp elements, to secure the substrate and warp elements against relative displacement, and to stabilize the fabric against running or lifting off of the warp elements from the fabric surface. As a result of the knitting thread lock stitch configuration, the fabric exhibits an aesthetically pleasing appearance corresponding to the loft imparted to the warp elements by virtue of the non-binding of the warp elements by the chain stitch components of the knitting thread network.
A fabric having a novel lock-stitch construction is made on a stitch-through type machine equipped with a single knitting thread guide bar and comprises a flexible substrate such as a layer of textile yarn filling elements, a plurality of warp elements laid on the substrate in the longitudinal or warpwise direction, and knitting thread forming a multiplicity of warpwise stitches in a lock-stitch configuration. The knitting thread lock-stitch configuration comprises a sequence of three-needle atlas stitch courses on a given knitting thread wale to bind together into an integrated structure the substrate and warp elements, to secure the substrate and warp elements against relative displacement, and to stabilize the fabric against running or lifting off of the warp elements from the fabric surface. As a result of the knitting thread lock stitch configuration, the fabric exhibits an aesthetically pleasing appearance corresponding to the loft imparted to the warp elements by virtue of the non-binding of the warp elements by the chain stitch components of the knitting thread network.
Description
SII`~GLE 131~11 L,OCI;-Sï'I'rCH LOF'rEI) F~13RIC CO~`~S~RL~CTION
DESCRIPTION
Technical Field This invention relates to non-woven fabrics.
More particularly, it relates to non-woven comp~site fabrics of novel functional and aesthetic design which are produced on stitch-through type machines and which are useful, among other things, in decorative applications such as draperies and bedspreads.
Background Art Stitch-through fabrics typically comprise a layer of substantially parallel warp elements or ends on a fl~xible substrate such as a layer of substantially parallel te~tile yarn~filling elements or ends. ~rhe warp ; 20 elements are affixe~ to the flexible suhstrate by layins them on top of the substrate and joining both components into an integrated fabric structure by means of relatively fine knitting or sewing threads. In cases where a more or less open ~esh fabric is desired, this can be achieved by controlling the spacing between the individual warp elements and, where the flexible substrate is a layer of textile yarn filling elements, by controlling also the spacing between the individual filling elements. ~his and other "stitch-through" type fabric structures can be obtained on various 30 ~achines, including those of the "Malimo" type, using methods and equipment described in U. S. 2,890,579; U. S. 3,030,7~6;
U. S. Re. 25,749; U. S. 3,253,426; U. S. 3,274,806; U~ S.
3,279,221; U. S. 3,309,~00; U. S. 3,389,583; U. S. 3,3~2,078;
U. S. 3l440,840; U. ~. 3,452,561; U. S. 3,457,i38; U. S.
3,~60,599; IJ. S. 3,540,238; U. S. 3,541,812; U. S. 3,567,565;
and 3,592,0;25.
.
_ -2-1 The àbility to rea~ily mass-produce a basic fabric in a variety of designs and patterns is extrernely important to the commercial success of the fabric. While stitch-through fabrics can be produced at rela.ively high speed compared to woven fabrics, much attention has been given to augmenting this desirable feature with design flexibility, e.g., with respect to the nature, density~
gauge, and color of the fabric components, the spacing beween them, and the purposeful omission of a component or 10 the addition of other components.
.
However, a need has existed for stitch-through fabrics of still further design flexibility, not only with respect to the creation of unusual visual effects but also 15 with respect to achieving new and useful functional features. For example, in prior commercial Malimo fabrics having warp elements, the latter are secured to the sub-strate by the sewing or knitting thread network in a half-tricot stitch configuration. Such a network inherently 20 causes the warp elements to lie flat against the substrate with no possibility for creating a "ioft" or i'blooming"
effect in the warp component which would be a highly desirable way of simulating the appearance of depth, as for example, in relatively expensive hand-woven fabrics.
25 Alsot the nature of the conventional half-tricot stitch configuration of the knitting thread network is such that the warp elements are inherently susceptible to destructive runs or lifting off from the fabric surface due to "unzip-pering" or unravelling of the knitting thread network 30 beginning-at the cut end of the fabric. In the past, this drawbac~ in Malimo fabrics could be dealt with only by a separate and, therefore, time consuming and costly secure-ment operation performed on the cut ends oE greige goods subse~uent to doffing and each time the fabric is cut 35 during converting and finishing.
'. ' --- - -- , . . .
/.. .
l Accordingly, it is an object of the present inven-tion to provide a novel decorative fabric concept using stitch-through type machines, Another object is to provide novel decorative fabrics using stitch-through type machines wherein the warp elements of the fabric exhibit a lofted and/or bloomed appearance.
Yet another object is to provide novel decorative fabrics usin~ stitch-through type machines wherein the warp elements have a substantially increased resistance to running or being lifted off the fahric due to unzippering or unravelling of the sewing o.r knitting threa~ network These and othe.r ob3ects of the invention as well as a fuller understanding of the advantages thereof can be had by reference to the following detailed aescription, . drawings and claims.
Disclosure Of The Invention -The.foregoing objects are achieved according to the present invention by a novel ~abric concept utili~ing at 25 least one needle yuide bar on ,a stitch-thro~gh type machine s~ch .asr but not limited to a Malimo,machine. Such a fabric comprises a flexible substrate, a plurality o~ warp ele-ments laid on the substrate in the warpwise.or machine.
(.i.e., longitudinal) direction, and knitting or sewing . 30 threads in parallel warpwise wales across the width of the ,. fabric and containing a multiplicity of warpwise stitches ln .a lock-stitch configuration having~ on a given knitting thread wale, ~ sequence of three-needle atlas stitch courses. The knitting thread thus forms a "lock-stitch" network which binds , __ ... .. ... . ... , ... ;..... ,_ $
together into an integrated fabric structure the substrate and warp elements and secures the substrate and warp elements against relative displacement.
The term "lock-stitch" as used herein and as will be more fully explained below~ refers to a knitting thread configuration which affords increased resistance to running of the warp elements by virtue of the fact that such elements pass over some of the courses of the knitting thread network.
Due to the intermittent non-binding effect of the lock-stitch knitting thread configuration the fabrics of the invention possess an aesthetically pleasing appearance corresponding to the loft or "loose look" imparted to the lofted warp element segments by the non-binding or relaxation effect of the chain stiteh courses or components of the lock-stitch knitting thread configuration. In addition, it has been discovered that this uni~ue lock-stitch configuration of the knitting thread network effectively stabilizes the fabric, in a manner no-t heretofore possible, against destruetive unzippering or unravelling of the knitting thread network and resultant running or lifting off of the warp elements from the fabric surface, particularly at the cut ends of the fabrie where sueh unravelling and runs are most likely to begin.
In one embodiment of the fabrie of the present invention, the lock-stitch knitting thread eonfiguration eomprises, on a given knitting thread wale r at least one half-tricot stitch followed by one or more chain stitches, wi-th generally from 3 to 32 loops or courses per linear inch as measured in the warp-wise direction and generally from 3 to 22 parallel knitting thread wales per linear inch as measured in the weftwise dir-eetion. Desirably, the fabric has Erom 6 to 16 and pre-ferably from 6 to 1~ knitting thread courses per ineh and from ~ to 18, ancl perferahly from 7 to 10 knitting thread wales per inch.
In the preferred case of a fabric havina from 6 to 12 eourses per :Lnch and from 7 to 10 wales per inch, the knitting thread L3~
lock-stitch se~uence will preferably have at l.east three con secutive chai.n stitch courses followed by one or more half~
tricot stitch courses.
It is a feature of the above-described knitting thread lock-stitch configuration that :it stabilizes the fabric to an -extent not heretofore possible by virtue of the discovery that on a given knitting thread wale, the chain stitches "lock" the tricot stitches down on the body of the fabric so that any u.n-ravelling or unzippering which develops in the half-tricot stitch portion of the wale are arrested at the half-tricot stitch/chain stitch juncture. In this way, when a warp element is pulled or subjected to a displacement force, say, at the cut end of the fabricJ any running or "lifting off" of the warp element from the surface of the fabric can only commence in and proceed through the first half-tricot stitch region of a knitting thread wale. As soon as the unravelment encounters the juncture or intersection of the first chain stitch portion with the following half-tricot stitch portion of the.wale, the run is effectively halted.
Another uni~ue and -totally unexpected feature of the fabric construction described is the fact that, as.the ratio of the number of chain stitch courses to the number of half-tricot stitch courses increases per unit ~enqth along a given wale (having a given number of courses per unit length) the loft or "loose looX'! of the fabric increases while the strength of the fabric, i.e., the resistance of the warp elements to running or lifting off, also increases. In addition, such stability of the warp elements increases with increasing number of courses per unit length along the wale.
~he warp elements suitable Eor use in the present invention can be any of t:hose elements heretofore used in stitch-through fabric construc-tion. Of particular preference are yarns' such as multifilamerlt ~igure yarns, multifilament low twist crimped yarns, taslani~ed (air-entangled) yarns, spiral yarns consisting of low twist spun yarns combined with a fine binder yarn; and/or ribbons, such as fabric or elted ribbons because of their ability to exhibit optimum unfettered loft or bloom in those regions where the elements are free of the confining effect of the knitting thread ~en employed in the present fabric construction, the warp elements can be laid on the flexi~le substrate component in either mutually contacting relationship or can be spaceA apart ~rom one another in the weftwise dir-ection at any predetermined aistance. In one emhodiment othe invention, the warp elements are substantially spaced ; apart in order to amplify and enhance the visual effect o~ the "home spun" or "open-weave look" characteristic of fabrics pro-auced in stitch-through type machines. In addition, the warp 1~ elements can be laid on the fleY~ible substrate in a substantially : rectilinear or straight line fashion parallel to the warpwise direction. Alternatively, as described in U.S. Patent No.
3,672,187, the warp or "design" elements (so called because of the aesthetically pleasing appearance and ornamental effect which they impart to the fabric) can be caused to follow non-rectilinear paths along the warpwise direction, and/or in a : twisted configuratiQn.in the manner disclosed in U.S. Patent No. 4,144,727. -:' .
-- .
- 7 ~
1 The flexible substrate upon which the warp e~ements are laid in forming the fabric of the present invention can be a pre-knitted le g., tricot) or pr~-woven fabric; fibrous batting, or any other continuous sheeting;
one or more layers of textile filling elements running in 5 a general weftwise dire~tiorl with respect to the warp elements, or any other flexible structure capable o~
being secured to the warp elements ~ith knitting thread accordin~ to procedures described in U~ S. 3,672,187 and now familiar to those skilled in the art of stitch-10 through fabric construction. In-the case of fabrics havirg the open-mesh "home spun" appearance characteristic of casement or drapery ~abric~, a 1exible s~bstrate in the form o~ at least one layer of more or less spaced-apart textile filling yarns or elements is'preferred.
'- The knitting thread used to bind together into an integrated textile fabric structure the war~ elements and flexible substrate can be any thread heret'ofore used in stitch-thro~gh fabri~ construction and is appliea to
DESCRIPTION
Technical Field This invention relates to non-woven fabrics.
More particularly, it relates to non-woven comp~site fabrics of novel functional and aesthetic design which are produced on stitch-through type machines and which are useful, among other things, in decorative applications such as draperies and bedspreads.
Background Art Stitch-through fabrics typically comprise a layer of substantially parallel warp elements or ends on a fl~xible substrate such as a layer of substantially parallel te~tile yarn~filling elements or ends. ~rhe warp ; 20 elements are affixe~ to the flexible suhstrate by layins them on top of the substrate and joining both components into an integrated fabric structure by means of relatively fine knitting or sewing threads. In cases where a more or less open ~esh fabric is desired, this can be achieved by controlling the spacing between the individual warp elements and, where the flexible substrate is a layer of textile yarn filling elements, by controlling also the spacing between the individual filling elements. ~his and other "stitch-through" type fabric structures can be obtained on various 30 ~achines, including those of the "Malimo" type, using methods and equipment described in U. S. 2,890,579; U. S. 3,030,7~6;
U. S. Re. 25,749; U. S. 3,253,426; U. S. 3,274,806; U~ S.
3,279,221; U. S. 3,309,~00; U. S. 3,389,583; U. S. 3,3~2,078;
U. S. 3l440,840; U. ~. 3,452,561; U. S. 3,457,i38; U. S.
3,~60,599; IJ. S. 3,540,238; U. S. 3,541,812; U. S. 3,567,565;
and 3,592,0;25.
.
_ -2-1 The àbility to rea~ily mass-produce a basic fabric in a variety of designs and patterns is extrernely important to the commercial success of the fabric. While stitch-through fabrics can be produced at rela.ively high speed compared to woven fabrics, much attention has been given to augmenting this desirable feature with design flexibility, e.g., with respect to the nature, density~
gauge, and color of the fabric components, the spacing beween them, and the purposeful omission of a component or 10 the addition of other components.
.
However, a need has existed for stitch-through fabrics of still further design flexibility, not only with respect to the creation of unusual visual effects but also 15 with respect to achieving new and useful functional features. For example, in prior commercial Malimo fabrics having warp elements, the latter are secured to the sub-strate by the sewing or knitting thread network in a half-tricot stitch configuration. Such a network inherently 20 causes the warp elements to lie flat against the substrate with no possibility for creating a "ioft" or i'blooming"
effect in the warp component which would be a highly desirable way of simulating the appearance of depth, as for example, in relatively expensive hand-woven fabrics.
25 Alsot the nature of the conventional half-tricot stitch configuration of the knitting thread network is such that the warp elements are inherently susceptible to destructive runs or lifting off from the fabric surface due to "unzip-pering" or unravelling of the knitting thread network 30 beginning-at the cut end of the fabric. In the past, this drawbac~ in Malimo fabrics could be dealt with only by a separate and, therefore, time consuming and costly secure-ment operation performed on the cut ends oE greige goods subse~uent to doffing and each time the fabric is cut 35 during converting and finishing.
'. ' --- - -- , . . .
/.. .
l Accordingly, it is an object of the present inven-tion to provide a novel decorative fabric concept using stitch-through type machines, Another object is to provide novel decorative fabrics using stitch-through type machines wherein the warp elements of the fabric exhibit a lofted and/or bloomed appearance.
Yet another object is to provide novel decorative fabrics usin~ stitch-through type machines wherein the warp elements have a substantially increased resistance to running or being lifted off the fahric due to unzippering or unravelling of the sewing o.r knitting threa~ network These and othe.r ob3ects of the invention as well as a fuller understanding of the advantages thereof can be had by reference to the following detailed aescription, . drawings and claims.
Disclosure Of The Invention -The.foregoing objects are achieved according to the present invention by a novel ~abric concept utili~ing at 25 least one needle yuide bar on ,a stitch-thro~gh type machine s~ch .asr but not limited to a Malimo,machine. Such a fabric comprises a flexible substrate, a plurality o~ warp ele-ments laid on the substrate in the warpwise.or machine.
(.i.e., longitudinal) direction, and knitting or sewing . 30 threads in parallel warpwise wales across the width of the ,. fabric and containing a multiplicity of warpwise stitches ln .a lock-stitch configuration having~ on a given knitting thread wale, ~ sequence of three-needle atlas stitch courses. The knitting thread thus forms a "lock-stitch" network which binds , __ ... .. ... . ... , ... ;..... ,_ $
together into an integrated fabric structure the substrate and warp elements and secures the substrate and warp elements against relative displacement.
The term "lock-stitch" as used herein and as will be more fully explained below~ refers to a knitting thread configuration which affords increased resistance to running of the warp elements by virtue of the fact that such elements pass over some of the courses of the knitting thread network.
Due to the intermittent non-binding effect of the lock-stitch knitting thread configuration the fabrics of the invention possess an aesthetically pleasing appearance corresponding to the loft or "loose look" imparted to the lofted warp element segments by the non-binding or relaxation effect of the chain stiteh courses or components of the lock-stitch knitting thread configuration. In addition, it has been discovered that this uni~ue lock-stitch configuration of the knitting thread network effectively stabilizes the fabric, in a manner no-t heretofore possible, against destruetive unzippering or unravelling of the knitting thread network and resultant running or lifting off of the warp elements from the fabric surface, particularly at the cut ends of the fabrie where sueh unravelling and runs are most likely to begin.
In one embodiment of the fabrie of the present invention, the lock-stitch knitting thread eonfiguration eomprises, on a given knitting thread wale r at least one half-tricot stitch followed by one or more chain stitches, wi-th generally from 3 to 32 loops or courses per linear inch as measured in the warp-wise direction and generally from 3 to 22 parallel knitting thread wales per linear inch as measured in the weftwise dir-eetion. Desirably, the fabric has Erom 6 to 16 and pre-ferably from 6 to 1~ knitting thread courses per ineh and from ~ to 18, ancl perferahly from 7 to 10 knitting thread wales per inch.
In the preferred case of a fabric havina from 6 to 12 eourses per :Lnch and from 7 to 10 wales per inch, the knitting thread L3~
lock-stitch se~uence will preferably have at l.east three con secutive chai.n stitch courses followed by one or more half~
tricot stitch courses.
It is a feature of the above-described knitting thread lock-stitch configuration that :it stabilizes the fabric to an -extent not heretofore possible by virtue of the discovery that on a given knitting thread wale, the chain stitches "lock" the tricot stitches down on the body of the fabric so that any u.n-ravelling or unzippering which develops in the half-tricot stitch portion of the wale are arrested at the half-tricot stitch/chain stitch juncture. In this way, when a warp element is pulled or subjected to a displacement force, say, at the cut end of the fabricJ any running or "lifting off" of the warp element from the surface of the fabric can only commence in and proceed through the first half-tricot stitch region of a knitting thread wale. As soon as the unravelment encounters the juncture or intersection of the first chain stitch portion with the following half-tricot stitch portion of the.wale, the run is effectively halted.
Another uni~ue and -totally unexpected feature of the fabric construction described is the fact that, as.the ratio of the number of chain stitch courses to the number of half-tricot stitch courses increases per unit ~enqth along a given wale (having a given number of courses per unit length) the loft or "loose looX'! of the fabric increases while the strength of the fabric, i.e., the resistance of the warp elements to running or lifting off, also increases. In addition, such stability of the warp elements increases with increasing number of courses per unit length along the wale.
~he warp elements suitable Eor use in the present invention can be any of t:hose elements heretofore used in stitch-through fabric construc-tion. Of particular preference are yarns' such as multifilamerlt ~igure yarns, multifilament low twist crimped yarns, taslani~ed (air-entangled) yarns, spiral yarns consisting of low twist spun yarns combined with a fine binder yarn; and/or ribbons, such as fabric or elted ribbons because of their ability to exhibit optimum unfettered loft or bloom in those regions where the elements are free of the confining effect of the knitting thread ~en employed in the present fabric construction, the warp elements can be laid on the flexi~le substrate component in either mutually contacting relationship or can be spaceA apart ~rom one another in the weftwise dir-ection at any predetermined aistance. In one emhodiment othe invention, the warp elements are substantially spaced ; apart in order to amplify and enhance the visual effect o~ the "home spun" or "open-weave look" characteristic of fabrics pro-auced in stitch-through type machines. In addition, the warp 1~ elements can be laid on the fleY~ible substrate in a substantially : rectilinear or straight line fashion parallel to the warpwise direction. Alternatively, as described in U.S. Patent No.
3,672,187, the warp or "design" elements (so called because of the aesthetically pleasing appearance and ornamental effect which they impart to the fabric) can be caused to follow non-rectilinear paths along the warpwise direction, and/or in a : twisted configuratiQn.in the manner disclosed in U.S. Patent No. 4,144,727. -:' .
-- .
- 7 ~
1 The flexible substrate upon which the warp e~ements are laid in forming the fabric of the present invention can be a pre-knitted le g., tricot) or pr~-woven fabric; fibrous batting, or any other continuous sheeting;
one or more layers of textile filling elements running in 5 a general weftwise dire~tiorl with respect to the warp elements, or any other flexible structure capable o~
being secured to the warp elements ~ith knitting thread accordin~ to procedures described in U~ S. 3,672,187 and now familiar to those skilled in the art of stitch-10 through fabric construction. In-the case of fabrics havirg the open-mesh "home spun" appearance characteristic of casement or drapery ~abric~, a 1exible s~bstrate in the form o~ at least one layer of more or less spaced-apart textile filling yarns or elements is'preferred.
'- The knitting thread used to bind together into an integrated textile fabric structure the war~ elements and flexible substrate can be any thread heret'ofore used in stitch-thro~gh fabri~ construction and is appliea to
2~ the ~ahric components by means of the mechanical stitching el2ments conventionally employed, for example, ~n Malimo~
type stitch-through rn'achines. These elements and theïr mode of operation are well known to those skille~ in the art and incluae a comb-like sinker bar an~ com~-like retainer pin bar, which together-de~ine an elongated space or work zone ~or fabric forma't;o~ between them. ~he stitching elements include a~ditionally a row of pronged or bearde'd pointed needles and corresponding closing wires the combination of which is caused to move in a reciprocat-30 ~ing fashion through the aforesaid work zone in coaction 'with a row of knitting threa~ guides for formi'ny a multi-plicity of warp-wise knitting thread loop chains Tn the operation of the machine, alternate loops in the half-tricot stitch portion of each chain are formed with a dif~erent knittin~ thread. Loop chains of the type ' :; characteristic of the half-tricot stitch confi~uration are ' ' . ' '.; ' ~ . . .
type stitch-through rn'achines. These elements and theïr mode of operation are well known to those skille~ in the art and incluae a comb-like sinker bar an~ com~-like retainer pin bar, which together-de~ine an elongated space or work zone ~or fabric forma't;o~ between them. ~he stitching elements include a~ditionally a row of pronged or bearde'd pointed needles and corresponding closing wires the combination of which is caused to move in a reciprocat-30 ~ing fashion through the aforesaid work zone in coaction 'with a row of knitting threa~ guides for formi'ny a multi-plicity of warp-wise knitting thread loop chains Tn the operation of the machine, alternate loops in the half-tricot stitch portion of each chain are formed with a dif~erent knittin~ thread. Loop chains of the type ' :; characteristic of the half-tricot stitch confi~uration are ' ' . ' '.; ' ~ . . .
3~
_ -8-1 preferred for use in combination with chain stitches when the fabric includes warp elements laid in rectilinear (straight line) fashion in the warpwise direction because of the normally greater structural integrity imparted to the overall fahric by the half-tricot stitch component of the knitting thread network. In such cases the fabric components are engaged and held together by the loops of knitting thread courses on the rear side of the fabric and by the laps of the ~nitting thread courses on the front surface by which, in the half-tricot stitch regions~ the diagonal segment or laps formed by the knitting thread secures the ~Jarp to the substrate. In this way the warp elements are "lapped" by the sewing thread around the substrate (e.g., textile yarn filling elements~ to achieve an integrated fabric structure. In those regions of the knitting thread network which are made up of chain stitches, such stitches are formed ~f a single knitting thread end which defines a single wale of the thread network.
In one embodiment of the fabric of the invention, at least two warp elements can be laid on the substrate along non-rectilinear paths in the warpwise direction thereby creating a design effect which serves to augment ~he aesthetically pleasing appearance oE the fabric~ More particularly, such warp "design elements" can include portions of substantial lenqth extending diagonally, relative to ~he warpwise direction, along straight lines or curving substantially uniformly. The warp elements can be disposed in groups composed of at least two adjacent elements following a substantlally identical pattern.
Alternatively, adjacent warp elements can be laid on the flexible substrate to form different patterns, e.g., wherein they ~orm the same pattern but one is reversed relative to the other. This fabric design feature and an ~5 apparatus and method for achieving it, which can be . , . .. .... .. _ .. . . . .. .. .. . .
' g~
.
practice~ in conjunction with the present invention, are described respectively in U. S. 3/67~t187, partic~larly at column 1, line 31 through column 3, line 44, and UO S.
3,677,D34, particularly at col~mn 1, linè 44 through 5 column 8~ line 2~, .
In another embodimenl: of the invention, which can, - if desire~, be employ.ed in combination with the embodiment 10 described in the preceding para~raph~ a further aesthetically pleasin~ appear~nce can be obtained by varying a plurality of adjacent warp elements in their relative level positions along the leng~h of the fabric hy twisting them at spaced-intervals along the warp direction in the manner di~closed 15 in the a~orementioned ~. S. Pat. No~ 4,144,727. In particu~ar, the adjacent warp elements which are twisted at spaced intervals along the warpwise direction of the fabric can be laid on the substrate ;n the in.tervals between twists in either mutual1y contacting relationship 20 or can be spaced apart from.one another in ~he weftwise direction at any predetermined distance. Desirably~
such warp elements are substamtially spacea apart in order to amplify the visual e~ect of the twist by contrast.
The degree of "twist" imparted to the warp elements 25 can be any angular amount from greater than ~-C to 36~-although a degree of-twist of desirably at least 90 and preferably 180.~ is preferred in order to maximize thë
visual effect created by the twist.configuration, and to achieve a~true twistin~ or crossing over of the warp 30 elements as opposed to apparent twisting brought about by . proximation of the warp elements without an actual crossing over of s~ch elernents, which apparent twisting obtains when t:he degree of twist is less than 90. In the case of a 180'' twist, opposite warp elements in a group of two or more are caused to exchange places.with each other . ............... ..... .. ...... . . . . ...
. .
1 and then return to their original relativc Dositions along the fabric w.ith each alternate twist. In the rcgions or intervals between the twists, the elements can be laid on the flexible substrate in a substantially rectilinear or 5 straight line fashion parallel to the warpwise directions;
alternatively, as described hereinabove, the warp elements can be caused to follow non-rectilinear paths in conjunc-tion with their t~isted configuration.
In connection with the embodiments described .in the foregoing two paragraphs, it has been discovered, as a further embodiment o the invention, that the lock-stitch knitting thread network can be made up entirely or suhstan-tially entirely o~ looPs of the chain stitch type whereby 15 the warp elements are secured .to the substrate by the knitting thread wales at the points where the warp elements, running diagonally to the warpwise direction~
intersect the knitting-thread wales~ In such cases,.the a~orementioned loft effect in the warp elements is achieved 20 in those regions where such elements do not intersect the knitting thread ~ales, ~articularly where the war elements are substantially parallel to the knitting-thread wales, i.e., ~ in the longitudinal direction. At the same time, the warp 1 elements are effectively secured against running or lifting 25 off by virtue of the exclusively chain stitch nature of the knitting-thread wales, which are substantiall~ immune from unzippering .or unravelling in the longitudinal direction due to the absence of cross lap~ing over a warp element.
3~
In still another em~odiment of the invention, the fabric further comprises a flexible self-liner material disp~sed beneath the flexib]e substrate (which in turn is laid beneath the warp elements). The knitting thread network having the aforementioned lock-stitch configuration, whose loops appear on the rear surfac~
of the lining material, likewise binds together into an integrated self-lined textile fa~ric structure the lining material, the flexihle substrate and the warp elements and secures said com~
ponents against relative displacement. The ~abric of this embodiment achieves a further combination of functional utility and decorative visual effect of aesthetically pleasing ap~earance through the unique placement of the functional lining of flexible material which is disposed behind or beneath the flexible substrate ~e.g.~ of textile filling elements~ and the textile warp elements. In this way, the lining material perEorms its function (e.g., thermal acoustic or optical insulation) without interfering ~ith the unity of warp and filling or obstructing the effect of the intermediate substrate layer (e.g., of filling yarn elements) and the outer lay~r 2~ of warp yarn elements. Such self-lined fabric construction provides practical as well as aesthetically useful composite fabrics in which the lining material performs a definite function (e.g., therm~
insulation) either per se or through various post~treatments (e.g., resin back-coating which also provides a convenient ~ay of achieving ~5 a l'blackout" effect when desired) without interferi~g with the de-corative function of the remaining components of the fabric which 1 are positioned in front of the lining or hacking component.
The flexible lining or bac~ing material cornDonent of the foregoing embodiment is preferably a layer of 5 fibrous non-woven, pre-knitted (e.g., tricot) or ~re-~oven fabric. The use of such lining material.s is particularly advantageous because of the ease with which, say, an ap~lied fibrous non-woven lining can be subse~uentl~
back-coated with a thin layer oE polymer, e.~., acrylic or 10 urethane foam, to impart effective thermal insulating or barrier properties while retaining the desired casement-like "feel" and "look" of the co~posite fabric as a ~hole.
Alternatively, the lining can be any other flexihle material ca~able of being stitched-throuah by ]cnitting 15 thread and secured thereby to the overlying substrate (e.g., filling yarns) and warp elements. Such other lining materials inc]ude, without limitation, synthetic polymeric compositions such as foamed polyurethane, polymeric film, and fi~rous batting, e.g., continuous 20 filament batting, and these can also be given a polymeric back-coatin~, if desired. Examples of embodiments of the invention include fahrics in which the self-liner is a con-I tinuous sheet material in the form of randomly arran-ged highly I dispersed continuous filaments, e.g., spun-bonded continuous 25 filament polyester sold by E. I. du Pont de Nemours & Co.
under the trademark "Reemay", and entangled staPle fiber, e.g., spun-laced polyester staple sold by du Pont under the trade-mark "Sontara". As indicated above, these liners can be bac~-coated with polymeric compositions. Other materials 30 suitable for use as the self-liner of the fabric of the present invention will be apparent to those skilled in the art upon appreciation o~ the present disclosure. In the case where the substrate .is other than a layer of textile filling yarns, e.g., continuous sheet material, a fabric -3~
__ -13-1 is obtained which in effect has two linings.
he self-lined fabric embodiment of the invention can also be heat-honded in pattern design to another fabric by use of Pinsonic type guilting, the details of the application of which to the fabric of this invention will be apparent to those skilled in the art and having the benefit of the present disclosure before them. The self-lined fabric of such embodiment can be either foamed or unfoamed. In this manner, the back of the fabric will be quilted whlle the face side is unquilted.
The fabrics produced in the manner of the present invention employing knitting thread to bind the warp elements and the flexible substrate into an integrated structure have the feature in which the knitting thread pierces the individual warp elements and pierces the flexihle substrate (in the case of filling yarns) at a substantial number of random ppints to further secure the substrate and warp elements against relative displace-ment.
In its broad aspect, the fabrics of the present invention can ~e produced on a stitch-through machine, e.g., a Malimo-type stitch-through machine, by the steps of (a) delivering a flexible substrate to the above-described work zone of the stitch-through type machine and (b) delivering to the work zone conjointly with and in superimposed relation to the substrate a plurality of warp elements. The superimposed warp elements and flexible substrate are bound together at the work zone o the machine by the warpwise knitting thread network to form an inteyrated structure which is the fabric of the present invention in greige orm, and which is ready for urther processing to finished fabric according to art-.
3~L
recogni7e~ procedures, e.g., dyein~, dr~ing, resina~ing,etc.
The particular aspect of the foregoing proced~re which makes possible the formation of the present novel fahric construction is the use oE at least one and preferably a single };nitting thread needle guide bar which can be pro-~rammed, in a manner which will be apparent to those skilled in the art and having the benefit of the present disclosure of the invention before them, to deliver the knittiny thread.s of each wale to the stitching elements in one or more of the - above-described stitching se~uences. In one embodiment the guide bar shaft of a ~alimo machine which carries the stitch-ing yarn guides i5 disconnected from the horizontal motion eccentric and its horizontal motion is derived from and con-trolled by a pattern chain similar to those used on tricot or raschel warp knitting machines for control of their yarn guides.
- The said pattern chain could be driven from the main ~1alimo machine shaft or other shaft by gears, sprockets or timing belts. In this way, it is possible to produce the present ; fabrics at a rate of speed comparable to that at which conven-tional stitch-through fabrics are produced having the nor~al 20 half-tricot stitch knitting thread configuration throughout.
In addition, the use of at least one and preferably a single knittin~ thread needle bar to lay the wales of knitting thread results in a fabric in which the lofted and unlofted portions of the warp yarn elements extend in parallel bands transverselv 25 across the fabric, i.e., in the weftwise direction, there~y irnparting a unique secondary pattern to the "loose look" of the fabric.
. .
Brief Descri~tion of The Drawing -- .
Further details of the present invention and the ad-vantages thereof can be had by reference to the accompanying drawings wherein:
_ FI~. 1 is a plan view of the front surface of a prior ;? art fabric of conventional structure with res~ect to the ~ 35 disposition of the warp elements on the flexible substrate.
~4~
-- -15-. 1 I FIG. 2 is a schematic representation oE the movement of the knitting-needle guicle bar for producing a segment of a stitch-through fabric of the invention;
FIG. 3 is a schematic representation of the movement. of the kni.tting-neec31e guide bar for producing a segment of another type of stitch-through fabric of the invention;
PIG. 4A is a plan view of the front surface oE
a first embodiment of the fabric of the invention;
FIG. 4B is an enlarged front view of a portion of the fabric of FIG. 9A showing the relationship 15 between the elements thereof;
FIG. 4C is a further enlarged front view of a portion of the fabric of FIG. 4A showing the relationship between the flexible substrate and knitting thread;
FIG. 4D is an enlarged plan view of the rear surface of a portion:of the fabric of FIG. 4A;
. FIG. 5A is a plan view of the front surface of a 25 second embodiment of the fahric of the invention;
FIG. 5B is an enlarged front view of a portion of the fabric of FIG. 5A sho~ing the relationship between the elements thereof;
PIG. 5C is a plan view of the rear surface of the fabric of FI~. 5A; and ~ IG. 5D is an enlarged view of the rear surface 35 of a portion of the fabric of FIG. SA.
~ .
_ -16-1 FIG. 6~ is a plan view o~ the front surface of a thircl embodiment of the fabric of the invention;
FIG. 6B is an enlarged ront view of a portion of the fabric of FIGA 6A showi.ng the .relationship between the elements the~eof;
FIG. 6C is a further enlarged front view of a portion of the fabric of FIG. 6~ showing the relationship between the elements thereof., FIG. 6D is a plan view of the rear surface of the fabric of FIG. 6A;
FIG. 7A is a plan view of the front surface of a fourth embodiment of the fabric of the invention;
FIG. 7B is an enlarged front view of a portion of the fabric of FIG. 7A showing the relationship between the elements thereof;
. FIG. 7C is a further enlarged front view of a portion of the fabric of FIG. 7A showing the relationship . between the elements thereof;
FIG. 7D is a plan view of the rear surface of the fabrlc of FIG. 7A.
Description of the Preferred Ernbodiments In the following description, the corresponding elements as shown in each figure of the drawings are given the same reEerence number, and letter sufixes are added to designate specific ones of these elements where necessary.
3~
1 Referring to FIG. 1, there is shown a conventional stitch-through fabric composed of warp yarn elements 1, textile yarn filling elements 3, and knitting thread 5 applied in a half-tricot stitch configuration network 5 throughout. Of particular interest i~ the appearance of the warp yarn elernents 1 which are uniformly secured to the flexible substrate of textile filling elements 3 by virtue of the half-tricot stitch configuration of the knitting thread network. As a result, the fabric l~cks the three-- 10 dimensional appearance of the fabrics of the present inven-tion since the war~ yarn elements are prevented from loft-ing or blooming by the uniformly lapping or binding effect of the half-tricot sti*ches of the knitting thread.
Referring to FIGS. 2 and 3, the horizontal and vertical rows of equally spaced dots 7 represent the knitting needles of the stitch-through machine, and the vertical solid lines 9 represent the placement of the warp elemen-ts relative to the knitting thread 11. Each 20 horizontal row of dots can be visualized as the plan o~
the needle bar, each dot representing one needle head.
The bottom row of points indicates the needle bar at th~
first couxse, the second row indicates the needle bar at the second course, and so on. Thus each vertical column 25 of dots represents the same needies at successive courses, or alternatively, can be taken to represent one wale in the fabric. Since all the knitting thread guides on the single bar are rigidly mounted therein, they all make exactly the same movements at each course, 30 as can be seen in FIG. 2, which depicts the formation o~ a knitting thread lock-stitch configuration com-prising eight consecutive chain stitch courses fol-lowed by three consecutive half-tricot s-titch courses, or in FIG. 3, which depicts the ~ormation of a knitting thread lock~stitch con~iguration comprising a -three-_ ~ t 1 n~edle atlas stitch network.
Referring to FIG. 4A, which is a plan viewof the front surface of a first embodiment of the fabric construction of the invention, the warp elements 13 impart a three-dimensional effect or appearance of depth to the fabric by virtue of t'he ]oft created in those lengths where the warp elements pass over the chain stitch segment of each knitting thread wale lS of the 3-chain/1-half-tricot stitch configuration as depicted in FIG. 4B. FIG. ~C shows in detail the aforementioned configuration of the knitting threads 17 in relation to the textile yarn filling elements 19.
eferring to FIG. 4D, the loops 21 of the knitting thread courses of each wale 15 on the rear side of the fabric of FIG. ~A can be readily seen. These loops bind the non-woven fibrous batting 23 of the self-lin~r to the textile filling yarn substrate 19 and to 20 the warp elements (not shown).
.
Referring ~o FIG. 5A, which is a plan vi-ew of -the front surface of a second embodiment of the fabric construction of the invention, the lofting of the warp - 25 elements 25 can be seen over the chain stitch portion of the 3-chainf'4-half-tricot stitch knitting thread network sho~n in greater detail in FIG. 5B. Since the number~of chain stitches 27 to half-tricot stitches 29 is greater in the fabric of FIG. 5A than in the fabric of FIG. ~A
(both fabrics having the same ~umber of knitting thread courses per unit length), the loft imparted to the warp elements of the former is correspondingly greater.
A'; seen in FIG. 5C and in greater detail in FIG. 5D, the loops 31 of the knitting thread courses 32 on the rear side of the fabric of FIG. 5A bin'd the fibrous _ -19-1 non-woven batting of the self liner (barely visible in the photographs) to the textile yarn filling elements 33 of the flexible substrate and to the warp elements ~not shown).
. .
Referring to FIG. 6~ which is a plan view of a portion of the front surface of a third embodiment of the fabric construction of the invention, there are de-picted warp elements 35 in the form of multifilament figure yarns in combination w:ith warp elements 37 in the form of felt-like ribbons, both being joined, as shown in FIGS. 6B and 6C,to the textile filling yarns 39 of the .
flexible substrate by the diagonal laps .40 of the half-tricot stitch courses 41 of the 3-chain/~-half-tricot stitch knitting thread configuration, and, as shown in FIG. 6D, to the fibrous non-woven batting of the flex-ible self-liner by the loops of the knitting thread courses of the wales 43 on the rear surface. of the fabric.
FIG. 6C illustrates the dramatic effect of lo~t ~and 20 bloom 45 of the warp elements 35 and 37 in the region 45 where these elements pass over and in non-secured relation to the chain stitch-courses (not shown) of the knitting thread wales, as contras;ted to the fettered appearance 49 of the.warp elements where they.are 25 secured to the textile filling e~ements 51 by the diagonal laps 53 of the half-tricot stitch courses 41 of the knitting thread. FIG. 6~ also demonstrates the decorative transverse band-like arrangement of the lofted warp element segments created by the alternating chain 30 stitch and half-tricot segments of the knitting thread wales which is inherent in -the use of a single needle guide bar as discussed above in connection with FIGS. 2 and 3.
~eferring to FIG. 7~, which is a plan view of a portion of the front surface of a fourth embodiment of the fabric construction of the invention, substantial
_ -8-1 preferred for use in combination with chain stitches when the fabric includes warp elements laid in rectilinear (straight line) fashion in the warpwise direction because of the normally greater structural integrity imparted to the overall fahric by the half-tricot stitch component of the knitting thread network. In such cases the fabric components are engaged and held together by the loops of knitting thread courses on the rear side of the fabric and by the laps of the ~nitting thread courses on the front surface by which, in the half-tricot stitch regions~ the diagonal segment or laps formed by the knitting thread secures the ~Jarp to the substrate. In this way the warp elements are "lapped" by the sewing thread around the substrate (e.g., textile yarn filling elements~ to achieve an integrated fabric structure. In those regions of the knitting thread network which are made up of chain stitches, such stitches are formed ~f a single knitting thread end which defines a single wale of the thread network.
In one embodiment of the fabric of the invention, at least two warp elements can be laid on the substrate along non-rectilinear paths in the warpwise direction thereby creating a design effect which serves to augment ~he aesthetically pleasing appearance oE the fabric~ More particularly, such warp "design elements" can include portions of substantial lenqth extending diagonally, relative to ~he warpwise direction, along straight lines or curving substantially uniformly. The warp elements can be disposed in groups composed of at least two adjacent elements following a substantlally identical pattern.
Alternatively, adjacent warp elements can be laid on the flexible substrate to form different patterns, e.g., wherein they ~orm the same pattern but one is reversed relative to the other. This fabric design feature and an ~5 apparatus and method for achieving it, which can be . , . .. .... .. _ .. . . . .. .. .. . .
' g~
.
practice~ in conjunction with the present invention, are described respectively in U. S. 3/67~t187, partic~larly at column 1, line 31 through column 3, line 44, and UO S.
3,677,D34, particularly at col~mn 1, linè 44 through 5 column 8~ line 2~, .
In another embodimenl: of the invention, which can, - if desire~, be employ.ed in combination with the embodiment 10 described in the preceding para~raph~ a further aesthetically pleasin~ appear~nce can be obtained by varying a plurality of adjacent warp elements in their relative level positions along the leng~h of the fabric hy twisting them at spaced-intervals along the warp direction in the manner di~closed 15 in the a~orementioned ~. S. Pat. No~ 4,144,727. In particu~ar, the adjacent warp elements which are twisted at spaced intervals along the warpwise direction of the fabric can be laid on the substrate ;n the in.tervals between twists in either mutual1y contacting relationship 20 or can be spaced apart from.one another in ~he weftwise direction at any predetermined distance. Desirably~
such warp elements are substamtially spacea apart in order to amplify the visual e~ect of the twist by contrast.
The degree of "twist" imparted to the warp elements 25 can be any angular amount from greater than ~-C to 36~-although a degree of-twist of desirably at least 90 and preferably 180.~ is preferred in order to maximize thë
visual effect created by the twist.configuration, and to achieve a~true twistin~ or crossing over of the warp 30 elements as opposed to apparent twisting brought about by . proximation of the warp elements without an actual crossing over of s~ch elernents, which apparent twisting obtains when t:he degree of twist is less than 90. In the case of a 180'' twist, opposite warp elements in a group of two or more are caused to exchange places.with each other . ............... ..... .. ...... . . . . ...
. .
1 and then return to their original relativc Dositions along the fabric w.ith each alternate twist. In the rcgions or intervals between the twists, the elements can be laid on the flexible substrate in a substantially rectilinear or 5 straight line fashion parallel to the warpwise directions;
alternatively, as described hereinabove, the warp elements can be caused to follow non-rectilinear paths in conjunc-tion with their t~isted configuration.
In connection with the embodiments described .in the foregoing two paragraphs, it has been discovered, as a further embodiment o the invention, that the lock-stitch knitting thread network can be made up entirely or suhstan-tially entirely o~ looPs of the chain stitch type whereby 15 the warp elements are secured .to the substrate by the knitting thread wales at the points where the warp elements, running diagonally to the warpwise direction~
intersect the knitting-thread wales~ In such cases,.the a~orementioned loft effect in the warp elements is achieved 20 in those regions where such elements do not intersect the knitting thread ~ales, ~articularly where the war elements are substantially parallel to the knitting-thread wales, i.e., ~ in the longitudinal direction. At the same time, the warp 1 elements are effectively secured against running or lifting 25 off by virtue of the exclusively chain stitch nature of the knitting-thread wales, which are substantiall~ immune from unzippering .or unravelling in the longitudinal direction due to the absence of cross lap~ing over a warp element.
3~
In still another em~odiment of the invention, the fabric further comprises a flexible self-liner material disp~sed beneath the flexib]e substrate (which in turn is laid beneath the warp elements). The knitting thread network having the aforementioned lock-stitch configuration, whose loops appear on the rear surfac~
of the lining material, likewise binds together into an integrated self-lined textile fa~ric structure the lining material, the flexihle substrate and the warp elements and secures said com~
ponents against relative displacement. The ~abric of this embodiment achieves a further combination of functional utility and decorative visual effect of aesthetically pleasing ap~earance through the unique placement of the functional lining of flexible material which is disposed behind or beneath the flexible substrate ~e.g.~ of textile filling elements~ and the textile warp elements. In this way, the lining material perEorms its function (e.g., thermal acoustic or optical insulation) without interfering ~ith the unity of warp and filling or obstructing the effect of the intermediate substrate layer (e.g., of filling yarn elements) and the outer lay~r 2~ of warp yarn elements. Such self-lined fabric construction provides practical as well as aesthetically useful composite fabrics in which the lining material performs a definite function (e.g., therm~
insulation) either per se or through various post~treatments (e.g., resin back-coating which also provides a convenient ~ay of achieving ~5 a l'blackout" effect when desired) without interferi~g with the de-corative function of the remaining components of the fabric which 1 are positioned in front of the lining or hacking component.
The flexible lining or bac~ing material cornDonent of the foregoing embodiment is preferably a layer of 5 fibrous non-woven, pre-knitted (e.g., tricot) or ~re-~oven fabric. The use of such lining material.s is particularly advantageous because of the ease with which, say, an ap~lied fibrous non-woven lining can be subse~uentl~
back-coated with a thin layer oE polymer, e.~., acrylic or 10 urethane foam, to impart effective thermal insulating or barrier properties while retaining the desired casement-like "feel" and "look" of the co~posite fabric as a ~hole.
Alternatively, the lining can be any other flexihle material ca~able of being stitched-throuah by ]cnitting 15 thread and secured thereby to the overlying substrate (e.g., filling yarns) and warp elements. Such other lining materials inc]ude, without limitation, synthetic polymeric compositions such as foamed polyurethane, polymeric film, and fi~rous batting, e.g., continuous 20 filament batting, and these can also be given a polymeric back-coatin~, if desired. Examples of embodiments of the invention include fahrics in which the self-liner is a con-I tinuous sheet material in the form of randomly arran-ged highly I dispersed continuous filaments, e.g., spun-bonded continuous 25 filament polyester sold by E. I. du Pont de Nemours & Co.
under the trademark "Reemay", and entangled staPle fiber, e.g., spun-laced polyester staple sold by du Pont under the trade-mark "Sontara". As indicated above, these liners can be bac~-coated with polymeric compositions. Other materials 30 suitable for use as the self-liner of the fabric of the present invention will be apparent to those skilled in the art upon appreciation o~ the present disclosure. In the case where the substrate .is other than a layer of textile filling yarns, e.g., continuous sheet material, a fabric -3~
__ -13-1 is obtained which in effect has two linings.
he self-lined fabric embodiment of the invention can also be heat-honded in pattern design to another fabric by use of Pinsonic type guilting, the details of the application of which to the fabric of this invention will be apparent to those skilled in the art and having the benefit of the present disclosure before them. The self-lined fabric of such embodiment can be either foamed or unfoamed. In this manner, the back of the fabric will be quilted whlle the face side is unquilted.
The fabrics produced in the manner of the present invention employing knitting thread to bind the warp elements and the flexible substrate into an integrated structure have the feature in which the knitting thread pierces the individual warp elements and pierces the flexihle substrate (in the case of filling yarns) at a substantial number of random ppints to further secure the substrate and warp elements against relative displace-ment.
In its broad aspect, the fabrics of the present invention can ~e produced on a stitch-through machine, e.g., a Malimo-type stitch-through machine, by the steps of (a) delivering a flexible substrate to the above-described work zone of the stitch-through type machine and (b) delivering to the work zone conjointly with and in superimposed relation to the substrate a plurality of warp elements. The superimposed warp elements and flexible substrate are bound together at the work zone o the machine by the warpwise knitting thread network to form an inteyrated structure which is the fabric of the present invention in greige orm, and which is ready for urther processing to finished fabric according to art-.
3~L
recogni7e~ procedures, e.g., dyein~, dr~ing, resina~ing,etc.
The particular aspect of the foregoing proced~re which makes possible the formation of the present novel fahric construction is the use oE at least one and preferably a single };nitting thread needle guide bar which can be pro-~rammed, in a manner which will be apparent to those skilled in the art and having the benefit of the present disclosure of the invention before them, to deliver the knittiny thread.s of each wale to the stitching elements in one or more of the - above-described stitching se~uences. In one embodiment the guide bar shaft of a ~alimo machine which carries the stitch-ing yarn guides i5 disconnected from the horizontal motion eccentric and its horizontal motion is derived from and con-trolled by a pattern chain similar to those used on tricot or raschel warp knitting machines for control of their yarn guides.
- The said pattern chain could be driven from the main ~1alimo machine shaft or other shaft by gears, sprockets or timing belts. In this way, it is possible to produce the present ; fabrics at a rate of speed comparable to that at which conven-tional stitch-through fabrics are produced having the nor~al 20 half-tricot stitch knitting thread configuration throughout.
In addition, the use of at least one and preferably a single knittin~ thread needle bar to lay the wales of knitting thread results in a fabric in which the lofted and unlofted portions of the warp yarn elements extend in parallel bands transverselv 25 across the fabric, i.e., in the weftwise direction, there~y irnparting a unique secondary pattern to the "loose look" of the fabric.
. .
Brief Descri~tion of The Drawing -- .
Further details of the present invention and the ad-vantages thereof can be had by reference to the accompanying drawings wherein:
_ FI~. 1 is a plan view of the front surface of a prior ;? art fabric of conventional structure with res~ect to the ~ 35 disposition of the warp elements on the flexible substrate.
~4~
-- -15-. 1 I FIG. 2 is a schematic representation oE the movement of the knitting-needle guicle bar for producing a segment of a stitch-through fabric of the invention;
FIG. 3 is a schematic representation of the movement. of the kni.tting-neec31e guide bar for producing a segment of another type of stitch-through fabric of the invention;
PIG. 4A is a plan view of the front surface oE
a first embodiment of the fabric of the invention;
FIG. 4B is an enlarged front view of a portion of the fabric of FIG. 9A showing the relationship 15 between the elements thereof;
FIG. 4C is a further enlarged front view of a portion of the fabric of FIG. 4A showing the relationship between the flexible substrate and knitting thread;
FIG. 4D is an enlarged plan view of the rear surface of a portion:of the fabric of FIG. 4A;
. FIG. 5A is a plan view of the front surface of a 25 second embodiment of the fahric of the invention;
FIG. 5B is an enlarged front view of a portion of the fabric of FIG. 5A sho~ing the relationship between the elements thereof;
PIG. 5C is a plan view of the rear surface of the fabric of FI~. 5A; and ~ IG. 5D is an enlarged view of the rear surface 35 of a portion of the fabric of FIG. SA.
~ .
_ -16-1 FIG. 6~ is a plan view o~ the front surface of a thircl embodiment of the fabric of the invention;
FIG. 6B is an enlarged ront view of a portion of the fabric of FIGA 6A showi.ng the .relationship between the elements the~eof;
FIG. 6C is a further enlarged front view of a portion of the fabric of FIG. 6~ showing the relationship between the elements thereof., FIG. 6D is a plan view of the rear surface of the fabric of FIG. 6A;
FIG. 7A is a plan view of the front surface of a fourth embodiment of the fabric of the invention;
FIG. 7B is an enlarged front view of a portion of the fabric of FIG. 7A showing the relationship between the elements thereof;
. FIG. 7C is a further enlarged front view of a portion of the fabric of FIG. 7A showing the relationship . between the elements thereof;
FIG. 7D is a plan view of the rear surface of the fabrlc of FIG. 7A.
Description of the Preferred Ernbodiments In the following description, the corresponding elements as shown in each figure of the drawings are given the same reEerence number, and letter sufixes are added to designate specific ones of these elements where necessary.
3~
1 Referring to FIG. 1, there is shown a conventional stitch-through fabric composed of warp yarn elements 1, textile yarn filling elements 3, and knitting thread 5 applied in a half-tricot stitch configuration network 5 throughout. Of particular interest i~ the appearance of the warp yarn elernents 1 which are uniformly secured to the flexible substrate of textile filling elements 3 by virtue of the half-tricot stitch configuration of the knitting thread network. As a result, the fabric l~cks the three-- 10 dimensional appearance of the fabrics of the present inven-tion since the war~ yarn elements are prevented from loft-ing or blooming by the uniformly lapping or binding effect of the half-tricot sti*ches of the knitting thread.
Referring to FIGS. 2 and 3, the horizontal and vertical rows of equally spaced dots 7 represent the knitting needles of the stitch-through machine, and the vertical solid lines 9 represent the placement of the warp elemen-ts relative to the knitting thread 11. Each 20 horizontal row of dots can be visualized as the plan o~
the needle bar, each dot representing one needle head.
The bottom row of points indicates the needle bar at th~
first couxse, the second row indicates the needle bar at the second course, and so on. Thus each vertical column 25 of dots represents the same needies at successive courses, or alternatively, can be taken to represent one wale in the fabric. Since all the knitting thread guides on the single bar are rigidly mounted therein, they all make exactly the same movements at each course, 30 as can be seen in FIG. 2, which depicts the formation o~ a knitting thread lock-stitch configuration com-prising eight consecutive chain stitch courses fol-lowed by three consecutive half-tricot s-titch courses, or in FIG. 3, which depicts the ~ormation of a knitting thread lock~stitch con~iguration comprising a -three-_ ~ t 1 n~edle atlas stitch network.
Referring to FIG. 4A, which is a plan viewof the front surface of a first embodiment of the fabric construction of the invention, the warp elements 13 impart a three-dimensional effect or appearance of depth to the fabric by virtue of t'he ]oft created in those lengths where the warp elements pass over the chain stitch segment of each knitting thread wale lS of the 3-chain/1-half-tricot stitch configuration as depicted in FIG. 4B. FIG. ~C shows in detail the aforementioned configuration of the knitting threads 17 in relation to the textile yarn filling elements 19.
eferring to FIG. 4D, the loops 21 of the knitting thread courses of each wale 15 on the rear side of the fabric of FIG. ~A can be readily seen. These loops bind the non-woven fibrous batting 23 of the self-lin~r to the textile filling yarn substrate 19 and to 20 the warp elements (not shown).
.
Referring ~o FIG. 5A, which is a plan vi-ew of -the front surface of a second embodiment of the fabric construction of the invention, the lofting of the warp - 25 elements 25 can be seen over the chain stitch portion of the 3-chainf'4-half-tricot stitch knitting thread network sho~n in greater detail in FIG. 5B. Since the number~of chain stitches 27 to half-tricot stitches 29 is greater in the fabric of FIG. 5A than in the fabric of FIG. ~A
(both fabrics having the same ~umber of knitting thread courses per unit length), the loft imparted to the warp elements of the former is correspondingly greater.
A'; seen in FIG. 5C and in greater detail in FIG. 5D, the loops 31 of the knitting thread courses 32 on the rear side of the fabric of FIG. 5A bin'd the fibrous _ -19-1 non-woven batting of the self liner (barely visible in the photographs) to the textile yarn filling elements 33 of the flexible substrate and to the warp elements ~not shown).
. .
Referring to FIG. 6~ which is a plan view of a portion of the front surface of a third embodiment of the fabric construction of the invention, there are de-picted warp elements 35 in the form of multifilament figure yarns in combination w:ith warp elements 37 in the form of felt-like ribbons, both being joined, as shown in FIGS. 6B and 6C,to the textile filling yarns 39 of the .
flexible substrate by the diagonal laps .40 of the half-tricot stitch courses 41 of the 3-chain/~-half-tricot stitch knitting thread configuration, and, as shown in FIG. 6D, to the fibrous non-woven batting of the flex-ible self-liner by the loops of the knitting thread courses of the wales 43 on the rear surface. of the fabric.
FIG. 6C illustrates the dramatic effect of lo~t ~and 20 bloom 45 of the warp elements 35 and 37 in the region 45 where these elements pass over and in non-secured relation to the chain stitch-courses (not shown) of the knitting thread wales, as contras;ted to the fettered appearance 49 of the.warp elements where they.are 25 secured to the textile filling e~ements 51 by the diagonal laps 53 of the half-tricot stitch courses 41 of the knitting thread. FIG. 6~ also demonstrates the decorative transverse band-like arrangement of the lofted warp element segments created by the alternating chain 30 stitch and half-tricot segments of the knitting thread wales which is inherent in -the use of a single needle guide bar as discussed above in connection with FIGS. 2 and 3.
~eferring to FIG. 7~, which is a plan view of a portion of the front surface of a fourth embodiment of the fabric construction of the invention, substantial
4~
_ -20-1 lengths of warp elements 55 are disposcd in a non-rectilinear fashion in the general warpwise direction of the fabric and the knitting thread wales 57 consist essentially of chain stitches which bind the warp elements
_ -20-1 lengths of warp elements 55 are disposcd in a non-rectilinear fashion in the general warpwise direction of the fabric and the knitting thread wales 57 consist essentially of chain stitches which bind the warp elements
5 to the textile filling elements at the points 6l whexe such warp elements intersect the knitting thread wales 63 as shown in greater detail in FIGSo 7B and 7C. The loops of the knitting thread courses of each wale 63 also bind the fibrous, gossamer-like non-woven batting of the self-10 liner on the rear surface of the fabric as shown in FIG. 7D~ -The foregoing examples are presented for thepurpose of illustrating, without limitation, the novel single needle bar lock-stitch lofted fahric construction of the present invention. It is understood, of course, that changes and variations therein can be made without departing from the scope of the invention as defined in the following claims.
'.
~9~3~3~
-2l-1 Industrlal ~pplicahility The present invention introduces a novel concept in decorative and functionally useful fal~rics using a stitch-through type machine equipped with a single knitting thread guide bar for feeding the knitting thread to the work zone of the machine so that the other components of the fabric, i.e., the substrate and warp elements, a~e held together by the knitting thread in a lock--stitch configura-tion. In this way the warp elements are secured in such away as to have increased resistance to running which otherwise could occur, particularly at the cut ends of the fabric. The fabric also has imparted to it a decorative lofted appearance in the warp elements which creates the illusion of depth and the appearance of a three-dimensional fabric structure.
Fabrics produced according to the present inven-tion are useful in many decorative and functional applica-tions, including draperies, tablecloths and bedspreads.
.
'.
~9~3~3~
-2l-1 Industrlal ~pplicahility The present invention introduces a novel concept in decorative and functionally useful fal~rics using a stitch-through type machine equipped with a single knitting thread guide bar for feeding the knitting thread to the work zone of the machine so that the other components of the fabric, i.e., the substrate and warp elements, a~e held together by the knitting thread in a lock--stitch configura-tion. In this way the warp elements are secured in such away as to have increased resistance to running which otherwise could occur, particularly at the cut ends of the fabric. The fabric also has imparted to it a decorative lofted appearance in the warp elements which creates the illusion of depth and the appearance of a three-dimensional fabric structure.
Fabrics produced according to the present inven-tion are useful in many decorative and functional applica-tions, including draperies, tablecloths and bedspreads.
.
Claims (13)
1. A fabric made on a stitch-through type machine, comprising:
a flexible substrate;
a plurality of warp elements laid on the substrate in the general warpwise direction; and knitting thread wales extending in the warpwise direction and containing a multiplicity of warpwise stitches in a lock-stitch configuration network having, on a given knitting thread wale, a sequence of three-needle atlas stitch courses, said knitting thread binding together into an integrated structure the substrate and warp elements, to secure the substrate and warp elements against relative displacement, and to stabilize the fabric against un-ravelling of the knitting thread network and lifting off of the warp elements, said fabric having an aesthetically pleasing appearance corresponding to the loft imparted to the warp elements by the intermittent non-binding effect of the lock-stitch knitting thread configuration.
a flexible substrate;
a plurality of warp elements laid on the substrate in the general warpwise direction; and knitting thread wales extending in the warpwise direction and containing a multiplicity of warpwise stitches in a lock-stitch configuration network having, on a given knitting thread wale, a sequence of three-needle atlas stitch courses, said knitting thread binding together into an integrated structure the substrate and warp elements, to secure the substrate and warp elements against relative displacement, and to stabilize the fabric against un-ravelling of the knitting thread network and lifting off of the warp elements, said fabric having an aesthetically pleasing appearance corresponding to the loft imparted to the warp elements by the intermittent non-binding effect of the lock-stitch knitting thread configuration.
2. The fabric according to claim 1 wherein:
said fabric has from 3 to 22 knitting thread wales per linear inch in the weftwise direction; and each knitting thread wale has from 3 to 32 courses per linear inch in the warpwise direction.
said fabric has from 3 to 22 knitting thread wales per linear inch in the weftwise direction; and each knitting thread wale has from 3 to 32 courses per linear inch in the warpwise direction.
3. The fabric according to claim 1 wherein:
said fabric has from 4 to 18 knitting thread wales per linear inch in the warpwise direction; and each knitting thread wale has from 6 to 16 courses per linear inch in the warpwise direction.
said fabric has from 4 to 18 knitting thread wales per linear inch in the warpwise direction; and each knitting thread wale has from 6 to 16 courses per linear inch in the warpwise direction.
4. The fabric according to claim 1 wherein:
said fabric has from 7 to 10 knitting thread wales per linear inch in the weftwise direction; and each knitting thread wale has from 6 to 12 courses per linear inch in the warpwise direction.
said fabric has from 7 to 10 knitting thread wales per linear inch in the weftwise direction; and each knitting thread wale has from 6 to 12 courses per linear inch in the warpwise direction.
5. The fabric according to claim 1 wherein:
the flexible substrate comprises a layer of textile yarn filling elements; and the warp elements are selected from the group consisting of yarns and ribbons.
the flexible substrate comprises a layer of textile yarn filling elements; and the warp elements are selected from the group consisting of yarns and ribbons.
6. The fabric according to claim 1, 2 or 3 wherein one or more of said warp elements in one position cross over on top of one or more adjacent warp elements and, in a second position, cross back under said one or more adjacent warp elements to provide a further aesthetically pleasing appearance corresponding to a twisted configuration of said warp elements at spaced intervals.
7. The fabric according to claim 1 wherein at least two warp elements are laid on the substrate along non-rectilinear paths in the warpwise direction, each warp element including portions of substantial length extending non-parallel to the warpwise direction.
8. The fabric according to claim 7 wherein one or more of said warp elements in one position cross over on top of one or more adjacent warp elements and, in a second position, cross back under said one or more adjacent warp elements for providing a further aesthetically pleasing appearance corresponding to a twisted configuration of said warp elements at spaced intervals in combination with the non-rectilinear disposition of the war elements.
9. The fabric according to claim 1 comprising additionally a flexible lining material underlying the flexible substrate and warp elements such that the substrate is disposed between the lining and warp elements, and wherein the knitting thread engages and holds together the lining material, substrate and warp elements by loops of knitting thread courses on the rear surface of the fabric and by laps of knitting thread courses on the front sur-face of the fabric.
10. The fabric according to claim 9 wherein said fabric is further characterized in having a flexible back-coating of polymeric material.
11. The fabric according to claim 9 wherein one or more of said warp elements in one position cross over on top of one or more adjacent warp elements and, in a second position, cross back under said one or more adjacent warp elements to provide a further aesthetically pleasing appearance corresponding to a twisted configuration of s-aid warp elements at spaced intervals.
12. The fabric according to claim 9 wherein at least two warp elements are laid on the substrate along non-rectilinear paths in the warpwise direction, each warp element including portions of substantial length extending non-parallel to the warpwise direction.
13. The fabric according to claim 12 wherein one or more of said warp elements in one position cross over on top of one or more adjacent warp elements and, in a second position, cross back under said one or more adjacent warp elements for providing a further aesthetically pleasing appearance corresponding to a twisted configuration of said warp elements at spaced intervals in combination with the non-rectilinear disposition of warp elements.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US033,181 | 1979-04-26 | ||
| US06/033,181 US4285216A (en) | 1979-04-26 | 1979-04-26 | Single bar, warp lift-off-resistant, lofted fabric construction |
| CA000347825A CA1150961A (en) | 1979-04-26 | 1980-03-17 | Single bar lock-stitch lofted fabric construction |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000347825A Division CA1150961A (en) | 1979-04-26 | 1980-03-17 | Single bar lock-stitch lofted fabric construction |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1194331A true CA1194331A (en) | 1985-10-01 |
Family
ID=25669054
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000432045A Expired CA1194330A (en) | 1979-04-26 | 1983-07-07 | Single bar lock-stitch lofted fabric construction |
| CA000432046A Expired CA1194331A (en) | 1979-04-26 | 1983-07-07 | Single bar lock-stitch lofted fabric construction |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000432045A Expired CA1194330A (en) | 1979-04-26 | 1983-07-07 | Single bar lock-stitch lofted fabric construction |
Country Status (1)
| Country | Link |
|---|---|
| CA (2) | CA1194330A (en) |
-
1983
- 1983-07-07 CA CA000432045A patent/CA1194330A/en not_active Expired
- 1983-07-07 CA CA000432046A patent/CA1194331A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| CA1194330A (en) | 1985-10-01 |
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| MKEX | Expiry |