Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B39/00—Knitting processes, apparatus or machines not otherwise provided for
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04B—KNITTING
  • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
  • D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials

Definitions

• the present invention relates to an improved process for manufacturing textile products directly from fibers and / or filaments.
• the invention also relates to a device allowing the implementation of the process and extends to the products resulting from the process and / or obtained by said device. Summary of the state of the art.
• each fiber and / or filament is involved in at least one looping, so as to constitute the pseudo-thread obtained by the accumulation of elementary fibers and / or filaments well parallelized. This accumulation in the form of a pseudo-thread takes place directly in the eye of the needles according to the various embodiments represented in the patent.
• loops in the form of pseudo-wire can be secured in various ways, and inter alia to a support. It is also described a finished product where the loops can be organized in the form of rows of stitches, but it does not describe the means of arriving at such a product.
• the same principle of forming a mesh product can be applied to a circular knitting machine where the needles are mounted according to the generatrices of a cylinder and move successively in a uniform rotation in one direction. This optionally makes it possible to place several fixed cams and thus to increase the productivity of the loom. These trades are particularly well suited to the production of "mesh fabric" by the meter but do not allow the production of shaped articles.
• a final type of machine in this first family consists of the Cotton trades. On this type of machine, the thread is not distributed directly to the needles but is gradually distributed to auxiliary members which make it possible to create an undulation in the thread.
• the starting product used to feed the knitting machines be constituted by a fibrous assembly which is in the form either of a sheet of fibers obtained by coating or quilting of an elementary veil, either in the form of a pleated veil in the direction of advance.
• the main object of the present invention is to propose a method and a device for manufacturing textile products directly from fibers and / or filaments as described in patent EP-A-0479880, which make it possible to dissociate the stages of formation of a pseudofilament and the steps for producing the product itself, either as a floor covering or as a mesh product.
• the present invention aims in particular to solve the problem of producing non-standard needles.
• Another aspect of the present invention aims to provide a method and a device which make it possible to propose to manufacture textile products in mesh form by eliminating the spinning step, that is to say by allowing the direct creation of a "spun" thread (twisted, gimped or glued) which is necessary for conventional techniques of mesh (picked mesh techniques) while preserving the specific characteristics of mesh products, which are elasticity, drape, washability, ....
• the present invention aims to propose being able to use fibers and / or filaments directly, including fibers and / or filaments which are particularly difficult to spin to produce mesh products.
• the present invention also aims to achieve the creation of mesh products where the meshes are obtained with a "yarn" having even finer titles than those obtained by conventional spinning techniques.
• the present invention also aims to achieve better color management and more particularly to allow dyeing directly on the fibers without going through the yarn dyeing step just after the spinning step.
• the present invention relates to a process for manufacturing textile products from fibers and / or filaments flowing in the form of a veil, in which the individual fibers and / or filaments are subjected to transverse looping accompanied by stretching, and these fibers and / or filaments are accumulated in the form of at least one wavy pseudo-wire of a certain length in which the fibers and / or filaments are well parallelized.
• these fibers and / or filaments are accumulated against or in picking and transfer elements, these elements picking and transfer will then transfer the pseudo-wire over its entire length, preferably simultaneously, to needles.
• these needles can be tufting needles in order to produce a product such as a floor and / or wall covering.
• the needles can be mesh needles which allow the creation of an additional row of stitches of a mesh product.
• the present invention allows the needles to perform movements of small amplitude while the transfer is carried out by independent picking and transfer elements which carry out, if necessary, a movement of greater amplitude.
• the present invention also relates to the device for implementing the method according to the invention, and which comprises spaced rotary spoilers and disposed on an axis transverse with respect to the advance of the web and between which are spoiler fingers .
• a picking and transfer plate In the extension of each sulking finger is provided a picking and transfer plate on which the fibers and / or filaments intended to form the pseudo-wire come to abut. When this pseudo-wire is created, said picking and transfer plates then transfer said pseudo-wire to needles.
• the needles may be tufting needles intended to secure the pseudo-yarn to a support for the production of a floor covering and / or wall, for example.
• the needles are gill needles, which are intended to use the pseudo-wire for the creation of an additional row of stitches.
• the meshing needles are in the form of two series.
• a first series of meshing needles receive the created thread and create an additional row of stitches; then this first series of meshing needles transfer the same thread to a second series of meshing needles which in turn create a row of stitches.
• This allows the creation of a mesh product in the form of ribs.
• the present invention also relates to textile products in mesh form obtained by the process and the device described above.
• These textile products are essentially characterized by the fact that they have a network of interfering fibers and / or filaments which extends in both directions and which makes the product difficult to dismantle.
• the level of fibers and / or filaments is between 2 and 25%.
• the mesh product is perfectly balanced, so that it has no tendency to twist.
• the present invention also relates to the use of the method or the device according to the present invention for the creation of mesh products of jersey type, of rib type, structured, quilted, vanissized or still jacquard.
• Figure 1 shows a schematic perspective view of a device according to the present invention, intended to create a tufted product.
• 2 shows a side sectional view of the device shown in Figure 1.
• Figure 3 shows a schematic perspective view of a device according to the present invention, for creating a mesh product which is in the form of jersey.
• FIG. 4 represents a side section view of the device represented in FIG. 3.
• FIGS. 5a to 5c represent the theoretical behavior of a fiber through the particular looping step for a device according to the present invention.
• FIGS. 6a to 6f represent a synoptic view of the different stages of the method according to the invention which allows the formation of a jersey mesh product.
• FIG. 7 represents a schematic view of a jersey mesh product obtained according to the method described in FIGS. 6a to 6f.
• FIG. 8 represents a schematic view of the various constituent elements of a device according to the present invention in which the parameters used have been presented in the case of the production of a mesh product.
• Figure 9 shows a side sectional view of a device according to the present invention for creating a mesh product which is in the form of ribs.
• FIGS. 10a to 10f show a synoptic view of the different stages of the method according to the invention allowing the formation of the mesh product in the form of ribs.
• FIG. 11 represents a schematic view of a mesh product in the form of ribs obtained according to the method described in FIGS. 10a to 10f.
• FIG. 12 shows a side sectional view of a device according to the present invention for the creation of a fleece or vanized mesh product.
• FIG. 13 represents a schematic view of a mesh product where an interfering fiber appears.
• Figure 14 shows a perspective view of a device according to the present invention for creating a shaped mesh product. Detailed description of several embodiments of the present invention.
• the devices as described in FIGS. 1 to 4 are devices which would be "grafted" onto a line for preparing a pseudo-wire by the verticalization technique described by European patent EP-A-0479880. This means that all the preparation of the veil in order to obtain a pseudo-yarn, that is to say the working, carding, lapping and prior orientation of the fibers, will essentially be carried out according to the methods described in this European patent.
• a transverse looping is carried out accompanied by a drawing for each individual fiber and / or filament by the interpenetration of metal parts so as to give an undulating shape to each fiber and / or filament.
• the looped elementary fibers are then accumulated, by compression in the direction of advance, in order to constitute a transverse row of loops. This accumulation makes it possible to obtain very good parallelization of the fibers.
• a wire is therefore formed, except for twisting, in the form of an undulation of a desired size or title.
• the density, and more precisely the weight per unit area of the veil of fibers and / or filaments is low, and preferably between 15 and 50 g / m 2 , in order to optimize this creation step wavy wire.
• the majority of the constituent elements of the veil should have an angle of orientation relative to the direction of advance of the veil of between 15 and 45 degrees, and preferably between 20 and 35 degrees.
• Figures 1 and 3 each show a schematic perspective view of two embodiments of a device according to the present invention, in which there is shown each time a series of sets of elements, which are multiplied over the entire width corresponding devices (also called working width), while Figures 2 and 4 show a cross-sectional view where each time appears a single set of elements.
• J the machine gauge (that is to say the number of needles per inch)
• the devices each include a common transverse axis 1, driving a series of sulking elements 3, preferably at a continuous speed of rotation, so that the peripheral speed of the sulking elements 3 is equal to the speed d entry of the veil 0 consisting of fibers and / or filaments.
• These loosening elements 3 are generally loosening discs provided over their entire periphery with a toothing 300. This toothing 300 forms an angle relative to the tangent, which allows the entrainment of the fibers and / or filaments.
• each sulking element 3 is disposed a sulking finger 7.
• the interpenetration of the various sulking elements 3 with the sulking fingers 7 causes looping accompanied by a transverse drawing of the fiber or filament individually (this looping operation will be described in more detail above using Figures 5a to 5c).
• FIGS. 1 and 2 show more particularly a first embodiment intended for the production of a tufted product, and where there have been shown picking plates and transfer 9 transmitting the corrugated yarn obtained by the accumulation of fibers and / or filaments well parallelized to tufted needles 11.
• FIG. 1 and 2 show, in addition to the various elements mentioned above, a series of anvils 2 on which moves the support intended to produce the floor covering. These anvils serve as reaction elements to the penetration of the needles 11 into the support.
• hooks 4 are provided which hold the various loops produced using the pseudo-thread as well as knives 6 used in the case where it is desired to make a covering in the form of cut tuft.
• the picking and transfer plates 9 allow the transfer of the pseudo-wire also obtained by the 'accumulation of fibers and / or filaments well parallelized to mesh needles 21, which themselves ensure the formation of an additional row of stitches. It should be noted that in the various embodiments shown in FIGS. 1 to 4, the transfer of the pseudo-wire takes place simultaneously over its entire length which generally corresponds to the working width, using plates of picking and transfer, which perform exactly the same movement preferably simultaneously.
• the tufting needles 11 or mesh 21 are all mounted on a single movable front 15 or 25 also performing the same movement simultaneously to receive the pseudo-thread and to create either an additional row of loops in a support of floor covering (see figures 1 and 2), i.e. an additional row of meshes (see figures 3 and 4).
• FIGS. 5a to 5c the relationship which exists between the prior orientation of the fibers in the web and the quality of the pseudo-yarn obtained is highlighted. More specifically, in FIGS. 5a to 5c, the theoretical behavior of a fiber has been represented schematically through the looping and pseudo-yarn formation device in which there is: - the axis EE 'which represents the transverse axis of entry into the device (penetration of the discs in the fingers)
• the disks which allow the fibers to advance are not shown.
• FIG. 5a it can be seen that the fiber F0 F3 is already engaged in the device. Its head F0 has just encountered a plate on the axis SS 'and is therefore blocked.
• the points FI, F2, and F3 of the fiber coincide respectively with the points A1, A2 and A3 of the sulking fingers.
• FIG. 5b it can be seen that the discs have caused the fiber to advance (that is to say its displacement along XX ').
• FI slid along the sulking finger Bl B'1 met the axis SS 'and blocked in turn.
• a fiber ripple was thus produced between F0 and FI.
• Either the orientation angle of the fibers in the web is such that:
• Figures 6a to 6f schematically show the different stages of the method according to the present invention in the particular case of the creation of a mesh product in the form of jersey.
• a tufted product essentially takes the same steps as those described in Figures 6a to 6c.
• the subsequent steps consist of penetration of the needle into the substrate and hooking of the pseudo-thread which are conventional operations of tufting not shown.
• the formation and accumulation cycle of the pseudo-yarn in the transfer stage, as regards tufting, is strictly the same as that shown in FIGS. 6a to 6f.
• FIGS. 6a to 6f represent cross-sectional views taken for different phases of the method corresponding to a cycle of formation of a mesh or more exactly of a row of meshes in which:
• FIG. 6a is considered as the basic figure and corresponds to the picking or grasping phase of the wire created.
• the plate 9 is at its top dead center and collects the corrugated wire 100 resulting from the accumulation of the individual fibers looped during the previous cycle.
• This wire 100 is placed by itself in the lug 90 of the plate 9, owing to the fact that it is kept under tension by the action of the teeth 300 of the various looper discs 3 in continuous rotation.
• FIG. 6b corresponds to the preparation phase for wire transfer.
• the plate 9 undergoes a downward movement to meet the mesh needle 11 in order to transfer the corrugated wire 100 to it. It is observed that the mesh needle 21 is present with the eye 210 open (valve 23 in the open position).
• FIG. 6c corresponds to the actual phase of the wire transfer.
• the picking plate 9 deposits the corrugated wire 100 in the eye 210 of the mesh needle 21.
• the stroke of the plate 9 is adjusted so as to exert a slight tension of the wire 100 on the mesh needle 21
• Figure 6d corresponds to the phase of the start of the mesh.
• the transfer has taken place, and the movement of the meshing needle 21 must be accelerated to rapidly release the wire 100 from the lug 90 of the plate 9, in order to prevent the latter from going up a part of said wire 100 with it.
• the valve 23 of the needle 21 is pushed by the preceding stitch and switches so as to close the eye 210 of the gill needle 21.
• FIG. 6e corresponds to the phase of formation of the mesh and the felling thereof.
• the valve 23 of the mesh needle 21 is closed, which allows the penetration of the corrugated wire 100 through the previous row of stitches and allows the formation of a new row of stitches.
• FIG. 6f corresponds to the knitting phase of knitting.
• the meshing needle 21 is returned to its position for receiving a corrugated wire 105.
• the needle has encountered the nose 93 of the plate 9, which blocks the mesh or knitted product in formation and causes the valve 23 of the needle 21 to open.
• the plate 9 is raised upwards in order to collect the new corrugated wire 105 in formation.
• the picking plate 9 remained in "contact" with the end of the corresponding sulking finger 7 in order to allow the formation of a new wire 105 by accumulation of the fibers and / or filaments looped individually , and which will be entered in the next cycle.
• the picking and transfer plates 9 can also serve to block the knitting during the advance of the gill needle 21, as well as allow the opening of the eye 210 of each needle if the latter is closed by a valve or pallet 23. It is also advisable to provide a traction device (not shown) which conventionally provides constant tension on the mesh product being formed.
• the thread tension is controlled by various devices, for example disc brakes. This tension is important because it contributes to certain properties of knitting (tightness, elasticity) and conditions the regularity of appearance.
• the device according to the invention it is possible to adjust the thread tension by varying the length of penetration of the needles into the plates.
• FIG. 7 represents a jersey-type product obtained by the process described in FIGS. 6a to 6f. If we define, as shown in Figure 8:
• FIG. 9 represents a side section view of a mesh device called "double front" which allows the production of mesh products in ribs.
• the needles are separated into two series (series of needles 21 and series of needles 31) arranged on two fronts 25 and 35 forming between them an angle of 90 e .
• the precise arrangement of the needles on the fronts is carried out in a staggered manner so as to allow obtaining ribs 1-1 (that is to say the creation of a column of stitches at the place for a column backwards). It is understood that other arrangements are possible such as the creation of 2-2 ribs or more complex bindings.
• FIGS. 10a to 10f describe in a synoptic manner the different stages of the method according to the invention for the creation of a product with a rib mesh.
• - Figure 10a is considered the basic figure and represents the phase of picking or gripping the wire. This step is completely similar to that described for the process for a jersey product (see Figure 6a). In this case, only the horizontal needles 11 work.
• - Figure 10b corresponds to the phase of transfer of the plate 9 to the first series of horizontal needles 21. Again this step fully corresponds to the transfer step performed in the case of the creation of a jersey product (see Figure 6b).
• FIG. 10c corresponds to the start of mesh phase.
• the horizontal needles 21 drive the wire 100 inside the preceding row of stitches; while the vertical needles 31 are positioned so as to receive the thread. Consequently, the valves 33 of the vertical needles are therefore open.
• the cleaning function is in this embodiment exerted by the horizontal needles 21.
• FIG. 11 represents a product in the form of ribs obtained according to the method described in FIGS. 10a to 10f.
• FIG. 12 represents a side section view of a device according to the present invention allowing the creation of a mesh product based on jersey, but having velvet loops under the back.
• the device according to the present invention is supplied with two sails 01 and 02 which either come from two different cards, or have been pre-stored separately, or come from two combers of the same card. These two webs are treated through two separate sets of sulking discs 301 and 302 and sulking fingers 71 and 72 in order to form two completely independent wires 101 and 102.
• the wire 101 having been looped at a height lower than the looping height of the wire 102.
• the second plate 92 preferably has a truncated shape (absence of a nose 93) to allow the passage of the thread which it deposits, and the plate 91 ensuring only the cleaning function (presence of a nose 93).
• the looped product it is possible to mow the looped product on the back in order to obtain a velvet after mowing.
• the so-called short stitches created by the thread 101 constitute the knitting proper and the long stitches formed by the thread 102 which are partly retained by the knitting produce the velvet.
• the pre-looping heights are identical for the two wires, but two wires are produced from fibers of different types, sizes or colors in order to obtain a vanized product.
• the interfering fibers will appear on the back of the mesh product in the form of loops.
• the product is also foolproof.
• the percentage of interfering fibers is a function of the length of the fibers and the length of the condensation of the veil, that is to say the length of veil necessary to make a wire.
• this rate of interfering fibers is varied between 2 and 25%.
• the interfering fibers can even interfere in three or more rows of stitches. This notion of interfering fibers makes it possible to influence other characteristics of knitting such as elasticity, resistance to pilling, washing behavior, dimensional stability, etc.
• Another example of application of the present invention is the production of products called shaped products which, by sequential knitting, make it possible to directly produce "shaped" products.
• the entry veil is cut in width according to the desired shape and consequently a mesh product of non-constant width is produced (increasing or decreasing).
• edges The main problem 'in the realization of such products is the formation of edges.
• this problem is easily solved because the selvedge will be correctly formed even in the case where the width of the powered web is less than the working width of the elements. Indeed, in the case where the selvedge mesh is poorly formed, the material will nevertheless be extracted from the needle by the neighboring meshes throughout the cycle, which excludes any phenomenon of stuffing.
• the network of interfering fibers will guarantee the blocking of the edge mesh. Nevertheless, it is observed that in practice it is appropriate that the "increases" or “decreases” do not exceed 2 x 2.5 / J, that is to say do not concern more than two needles per row. Indeed in this case, the general draw of the knitting will be enough for the good formation of the edge mesh.
• An improvement consists in using compound needles instead of the traditional needles in order to ensure the opening of the eye during the "increases" (indeed, in the absence of material, the valves of the traditional needles exhibit a completely anarchic behavior).
• the width of the veil can be varied by various techniques such as suction or mechanical or thermal cutting of the veil.
• FIG. 12 represents a particular embodiment of a device intended for the creation of such a shaped mesh product.
• a device of rotary knives 50 and 60
• the cut material not used by the loom can be directly recycled, for example pneumatically upstream of the line.
• the raw material can be stored directly in the form of fibers without the need for intermediate stocks of threads. This means among other things a low value of the inventories generated.
• Another advantage is the immediate adaptation to demand without having to wait for the creation of a thread. It is also possible to envisage an instantaneous, or almost instantaneous, choice of the title of the yarn without it again being necessary to go through a spinning stage. One can also consider the variation of the title directly on the machine by varying for example the height of the loop.
• small series can easily be generated by the introduction into the line of a desired quantity of fibers, for example. From an aesthetic point of view, we can consider the creation of a whole series of fancy yarns (addition of flame, mixture of fibers, ).

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Knitting Of Fabric (AREA)
• Nonwoven Fabrics (AREA)
• Treatment Of Fiber Materials (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Preliminary Treatment Of Fibers (AREA)

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• 1995
  • 1995-09-29 ES ES95935417T patent/ES2210317T3/es not_active Expired - Lifetime
  • 1995-09-29 AT AT95935417T patent/ATE255184T1/de not_active IP Right Cessation
  • 1995-09-29 DE DE69532206T patent/DE69532206T2/de not_active Expired - Fee Related
  • 1995-09-29 US US08/809,626 patent/US5867880A/en not_active Expired - Lifetime
  • 1995-09-29 EP EP95935417A patent/EP0783608B1/de not_active Expired - Lifetime
  • 1995-09-29 AU AU37446/95A patent/AU3744695A/en not_active Abandoned
  • 1995-09-29 JP JP8511404A patent/JPH10506688A/ja not_active Ceased
  • 1995-09-29 WO PCT/EP1995/003871 patent/WO1996010667A1/fr active IP Right Grant

Non-Patent Citations (1)

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