EP0783608B1 - Method and device for producing textile products from fibres and/or filaments, and resulting products - Google Patents

Abstract

PCT No. PCT/EP95/03871 Sec. 371 Date Jun. 18, 1997 Sec. 102(e) Date Jun. 18, 1997 PCT Filed Sep. 29, 1995 PCT Pub. No. WO96/10667 PCT Pub. Date Apr. 11, 1996A method for producing textiles from fibers and/or filaments circulating in the form of a web by performing transverse texturing of the fibers and/or filaments as well as stretching thereof, and collecting the fibers and/or filaments in the form of at least one crinkled pseudo-yarn (100) of a given length in which the fibers and/or filaments are properly parallelized. The method is characterized in that said fibers and/or filaments are collected in or against transfer members (9) separate from the needles and the full length of said pseudo-yarn (100) is transferred to needles (11 or 21) for receiving the pseudo-yarn (100).

Description

Subject of the invention.

The present invention relates to a method advanced manufacturing of textile products directly from fibers and / or filaments.

The invention also relates to a device allowing the implementation of the method.

Summary of the state of the art.

By European patent EP-A-0479880 issued in the name from the Applicant, a new technique called technique of "verticalization" has been proposed to manufacture textile products, and more particularly coatings carpet-type floors and walls, directly from fibers and / or filaments, flowing in the form of a veil. The technique involves subjecting the fibers and / or filaments transverse looping accompanied by stretching, and accumulate these fibers and / or filaments in the form of a pseudo-yarn in which the fibers and / or filaments are parallelized. The pseudo-wire is a non-twisted and wavy wire.

In this document, it is described that the closure transverse accompanied by stretching is carried out for each individual fiber or filament using looping elements rotary or discs spaced apart and arranged on an axis transverse to the web advance, between which are arranged looping fingers. In principle, each fiber and / or filament is involved in at least one closure, so as to constitute the pseudo-thread obtained by the accumulation well parallel elementary fibers and / or filaments. 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.

The main disadvantage of such a provision is that the needles should then be placed right in the extension of the looping fingers, that is to say between the looping discs. Since the needles are items called consumables, that is, they must be replaced regularly due to wear and tear, particular arrangement which is between the discs makes them inconvenient replacement procedures.

In addition, this configuration makes the drawing of pretty unusual needles. Indeed, the tolerances and lengths which they must present are unusual, and thereby make the production of such needles particularly expensive.

It is also described in the alternative in this document that loops in the form of pseudo-wire can be joined in various ways, and among others to a support.

There is also described a finished product where the loops can be organized as rows of but it doesn’t describe how to get there product.

Currently we can basically divide into two large families the various classical techniques of mesh: on the one hand, the techniques known as "mesh" picked ", and on the other hand the techniques known as" sewing-knitting ".

In the first large family, we can cite the rectilinear type knitters where a thread is distributed gradually and therefore successively at each of needles by a device called "thread guide". The needles then slide successively into a fixed front thanks to to the action of a cam which is itself driven with the wire guide by a carriage moving back and forth across the width of the loom.

We can apply the same training principle of a mesh product to a circular knitting machine where the needles are mounted according to the generators of a cylinder and move successively in a rotation uniform in a sense. This eventually allows you to place multiple fixed cams and thus increase productivity of career. These trades are particularly well suited to the realization of "mesh fabric" by the meter but do not not allow the production of shaped articles.

A last type of machine in this first family is made up of Cotton businesses. On this guy machines, the wire is not distributed directly to needles but is gradually distributed to organs auxiliaries that create a ripple in the thread. The undulations which will later form the meshes are then picked simultaneously by the needles that are attached to a movable straight front. These knitting looms are mainly intended for manufacture of shaped panels for clothing. However, the productivity of such trades is not very high.

We can highlight that all techniques belonging to the large knitting family to "picked mesh" use a thread which must have a well defined torque resistance. On the other hand, in in all cases, this thread must be distributed gradually either directly to the needles or to intermediate organs which greatly reduces productivity. Finally, in the case of the production of shaped articles this productivity is further diminished.

The second large family which is made up of techniques called "sewing-knitting" which uses to sheets of fibers or veils as starting material and who are directly processed to obtain a product mesh.

To use these methods, it is necessary that the starting material used to supply the machines of knitting is constituted by a fibrous assembly which present in the form of either a sheet of fibers obtained by covering or quilting of an elementary veil, either under the form of a pleated veil in the direction of advance.

In the first case, gill needles which act like needles on a needle loom come to take fibers from the tablecloth to organize them in the form of chains. Devices using this process are known as "Malivlies" or "Arachne".

In the second case, for the production of products mesh from a pleated veil should be referred to patents DE-A-4235858 plus particularly.

In general, it should be noted that the products obtained by techniques belonging to the great family of "sewing-knitting" although they have a fairly close appearance to the classic jerseys obtained from of sons, cannot in any way be assimilated to these with regard to features such as elasticity, drape, feel, or washability and more especially for everything related to characteristics necessary for clothing use. In effect, in the case of products manufactured by the processes above, we observe that the bad characteristics mainly due to the fact that the same fiber only participates in a small number of meshes (process "Malivlies") or else it is caught accordion inside the same mesh (according to the process using the pleating of a veil) which in a way general allows elongation but offers no elasticity to the product.

Document DE-A-1660779 describes a method of production of a "weft knit" type mesh product (Weft knitting), in which the thread used for mesh construction is arranged transversely to sense of knitting production.

The principle behind the realization of such products consists of creating a pseudo-thread transversely corrugated, in which each corrugation corresponds to the gauge. This pseudo-thread is then picked by needles which act simultaneously.

On the other hand, we observe that the various processes initially using a fibrous mass do not allow sophistication that is allowed by the processes classics using a thread such as making ribs, complex bindings (twists, ...) or the creation of patterns generated by placing needles.

On the other hand, we observe that these various processes only allow the use of specific needles with of a point which make it possible to cross the fibrous sheet, which is a major drawback in the case of a fine gauge and is a source of fragility for needles.

It can be seen that the products obtained by the techniques known as sewing-knitting are mainly intended to be used for "non-woven" applications after chemical consolidation for example in the field of coatings or in the field of technical panels.

Aims of the invention.

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 allow to dissociate the stages of formation of a pseudo-wire and the stages of production of the product itself, as a floor covering, or as a product mesh.

The present invention aims in particular to solve the problem of making needles not standard.

Another aspect of the present invention aims to propose a method and a device which make it possible to offer to manufacture textile products in the form mesh by suppressing the spinning step, i.e. by allowing the direct creation of a "spun" thread (twisted, gimped or glued) which is necessary for conventional techniques mesh (picked mesh techniques) while preserving the specific characteristics of mesh products, which are elasticity, drape, washability, ....

In addition, the present invention aims to propose to be able to directly use fibers and / or filaments, including fibers and / or filaments particularly difficult to wire for making mesh products.

The present invention also aims to achieve the creation of mesh products where the meshes are obtained with a "thread" with even finer titles than those obtained by conventional spinning techniques.

The present invention also aims to achieve better color management and more specifically to allow dyeing directly on the fibers without go through the yarn dyeing stage just after the spinning.

Other advantages and features of this invention will be described in the following.

Main characteristic elements of this invention.

The present invention relates to a method of manufacture of textile products from fibers and / or filaments flowing in the form of a veil, as described in claim 1.

According to a first embodiment, the needles can be tufted needles to achieve a product such as a floor and / or wall covering.

According to another embodiment, the needles. can be gill needles that allow the creation of an additional row of meshes of a product mesh.

The present invention allows the needles perform small amplitude movements while the transfer is carried out by picking plates and independent transfers who carry out, if necessary, a movement of greater amplitude.

It should be noted that these picking plates and transfer can be dimensioned as a minimum that they should no longer assume a function other than the pseudo-wire transfer.

The present invention also relates to device for implementing the method according to the invention, as described in claim 12.

According to a first embodiment, the needles may be tufting needles intended for secure the pseudo-wire to a support for the making a floor and / or wall covering, for example.

According to another embodiment, the needles are gill needles, which are intended to use the pseudo-wire for the creation of a row extra mesh.

According to another embodiment of this invention, the gill needles are in the form of two series. In this case, a first series of needles meshes receive the thread created and carry out the creation of an additional row of stitches; then this first series of gill needles transfer the same thread towards a second series of gill needles which in turn create a row of meshes. This allows the creation of a mesh product to be in the form of ribs.

According to another embodiment, in the case where we want to create curly or vanized mesh products, it is possible to create several pseudo-sons simultaneously by accumulation against picking elements and independent transfers. Then we take turns each of the pseudo-threads created towards gill needles who receive them successively and carry out successively creating an additional row of sts.

These textile products in mesh form obtained by the method and the device described above are essentially characterized by the because they have a network of fibers and / or filaments interfering which extends in both directions and which makes the product difficult to remove. Preferably, the rate of fibers and / or filaments is between 2 and 25%.

On the other hand, we observe that the mesh product is perfectly balanced, so that it does not present no tendency to twist.

The present invention also relates to the use of the method or the device according to the present invention for creating mesh type products jersey, rib type, structured, quilted, vanissized or still jacquard.

Another use would be to create shaped mesh products, that is to say directly in shape.

Brief description of the figures.

Figure 1

represents a schematic perspective view of a device according to the present invention, intended to create a tufted product.

Figure 2

represents a side section view of the device shown in Figure 1.

Figure 3

represents a schematic perspective view of a device according to the present invention, intended to create a mesh product that present in the form of jersey.

Figure 4

represents a side section view of the device shown in Figure 3.

Figures 5a to 5c

represent theoretical behavior of a fiber through the particular stage of loopback for a device according to this invention.

Figures 6a to 6f

represent a synoptic view of different process steps according to the invention which allows the formation of a jersey mesh product.

Figure 7

represents a schematic view of a product jersey mesh obtained by the process described in Figures 6a to 6f.

Figure 8

represents a schematic view of the different components of a device according to the present invention where we presented the parameters used in the case of the production of a mesh product.

Figure 9

represents a side section view of a device according to the present invention intended to create a mesh product that looks like rib shape.

Figures 10a to 10f

represent a synoptic view of different process steps according to the invention allowing the formation of the product mesh in the form of ribs.

Figure 11

represents a schematic view of a product ribbed mesh obtained according to the method described in Figures 10a to 10f.

Figure 12

represents a side section view of a device according to the present invention intended creating a fleece mesh product or vanized.

Figure 13

represents a schematic view of a product mesh where appears an interfering fiber.

Figure 14

represents a perspective view of a device according to the present invention intended to create a shaped mesh product.

Detailed description of several embodiments of the present invention.

The devices as described in Figures 1 to 4 are devices which would be "grafted" onto a line for preparing a pseudo-thread by the technique of verticalization described by European patent EP-A-0479880. This means that all the preparation of the veil in sight to obtain a pseudo-thread, that is to say the working, the carding, lapping and prior orientation of the fibers, will essentially be carried out according to the procedures described in this European patent.

Possibly, we could also adapt the improvement provided for this verticalization device as described in patent application EP-95870093.2.

In practice, to obtain said pseudo-wire, we performs a transverse looping accompanied by a stretching for each individual fiber and / or filament by interpenetration of metal parts so as to give a wavy shape to each fiber and / or filament.

The looped elementary fibers are then accumulated, by compression in the direction of advance, so to form a transverse row of loops. This accumulation provides very good parallelization fibers. At this stage, we therefore constituted, at the twist up close, a wire in the form of a wavy size or desired title.

It is preferable that the density, and more precisely the weight per unit area of the veil of fibers and / or filaments, be low, and preferably between 15 and 50 g / m ² , in order to optimize this creation step. wavy wire.

The majority of the elements should constituent of the veil, that is to say the fibers and / or filaments, have an angle of orientation relative to the direction of advance of the veil between 15 and 45 degrees, and preferably between 20 and 35 degrees.

Figures 1 and 3 each represent a view schematic in perspective of two embodiments of a device according to the present invention, in which each time represented a series of sets of elements, which are multiplied over the entire width of the devices corresponding (also called working width), while that Figures 2 and 4 show a sectional view transverse where only one set appears each time elements.

Indeed, if we define J as the gauge of the machine (i.e. the number of needles per inch), we find J times each of the elements represented in the figures 3 and 4 per inch.

Conventionally, we have represented in these figures a veil 0, made up of fibers and / or filaments, which advances towards the device in order to undergo there transverse to the direction of advance, a closure accompanied by a stretch.

To this end, the devices include each times a common transverse axis 1, resulting in a series looping elements 3, preferably at a speed of continuous rotation, so that the peripheral speed looping elements 3 is equal to the input speed of the veil 0 consisting of fibers and / or filaments.

These looping elements 3 are generally looper discs provided on their entire periphery with a toothing 300. This toothing 300 forms an angle with respect to tangent, which allows the training of fibers and / or filaments.

Between each looping element 3 is disposed a looping finger 7. The interpenetration of different elements curlers 3 with curly fingers 7 causes curl accompanied by a transverse drawing of the fiber or individual filament (this looping operation will be described in more detail above using the figures 5a to 5c).

In the extension of each looper finger 7 is provided with a picking and transfer plate 9, on which come up against the fibers and where they accumulate to form the twist-free wavy pseudo-wire mentioned above. This pseudo-thread is not represented in the different figures 1 to 4.

Figures 1 and 2 show more particularly a first embodiment intended for the realization of a tufted product, and where we have represented picking and transfer plates 9 transmitting the corrugated yarn obtained by the accumulation of fibers and / or filaments well parallelized to tufting needles 11.

It should be noted that the arrangement of tufting needles is, depending on the embodiment described in Figures 1 and 2, a little special, and more specifically these needles are arranged horizontally, while that the support in which the needles will place the pseudo-wire in the form of loops advances vertically towards top to these tufting needles. Figures 1 and 2 present, in addition to the various elements mentioned above, a series of anvils 2 on which the support intended to carry out the covering of ground. These anvils act as reaction elements to needle penetration 11 in the holder. Furthermore, conventionally, are provided with hooks 4 which hold the different loops made using the pseudo-thread as well as knives 6 used in the case where one wishes to make a covering in the form of cut tuft.

According to the other embodiment shown in Figures 3 and 4, which more particularly represent a device intended for the production of a mesh product, the picking and transfer plates 9 allow the transfer of the pseudo-thread also obtained by the accumulation fibers and / or filaments well parallelized to mesh needles 21, which themselves provide the forming an additional row of stitches.

It should be noted that in the different embodiments shown in Figures 1 to 4, the pseudo-wire transfer takes place simultaneously on all its length which generally corresponds to the width of work, using picking and transfer plates, who perform exactly the same movement preferably from simultaneously. Likewise, the tufting needles 11 or mesh 21 are all mounted on a single front mobile 15 or 25 also performing simultaneously the same movement to receive the pseudo-wire and to either create an additional row of loops in a floor covering support (see Figures 1 and 2), i.e. additional row of stitches (see Figures 3 and 4).

Referring to Figures 5a to 5c, we highlight evidence of the relationship between prior orientation fibers in the veil and the quality of the pseudo-yarn obtained.

• l'axe EE' qui représente l'axe transversal d'entrée dans le dispositif (pénétration des disques dans les doigts)
• l'axe SS' qui représente l'axe transversal de sortie ou d'implantation des platines
• les segments tels BB' représentent les doigts boucleurs espacés de la distance correspondant à la jauge J, soit L = 25.4 mm/J. Les disques qui permettent l'avance des fibres ne sont pas représentés.

More specifically, in FIGS. 5a to 5c, the theoretical behavior of a fiber has been shown schematically through the looping and pseudo-wire 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 axis SS 'which represents the transverse axis of exit or implantation of the plates
• the segments such BB 'represent the looping fingers spaced apart from the distance corresponding to the gauge J, ie L = 25.4 mm / J. The disks which allow the fibers to advance are not shown.

In FIG. 5a, it can be seen that the fiber F0 F3 is already engaged in the system. Its F0 head comes from meet a plate on the axis SS 'and is therefore blocked. Points F1, F2, and F3 of the fiber coincide respectively with points A1, A2 and A3 of the fingers loopers.

In FIG. 5b, it can be seen that the disks have caused the fiber to advance (i.e. its displacement according to XX '). During this operation, F1 slid along the looper finger B1 B'1, met axis SS 'and blocked in turn. We thus realized a ripple of the fiber between F0 and F1.

In FIG. 5c, it can be seen that F2 has reached at its turn the axis SS 'and stop. The looping of the fiber between B0, B1 and B1, B2 is finished. The rotation of the disc is continuing will cause the formation of loops over the entire fiber length according to the same logic. It is the accumulation of such individually wavy fibers which will reconstruct a thread of the desired title. We understand that all fibers waving in the same way are found perfectly parallelized in the wire thus formed.

If one defines LFA as the length of fiber necessary for the creation of a loop or a mesh, one thus sees that it is necessary that: LFA = AA1 = A1A2 = ..., that is, the length of the ripple is equal to the LFA.

Either the orientation angle of the fibers in the web is such that: sina = The LFA = 25.4 JxLFA

We also see that if this condition is filled, the tension in the fiber during its looping will be very weak and its integrity will be preserved since the looping or waving of the fiber is induced by its advance and not "forced" by the penetration of the discs inside the curly fingers.

Figures 6a to 6f show so overview of the different process steps according to the present invention in the particular case of creation of a mesh product in the form of jersey.

It should be noted that creating a product tufted basically takes the same steps as those described in Figures 6a to 6c. The next steps consist of the penetration of the needle into the substrate and hooking the pseudo-thread which are operations tufting classics not shown. The cycle of formation and accumulation of the pseudo-wire in the plate of transfer, with regard to tufting, is strictly the same as that shown in the figures 6a to 6f.

• la figure 6a est considérée comme la figure de base et correspond à la phase de cueillage ou de saisie du fil créé. Dans ce cas, la platine 9 est à son point mort haut et recueille le fil ondulé 100 résultant de l'accumulation des fibres individuelles bouclées lors du cycle précédent. Ce fil 100 se place de lui-même dans l'ergot 90 de la platine 9, du fait qu'il est maintenu sous tension par l'action des dents 300 des différents disques boucleurs 3 en rotation continue.
• la figure 6b correspond à la phase de préparation au transfert du fil. Dans ce cas, la platine 9 subit un mouvement vers le bas à la rencontre de l'aiguille maillante 11 en vue de lui transférer le fil ondulé 100. On observe que l'aiguille maillante 21 se présente avec le chas 210 ouvert (clapet 23 en position ouverte).
• la figure 6c correspond à la phase proprement dite du transfert du fil. A ce moment précis, la platine de cueillage 9 dépose le fil ondulé 100 dans le chas 210 de l'aiguille maillante 21. La course de la platine 9 est réglée de manière à exercer une légère tension du fil 100 sur l'aiguille maillante 21.
• la figure 6d correspond à la phase du début de maillage. Dans ce cas, le transfert a eu lieu, et le mouvement de l'aiguille maillante 21 doit s'accélérer pour libérer rapidement le fil 100 de l'ergot 90 de la platine 9, afin d'éviter que celle-ci ne remonte une partie dudit fil 100 avec elle. De même, le clapet 23 de l'aiguille 21 est poussé par la maille précédente et bascule de manière à fermer le chas 210 de l'aiguille maillante 21.
• la figure 6e correspond à la phase de formation de la maille et de l'abattage de celle-ci. Dans ce cas, le clapet 23 de l'aiguille maillante 21 est fermé, ce qui permet la pénétration du fil ondulé 100 à travers la rangée de mailles précédente et permet la formation d'une nouvelle rangée de mailles.
• la figure 6f correspond à la phase de débourrage du tricot. Dans ce cas, l'aiguille maillante 21 est repartie vers sa position de réception d'un fil ondulé 105. L'aiguille a rencontré le nez 93 de la platine 9, ce qui bloque le produit maillé ou tricot en formation et provoque l'ouverture du clapet 23 de l'aiguille 21. Pendant ce temps, la platine 9 est remontée vers le haut afin d'aller recueillir le nouveau fil ondulé 105 en formation.

More particularly, 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:

• Figure 6a is considered as the basic figure and corresponds to the picking or gripping phase of the wire created. In this case, 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, because it is kept under tension by the action of the teeth 300 of the various looping discs 3 in continuous rotation.
• Figure 6b corresponds to the preparation phase for wire transfer. In this case, 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).
• Figure 6c corresponds to the actual phase of wire transfer. At this precise moment, 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 .
• FIG. 6d corresponds to the phase of the start of the mesh. In this case, 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. Likewise, 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 of the felling thereof. In this case, 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.
• Figure 6f corresponds to the knitting phase of knitting. In this case, 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 opening of the valve 23 of the needle 21. During this time, the plate 9 is raised upwards in order to collect the new corrugated wire 105 in formation.

During all the operations mentioned above, the picking plate 9 has remained in "contact" with the end of the corresponding looper finger 7 in order to allow the formation of a new wire 105 by accumulation individually looped fibers and / or filaments, which will be entered in the next cycle.

Advantageously, it is observed that there is no thread sliding in the eye 210 of the needle 21, this which allows an increased longevity of the needles meshing.

It has been experimentally determined that strippers as described in patent n ° EP-A-0479880 were only useful from a cleaning angle of 30 °. This angle, for the pre-loop heights required in mesh, is reached for a larger disc diameter at 120 mm. If this condition is met the strippers can be deleted. This increases the angle as well that the depth of the teeth 300 of the disc (because any risk of trapping between the discs and the strippers is removed) therefore to increase the pressure exerted by the fibers on the barrel of the turntables and between them. This results in a easy accumulation in the lug 90 of the plate 9 and a grouping of fibers in the form of a "strand" accentuating the yarn look in the finished product.

Advantageously, in the case of the realization of a mesh product, picking and transfer plates 9 can also be used to block knitting when advancing of the mesh needle 21, as well as allowing the opening eye 210 of each needle if it is closed with a valve or pallet 23.

It is also advisable to provide a device for traction (not shown) which conventionally provides constant tension on the mesh product being formed.

It should be noted that the working needles simultaneously and that by nature knitting being elastic, it is imperative that the friction forces induced by the front of the needles 21 and the opening of the valve 23 of the needles are compensated by another "stripper system" which in this case consists of the nose 93 of turntables 9.

When training a knit on a loom conventional, the thread tension is controlled by various devices, for example disc brakes. This tension is important because it contributes to certain properties of the knitting (tightness, elasticity) and conditions its regularity appearance.

In the device according to the invention, it is possible to adjust the thread tension by playing on 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.

• PB comme la hauteur de prébouclage correspondant à la LFA souhaitée (PB ≈ LFA/2), et
• LM comme la longueur dont l'aiguille pénètre dans la platine,

dans ce cas, la tension communiquée au fil sera fonction de LM - PB. On constatera que ce réglage dépend de paramètres mécaniques du métier et est aisé, parfaitement reproductible sur l'arasement et dans le temps, et contribue donc à une excellent régularité du tricot réalisé.If we define, as shown in Figure 8:

• PB as the pre-loop height corresponding to the desired LFA (PB ≈ LFA / 2), and
• LM as the length of which the needle enters the stage,

in this case, the voltage communicated to the wire will be a function of LM - PB. It will be seen that this adjustment depends on mechanical parameters of the loom and is easy, perfectly reproducible over the leveling and over time, and therefore contributes to an excellent regularity of the knitted fabric produced.

In practice we will not exceed a few percent to avoid breakage of needles.

It is of course conceivable to use gill needles other than valve needles (or palette) described as compound needles (or needles needle), needle needles, mesh needles returned, etc.

Figures 9, 10 and 11 describe a third embodiment of a device according to the present invention intended for the production of mesh products presenting themselves in the form of ribs.

More particularly, FIG. 9 represents a side section view of a mesh device called "double front" which allows the realization of products ribbed.

For this device, the needles are separated in 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 °. In addition, the precise provision of needles on the fronts is staggered to allow the obtaining of 1-1 ribs (i.e. creating a column of stitches at the place for a backward stitch). It is understood that other provisions are possible such as the creation of 2-2 ribs or more complex bindings.

Nevertheless it should be noted that there are two times more needles 21 and needles 31 than disc elements looper 3, looper finger 7, or turntable 9. Indeed, if J is the desired gauge for knitting, J / 2 will be the gauge for the other elements (discs, fingers, and turntables transfer).

Figures 10a to 10f describe so overview of the different process steps according to the invention for the creation of a ribbed mesh product.

• la figure 10a est considérée comme la figure de base et représente la phase de cueillage ou de saisie du fil. Cette étape est totalement similaire à celle décrite pour le procédé destiné à un produit jersey (voir figure 6a). Dans ce cas, seules les aiguilles horizontales 11 travaillent.
• la figure 10b correspond à la phase du transfert de la platine 9 vers la première série d'aiguilles horizontales 21. A nouveau cette étape correspond totalement à l'étape de transfert effectuée dans le cas de la création d'un produit jersey (voir figure 6b).
• la figure 10c correspond à la phase de début de maillage. Dans ce cas les aiguilles horizontales 21 entraínent le fil 100 à l'intérieur de la rangée de mailles précédentes; tandis que les aiguilles verticales 31 sont positionnées de manière à recevoir le fil. Par conséquent, les clapets 33 des aiguilles verticales sont donc ouverts. La fonction de débourrage est dans cette forme d'exécution exercée par les aiguilles horizontales 21.
• la figure 10d correspond à la phase du deuxième transfert des aiguilles horizontales 21 vers les aiguilles verticales 31. Dans ce cas les aiguilles horizontales 21 sont à leur point mort arrière et viennent de terminer la constitution des mailles correspondantes. La distance de pénétration à l'intérieur de la platine d'abattage 19 dans le cas des aiguilles horizontales 21 correspond approximativement à la hauteur de prébouclage. Le fil 100 se trouve alors tendu sur les aiguilles horizontales 21.
• la figure 10e correspond à la phase de fin de maillage. Dans ce cas les aiguilles horizontales 21 se sont avancées pour permettre aux aiguilles verticales 31 de former à leur tour les mailles. Les mouvements des frontures 25 et 35 permettent au fil de rester tendu pendant cette opération. A cet instant, les distances de pénétration des aiguilles à l'intérieur de leur platine d'abattage respective sont identiques et correspondent à la LFA du tricot.
• la figure 10f correspond à la phase de débourrage du tricot. Dans ce cas les aiguilles horizontales 21 s'avancent et le débourrage est réalisé grâce au maintien du tricot par les aiguilles verticales 31 et éventuellement avec l'aide du nez 93 de la platine 9. A ce moment l'ouverture du clapet 23 des aiguilles horizontales 21 peut avoir lieu et réceptionner le nouveau fil 105 destiné à la création de la maille suivante.

More particularly, these figures represent cross-sectional views taken for different phases of the process in which:

• FIG. 10a is considered as 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.
• FIG. 10b corresponds to the phase of transfer of the plate 9 to the first series of horizontal needles 21. Again this step completely corresponds to the transfer step carried out in the case of the creation of a jersey product (see figure 6b).
• Figure 10c corresponds to the start of mesh phase. In this case 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. 10d corresponds to the phase of the second transfer from the horizontal needles 21 to the vertical needles 31. In this case the horizontal needles 21 are at their rear dead center and have just finished constituting the corresponding meshes. The penetration distance inside the felling plate 19 in the case of horizontal needles 21 corresponds approximately to the pre-closing height. The wire 100 is then stretched over the horizontal needles 21.
• Figure 10e corresponds to the end of mesh phase. In this case the horizontal needles 21 have advanced to allow the vertical needles 31 to in turn form the stitches. The movements of the fronts 25 and 35 allow the wire to remain taut during this operation. At this instant, the penetration distances of the needles inside their respective felling stage are identical and correspond to the LFA of the knitted fabric.
• Figure 10f corresponds to the knitting phase of knitting. In this case the horizontal needles 21 come forward and the cleaning is achieved by maintaining the knitting by the vertical needles 31 and possibly with the help of the nose 93 of the plate 9. At this time the opening of the valve 23 of the needles horizontal 21 can take place and receive the new wire 105 intended for the creation of the next stitch.

Figure 11 shows a product in the form of ribs obtained according to the method described in Figures 10a to 10f.

Figure 12 shows a side sectional view of a device according to the present invention allowing the creation of a jersey-based mesh product, but with velvet loops on the underside.

In FIG. 12, the device is powered according to the present invention with two sails 01 and 02 which either come from two different cards, either have been preset separately, either from two painters from one same card. These two sails are treated through two separate sets of 301 and 302 looper discs and looper fingers 71 and 72 to form two wires 101 and 102 fully independent. Preferably, it is expected that the two sons 101 and 102 were cordoned off at heights different. Wire 101 having been looped at a height less than the loop height of the wire 102. Then these wires are distributed in turn during the same cycle by two plates 91 and 92 to a single series of needles mesh 21 and mesh according to the logic of jersey previously described in Figures 3 to 6. The second platinum 92 preferably has a truncated shape (absence nose 93) to allow the passage of the wire which it deposits, and the plate 91 ensuring only the cleaning function (presence of a nose 93).

According to a preferred embodiment, it is possible to mow the looped product upside down in view to obtain a velvet after mowing. In this case the meshes say short created by the wire 101 constitute the knitting to properly speaking and the long meshes formed by the yarn 102 which is partly retained by knitting realize velvet.

According to another embodiment, one can envisage that the pre-loop heights are identical for two threads but we make two threads from fibers nature, title or different color in order to obtain a vanized product.

The products obtained according to the processes and devices described in figures 3 to 12 all present an essential characteristic which is non-runability (or the fact of making a product difficult to dismantle) due to the existence of a network of interfering fibers. In effect, at the end of the formation of a thread, certain fibers may on the one hand have an end which participates in the creation of a first wire while the other end is still present in the looper system and participates by consequent to the creation of the following thread. Therefore, as shown in Figure 13, the same fiber can participate in the formation of two rows of meshes consecutive. Such fibers are called fibers interfering.

• LI qui est la distance entre l'axe de formation des mailles et qui conditionne la longueur moyenne des fibres interférentes.

If we take the definitions and parameters given in Figure 6, we have:

• LI which is the distance between the axis of formation of the meshes and which conditions the average length of the interfering fibers.

In the case where LI is close to PB (i.e. in the case where LI <3PB), the interfering fibers will be stretched between two consecutive rows and will not appear visually on the back of the product. In this case the fibers will increase the cohesion of the product by making it very difficult to dismantle whatever the binding (product type jersey or rib).

In the case where LI is much higher than PB (with the condition LI> 3PB), the interfering fibers will appear on the back of the mesh product in the form of loops. In in this case the product is also foolproof.

The percentage of interfering fibers is a function the length of the fibers and the length of the condensation of the veil, i.e. the length of the veil necessary to make a thread. Preferably, we do vary this rate of interfering fibers between 2 and 25%. In in some cases the interfering fibers can even interfere with 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, ....

Another important feature of the products obtained is that the mesh is perfectly balanced, that knitting has no tendency to twist even in the case of making a product in the form of jersey.

Other improvements and products may be of course envisioned such as the creation of pseudo-jacquard by direct relationship on the veil before entering the trade or by the composite nature of knitting due to the superposition of several sails.

Another example of application of this invention is the making of products called products shaped which by a sequential knitting allow to realize directly from "fit" products. According to this aspect, we cut in width the entry veil according to the desired shape and therefore we produce a mesh product with a width not constant (increasing or decreasing).

The main problem in the realization of such products lies in the formation of selvedges. According to present invention, this problem is easily solved because that the selvedge will be correctly formed even if the width of the powered sail is less than the width of work of the elements. Indeed, in the case where the mesh of edge is poorly formed, the material will nevertheless be extracted of the needle through neighboring stitches throughout the cycle which excludes any phenomenon of jamming. In addition, the network of interfering fibers will guarantee the blocking of the meshes of edge. Nevertheless, we observe that in practice it is appropriate that "increases" or "decreases" do not exceed 2 x 2.5 / J i.e. not more than two needles per row. Indeed in this case, the general draw of the knitting will suffice for the proper formation of edge mesh.

An improvement is to use needles compound instead of traditional needles to ensure the opening of the eye during the "increases" (indeed, in the absence of material, the needle valves behave completely anarchic).

The veil width can be varied by various techniques such as suction or cutting mechanical or thermal of the veil.

Figure 12 shows an embodiment particular of a device intended for the creation of such shaped mesh product. In this case, a rotary knives (50 and 60) is used to increase cutting efficiency. Possibly, we can consider the provision of several sets of rotary knives so to increase the degree of shaping and in particular in the when making a sweater, a game allows you to separate the body sleeves and another set of knives allows make the neckline. The cut material not used by the loom can be directly recycled, for example so pneumatic upstream of the line.

An important goal of the process is to increase the productivity. Indeed, several aspects participate in increasing that productivity. We can cite different factors that play an important role in the increase in this productivity: the elimination of the spinning stage, the increase in work rates by creating movements of small amplitudes, the simultaneous work of all needles, ....

From an economic point of view, the use of a process according to the present invention makes it possible to obtain gains of up to a factor of 100 in favor of the processes according to the invention compared to the methods using separate spinning techniques.

The fact that it is not necessary to perform a intermediate independent spinning stage for creation a wire allows to obtain many other advantages.

In particular, we can cite by way of example the the fact that the raw material can be stored directly in the form of fibers without having to constitute intermediate stocks of yarn. Among other things, this means low value of inventories generated.

Another advantage is the adaptation immediately on demand without having to wait for the creation of a thread. We can also consider an instant choice, or almost instant, of the title of the thread without it being again necessary to go through a spinning stage. We can also consider the variation of the title directly on the machine by varying for example the height of the loop.

By the process of the present invention, one can also consider that small series could be easily be generated by entering the line a desired amount of fiber, 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, ...).

The savings will also be maximum in the case of sophisticated yarns (fancy or composite yarns), purposes (the process according to the invention would make it possible to obtain titles even finer than those obtained using techniques conventional spinning) and in the case of use fibers which are difficult to spin, such as recovery, ultra-fine fibers or even fibers techniques.

In conclusion, the different forms of execution methods and devices described above allow all to dissociate the stage of the formation of a pseudo-thread the stage of making the product itself, which can be either a flooring product or a mesh product. This allows that one can advantageously use conventional tufting machine parts or mesh machines by producing directly from of fibers and / or filaments the products concerned.

Claims (24)

1. A method for manufacturing textile products from fibres and/or filaments travelling in the form of a web having a weight ranging from 15 to 50 g/m² and wherein most of the fibres and/or the filaments have an orientation angle to the forward direction of the web ranging from 15 to 45 degrees, wherein by means of rotary looping elements (3) spaced apart and arranged on a transverse axis (1) relative to the web (0) forward movement and between which are arranged looping fingers (7), the fibres and/or the filaments are subjected to a transverse looping step followed by a drawing step and wherein the fibres and/or filaments are accumulated in the form of at least one wavy pseudo-yarn (100) with a given length, wherein the fibres and/or filaments are well parallelized, characterized in that said fibres and/or filaments are accumulated against picking and transfer sinkers (9) provided in the extension of each looping finger (7), and in that the pseudo-yarn (100) is intermittently transferred over its whole length by means of said picking and transfer sinkers (9) towards needles (11 or 21) receving said pseudo-yarn (100).
2. A manufacturing method according to claim 1, characterized in that the picking and transfer sinkers (9) simultaneously perform the same movement for receiving the fibres and/or filaments and transferring the pseudo-yarn (100) obtained with the fibres and/or filaments being accumulated towards the needles (11 or 21).
3. A manufacturing method according to claim 1 or 2, characterized in that the needles receiving the pseudo-yarn (100) are tufting needles (11).
4. A manufacturing method according to claim 1 or 2, characterized in that the needles receiving the pseudo-yarn (100) are stitching needles (21).
5. A manufacturing method according to claim 3 or 4, characterized in that the tufting needles (11) or the stitching needles (21) simultaneously perform the same movement for receiving the pseudo-yarn (100) and creating an additional row of loops or stitches.
6. A manufacturing method according to any one of the preceding claims, characterized in that the movements of the needles (11 or 21) are of very low amplitude, whereas the movements of the picking and transfer sinkers (9) are of higher amplitude.
7. A manufacturing method according to any one of preceding claims 4 to 6, characterized in that the picking and transfer sinkers (9) block the stitched product when the stitching needles (21) move forward.
8. A manufacturing method according to any one of claims 4 to 7, characterized in that a first series of stitching needles (21) receive the pseudo-yarn (100), perform the creation of a row of stitches and then transfer said pseudo-yarn (100) towards a second series of stitching needles (31) creating in turn a row of stitches.
9. A manufacturing method according to claim 8, characterized in that both series of needles (21 and 31) are arranged on front parts (25 and 35) forming therebetween a 90 degree angle, both series of needles being arranged in a staggered manner.
10. A method according to any one of preceding claims 4 to 9, characterized in that several wavy pseudo-yarns (101 and 102) are simultaneously created through accumulation against several series of picking and transfer sinkers (91 and 92), in that by means of a series of picking and transfer sinkers (91 or 92) , each yarn (101 or 102) is in turn transferred towards stitching needles (21) successively receiving each of the yarns and then allowing the subsequent creation of an additional row of stitches.
11. A manufacturing method according to any one of preceding claims 4 to 10, characterized in that the web width is continuously adapted to the width of the desired finished product.
12. A device for implementing the method according to any one of the preceding claims, comprising rotary looping elements (3) spaced apart and arranged on a transverse axis (1) relative to the web (0) forward movement and between which are arranged looping fingers (7), picking and transfer sinkers (9) arranged in the extension of each looping finger (7) and against which the fibres and/or the filaments are abutting so as to form a wavy pseudo-yarn (100), needles (11 or 21) arranged downstream said sinkers provided for receiving the pseudo-yarn (100) so as to create an additional row of loops or stitches and means for moving said sinkers (9) for intermittenly transferring said pseudo-yarn (100) over its whole length towards the needles (11 or 21).
13. A device according to claim 12, characterized in that the needles are tufting needles (11) intended for producing a floor and/or wall covering.
14. A device according to claim 12, characterized in that the needles are stitching needles (21) intended for producing a stitched product.
15. A device according to claim 14, characterized in that the picking and transfer sinkers (9) have a stud (90) intended for receiving the fibres and/or filaments so as to create the wavy pseudo-yarn (100) .
16. A device according to claim 14 or 15, characterized in that the picking and transfer sinkers (9) have a nose (93) allowing to block the stitched product when the stitching needles (21) are moving forward.
17. A device according to any one of claims 14 to 16, characterized in that the stitching needles are separated into two series (21 and 31) for successively processing the wavy pseudo-yarn (100).
18. A device according to claim 17, characterized in that there are twice as many needles (21 and 31) as looping discs (3), looping fingers (7) or picking and transfer sinkers (9).
19. A device according to claim 18, characterized in that both series of needles (21 and 31) are arranged on moveable front parts (25 and 35) arranged at 90 degrees.
20. A device according to any one of claims 17 to 19, characterized in that the needles from both series of stitching needles (21 and 31) are arranged in a staggered manner.
21. A device according to any one of claims 14 to 20, characterized in that two separate sets of looping discs (301 and 302) and looping fingers (71 and 72) are provided so as to form two totally independent pseudo-yarns (101) and (102) which are successively transferred using two series of elements (91 and 92) towards a single series of stitching needles (21) .
22. A use of the method according to any one of claims 1 to 3 or of the device according to claim 12 or 13 for creating a tufted floor and/or wall covering of the carpet type.
23. A use of the method according to any one of claims 4 to 11 or of the device according to any one of claims 14 to 21, for creating stitched, jersey, ribbed, textured, quilted, plaited as well as jacquard products.
24. A use of the method according to any one of claims 4 to 11 or of the device according to any one of claims 14 to 21 for creating figured products.

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