GB2059468A - Multiple filling layer stitch- trough fabrics and method and apparatus therefor - Google Patents

Abstract

A stitch-bonded type fabric produced in a stitch-through type machine comprises: (a) a flexible substrate in the form of two or more superimposed filling layers (2, 4) each consisting of one or more parallel continuous textile elements extending obliquely across the width of the fabric; and (b) a single system (5) of knitting thread wales extending along the length of the fabric, each wale comprising a multiplicity of looped stitch courses which secure the superimposed filling layers against relative displacement by loops on the rear surface of the fabric and by laps on the front surface. The method and apparatus involve delivering the filling layers obliquely between and in engagement with two parallel endless rows of advancing hooked leaded units by a corresponding number of comb-like carriages each adapted for synchronous reciprocating movement in a direction perpendicular to the leaded units. <IMAGE>

Description

SPECIFICATION Multiple filling stitch-through fabrics and method and apparatus therefor This invention relates to fabrics which are produced on stitch-through type machines such as a Malimo machine. More particularly, it relates to a novel improved Malimo-type fabric and to an apparatus and method used in making it wherein the improvement resides in the provision of a special filling yarn carriage whereby heretofore unattainable Malimo fabric designs can be achieved.

Malimo fabrics typically comprise a flexible substrate such as a layer of substantially parallel selvage-to-selvage textile filling elements or ends which are joined together into an integrated structure by means of relatively fine knitting threads. In the case where the flexible substrate is a layer of textile filling yarn elements, a more or less open mesh fabric can be obtained by controlling the spacing between the individual yarn elements. This and other "stitch-through" type non-woven fabric structures can be obtained on machines of the "Malimo" type, using methods and equipment described in U.S. Pat. Nos.

2,890,579; 3,030,786: 3,253,426; 3,274,806; 3,279,221; 3,309,900; 3,389,5831 3,392,078; 3,440,840; 3,452,561; 3,457,738; 3,460, 599; 3,540,238; 3,541,812; 3,567,565; 3,592,025; 3,672,187; 3,677,034; 4,144,727; and U.S. Re.

Pat. No. 25,749.

The ability to readily mass produce a basic fabric in a variety of patterns is extremely important to the commerical success of the fabric.

While non-woven fabrics can be produced on "Malimo"-type machines at relatively high speeds compared to the production of woven fabrics, much attention has been given to augmenting this desirable feature with design flexibility, not only with respect to the density, gage, and color combinations of the textile components, the spacing between them, and the purposeful omission of one or more of such components, but also with respect to the spatial configuration of the textile components in the fabric. In particular, there is a need for Malimo fabrics of still greater design flexibility, particularly with respect to the creation of unusual visual effects.The present invention makes possible an enhanced variety of patterns in which multiple layers of filling elements are disposed in the general width-wise or transverse direction of the fabric obliquely and in different angles with respect to the length-wise or longitudinal direction. Heretofore, there has been no means or method by which such an effect could be achieved on Malimo machines at commerical production speeds.

Accordingly, it is an object of the present invention to provide fabrics such as are produced on stitch-through type machines having enhanced design flexibility in the filling component.

A further object is to provide apparatus for producing fabrics on stitch-through type machines having enhanced design capabilities with respect to the filling.

Yet another object is to provide a method for producing fabrics on stitch-through type machines having enhanced design capabilities with respect to the filling.

These and other objects of the invention as weil as a fuller understanding of the advantages thereof can be had by reference to the following detailed description, drawings and claims.

The foregoing objects are achieved according to the present invention in the form of novel stitch-bonded fabrics such as Malimo-type fabrics of unique and heretofore unattainable design and aesthetic appearance and which are produced by an apparatus and method wherein the flexible substrate component is laid down during fabric formation in the form of two or more layers of parallel textile filling elements in predetermined widths obliquely across the width of the fabric and in superimposed relation to each other.Such variation in the configuration of the flexible substrate cannot be achieved using conventional Malimo-type machines whose design inherently restricts the fabrics produced thereon to constructions in which the flexible substrate is laid down in the form of a single layer in adjacent or sequential bands of a single width and at a fixed angle (generally slightly off-perpendicular to the direction of feed to the stitching elements).

In particular, fabrics made on stitch-through type machines according to the present invention comprise two or more superimposed filling layers of the same or different widths each consisting of one or more parallel continuous textile elements or ends extending obliquely across the width of the fabric (i.e., from selvage to selvage), and in which the elements of one filling layer can be more or less non-parallel to the elements of another filling layer.Each fabric also includes a single system of knitting thread wales extending along the length of the fabric, each wale comprising a multiplicity of looped stitch courses which engage and secure the superimposed filling layers against relative displacement by loops of knitting thread on the rear surface of the fabric and by the laps of the knitting thread courses on the front surface of the fabric to bind the superimposed filling layers into an integrated textile fabric structure having two or more times the filling thickness of conventional stitch-bonded fabrics. The knitting thread pierces the individual obliquely disposed textile filling elements at a substantial number of random points to further secure the fabric components against relative displacement.

In one of its embodiments the fabric of the invention contains two superimposed filling layers, and desirably in which at least one of the filling layers contains a plurality of textile yarn elements disposed, e.g., in a rearward position on the fabric in relation to the other filling layer, wherein the rearward or bottom filling layer becomes the "ground layer". Preferably, the fabric contains three or more superimposed filling layers of textile yarn elements, e.g., wherein at least one of the filling layers contains a plurality of textile yarn elements and which is preferably disposed in a rearward position on the fabric in relation to the other filling layers.In the case of fabrics having the open-mesh "home spun" appearance characteristic of casement or drapery fabrics, the parallel textile elements constituting each of the filling layers can be more or less spaced apart from one another to achieve such effect. In addition, the invention makes possible a variety of colored and/or textured filling layer design patterns undiluted on a filling base or ground layer. For example, the present invention makes possible putting a layer of one or more textile filling elements on top of, rather than mixed in with and diluted by, the textile filling elements of an underlying ground layer.

In addition to the aforemention plurality of superimposed filling layers, the flexible substrate can include optionally a pre-knitted or pre-woven fabric, an elastomeric foam sheet, fibrous batting (e.g., non-woven spun bonded fibrous batting) or any other continuous sheeting or flexible structure capable of being stitched through by knitting thread and secured thereby to the other fabric components without substantial loss of strength according to procedures described in the reference mentioned hereinabove and now famiiiar to those skilled in the art of stitch-through fabric formation.

Broadly, the apparatus of the invention is an improvement over and departure from prior stitchthrough type machines which typically comprise mechanicai stitching elements conventionally employed on stitch-through type machines. These elements and their mode of operation are wellknown to those skilled in the art and include a comb-like sinker bar and a comb-like retainer pin bar which together define an elongated space or work zone for the formation of fabric between them, means for delivering a flexible substrate to the aforesaid work zone, and a row of sharppointed, bearded (i.e., pronged) needles and corresponding closing wires the combination of which together with a row of sewing or knitting thread guides co-act in such a way that the needles pierce the substrate by moving in reciprocating fashion back and forth across the fabric formation space between the sinker bar and retainer pin bar. This action causes the thread to form a single system of longitudinal (i.e., machine wise) knitting thread wales each comprising a multiplicity of looped stitch courses along the length of the fabric, e.g., in a chain stitch or half tricot stitch configuration.In particular, the improvement of the invention resides in the nature of the delivery means for conveying the flexible substrate to the work zone of the machine for fabric formation, which means comprises two or more and preferably three or more comb-like or reed-iike carriages of the same or different widths, preferably from 4 to 18 inches, each adapted for reciprocating movement in synchronization with the other carriage(s) whereby a filling layer of predetermined width and consisting of a group of one or more parallel continuous textile elements is independently conveyed back and forth between and across two parallel endless rows of hooked leaded units (so-called "filling hooks") in a direction substantially transverse to the direction of movement of the filling hooks (i.e., transverse to the direction of delivery of the filling layers to the fabric formation zone). Whereas prior Malimo-type machines were capable of merely simulating a double filling laydown (by running the machine slowly and the filling carriage rapidly), the present invention makes possible a true multiple filling laydown with novel decorative fabric effects by virtue of the present indepently driven multicarriage apparatus.

In cases where it is desired to produce fabrics having a layer of warp elements superimposed on the multilayer flexible substrate, the machine can be equipped with any desired warp element delivery means for feeding conjointly with and in superimposed relation to the flexible substrate one or more warp elements in a generally lengthwise direction. The warp elements are then united with the substrate by the aforementioned system of knitting thread wales in the fabric formation zone of the machine. Exemplary of such warp element delivery techniques are those described in U.S.

Pat. Nos. 3,672,187; 3,677,034 and 4,144,727.

It is understood that the presence or absence of warp elements or other textile components as well as their distribution or configuration on the fabric do not constitute the critical features of the present invention, which resides in the nature of the flexible substrate component of the fabric and the means for applying it as described and claimed herein.

In the method of the invention, the multiple filling layers of the flexible substrate are disposed for delivery to the elongated fabric formation space or work zone by the plurality of comb-like filling carriages each of which independently reciprocates back and forth between and across the parallel rows of filling hooks thereby conveying a separate layer of filling elements to the moving rows of hooked leaded units in a direction substantially transverse to the direction of delivery of the substrate to the work zone. At the same time, the leaded units move in the direction of delivery of the substrate to the work zone.

Preferably, the comb-like carriages are timed by means of appropriate gearing to move in synchronous relation to one another, thereby achieving any one of a number of lay-down patterns in the flexible substrate. The filling layer which is laid upon the moving filling hooks first (i.e., farthest "upstream" from the stitching elements of the fabric forming work zone) will become the rearward or ground filling layer. The filling layer(s) which are laid on the filling hooks subsequently or downstream will become superimposed on the previously applied filling layers.As an application of this concept, one can put down, say, one or more textile filling elements of a given texture and/or color using a downstream filling carriage, so as to lay it on top of and not mixed in with (i.e., not diluted by) a ground or base layer of textile elements having different color and/or texture and which is laid down by an upstream filling carriage. Furthermore, whereas the upstream filling carriage can be made to reciprocate between the rows of filling hooks at a given speed coupled with the linear speed of the filling hooks so as to achieve a "solid" or uniform density ground layer effect, the second or downstream filling carriage can be made to traverse the distance between the filling hook rows at any other desired speed independently of the first or upstream carriage.In this way, the textile filling element(s) of the top filling layer can be disposed across the width of the fabric substantially non-parallei to the textile elements of the ground filling layer. Thus, as a result of the perpendicular (transverse) reciprocating movement of each filling carriage relative to the direction of movement of the filling hooks, the resulting fabric of the invention is characterized by a plurality of superimposed layers of substantially parallel continuous textile elements extending obliquely across the width of the fabric. Depending on the synchronization of the filling carriages, the elements of one filling layer can be disposed on the resulting fabric more or less non-parallel to the elements of at least one other layer.

Further details of the present invention and its preferred embodiments can be had by reference to the accompanying drawings, wherein corresponding elements are denoted by the same reference numeral: FIG. 1 is a top plan view of a fabric according to the invention comprising two superimposed layers of textile filling elements.

FIG. 2 is a top plan view of a fabric according to the invention comprising three superimposed layers of textile filling elements; FIG. 3 is an enlarged view of portions 3-3 of the fabric of FIG. 1; and FIG. 4 is a partially schematic view of a stitchthrough machine employing a multiple filling carriage apparatus in accordance with the invention.

Referring to FIG. 1, there is depicted a selvageto-selvage portion of fabric 1 comprising a continuous "ground" filling layer 2 and upper or design filling layer 4. As shown in FIG. 3, filling layers 2 and 4 are superimposed and bound together into an integrated unitary fabric construction by a single knitting thread network 5 of looped stitch wales extending along the length of fabric 1. Each wale consists of a multiplicity of looped stitch courses which engage and secure the superimposed filling layers 2 and 4 against relative displacement. The configuration of knitting thread network 5 can be in the form of the well-known chain-stitch or half-tricot stitch, the latter being preferred when the fabric contains additionally longitudinal warp elements.Such warp elements are not a feature of the fabric depicted in the drawings, except that a few such elements 6 can be incorporated into the fabric near the edges 7 for added strength along the selvage. Filling layer 2 is composed of a plurality of continuous parallel textile yarn ends 8 extending back and forth across the width of fabric 1 in a slightly diagonal or oblique direction (i.e., non perpendicular to the longitudinal axis of the fabric). Similarly, filling layer 4 is composed of a different plurality of continuous parallel textile yarn ends 9 extending back and forth across the width of fabric 1 in a more sharply diagonal or oblique direction than elements 8 of filling layer 2.

The number of and spacing between adjacent ends 8 of filling layer 2 which are laid down with each traverse of their corresponding upstream filling carriage is coordinated with the traversal frequency of the filling carriage and the velocity of the filling hooks toward the fabric-forming work zone of the stitch-through machine in order that such filling is laid down so as to simulate the appearance of a solid or continuous background upon which the relatively narrow bands of filling layer 4 are laid, thereby achieving an attractive zig-zag pattern effect in filling layer 4 which is set off against contrasting ground filling layer 2.It is in this sense that the traversal frequency of the upstream carriage for filling elements 8 is dependent on the movement of the filling hooks and stitching elements of the stitch-through machine while the traversal frequency of the downstream carriage for filling elements 9 is independent of such movement.

Referring to FIG. 2, there is depicted a selvageto-selvage portion of fabric 10 comprising continuous ground filling layer 11, intermediate design filling layer 12, and topmost design filling layer 13. Filling layers 11, 12, and 13 are superimposed on one another and are bound together into an integrated unitary fabric construction by a single knitting thread network of a type described hereinabove which engages and secures the superimposed filling layers against relative displacement.Filling layer 11 is composed of a plurality of continuous parallel yarn ends and which in general respects corresponds to the previously described ground filling layer 2 of FIG. 1 so as to simulate the appearance of a solid or continuous background upon which the relatively narrow bands of filling layers 12 and 13 are laid to achieve the desired diamond-shaped design ensemble effect as shown. Filling layers 12 and 13 are composed of the same or differing pluralities of continuous textile yarn ends having the same or different colors and/or textures extending back and forth across the width of fabric 10, each in a more sharply diagonal or oblique direction that the yarn elements of ground filling layer 11 and either in the same or different angles relative to each other. In this way the traversal frequencies of the carriages for filling layers 12 and 13 are respectively independent of the traversal frequency of the carriage for ground filling layer 11, and may or may not be made independent of each other, the latter relationship depending on the figure pattern desired to be achieved in the two design filling layers 12 and 13.

Referring to FIG. 4, stitch-through machine 20 comprises a stitch-through fabric-forming station 21, and substrate delivery means 22 for carrying a flexible substrate, such as a plurality of continuous textile filling yarn elements 23, supplied by a creel (not shown), to the fabric-forming station.

Typicaily, the substrate delivery means 22 comprises a pair of parallel endless rows of hooked leaded units or filling hooks familiar to those skilled in the art. An optional warp yarn element delivery means (not shown) can, if desired, be provided for feeding conjointly with the substrate and in superimposed relation thereto, a plurality of generally longitudinal warp elements to be united with the substrate in fabric-forming station 21.

The fabric-forming station 21 typically comprises a comb-like sinker bar and a comb-like retainer pin bar for defining between them an elongated space or work zone across the width of the machine for fabric formation. A row of "bearded" or barbed sharp-pointed needles each having an affiliated closing wire is provided for penetrating the substrate filling 23 and optional warp elements in co-action with a row of guides for sewing threads 24 for stitching a plurality of warpwise loop chains which unite and hold the fabric components together into a unitary non-woven textile structure 25.

The apparatus of the invention comprises, in the embodiment of FIG. 4, three comb-like filling carriages 26, 27 and 28 for receiving filling yarns 23 from an eyeboard 29 and delivering the yarns to opposite filling hook rows 22 by moving back and forth between the rows in a direction substantially transverse or perpendicular to the direction in which the rows feed the substrate to the fabric-forming station 21. The filling carriages 26, 27 and 28, which are the downstream, midstream and upstream filling carriages, respectively, each contains a comb-like reed 51 which serves to maintain a plurality of input filling yarns in separate, spaced relation for application to the filling hooks in rows 22.For this purpose, a pair of presser feet are advantageously disposed on either side of each carriage for pressing filling 23 yarns into engagement with the hook rows 11.

The presser feet are coupled with end path detection means, e.g., bumper elements, so as to raise the presser foot adjacent the hook row while lowering the foot opposite the row as the carriage presses the yarns over the hooks. This coupling can be conveniently effected by rack-and-pinion gear trains. An adjustable end bumper can be provided for adjusting the precise position of presser foot activation.

In accordance with the invention, filling carriages 26, 27 and 28 are independently controllable for delivering the filling yarns in three separate layers to the filling hook rows I liThe carriages 26, 27 and 28 can be conveniently driven back and forth by timing belts (not shown) and guided by rollers 30 on guide rods 31 attached to support members, e.g., 32. The timing beits are driven and guided by sprocket wheels rotatably mounted near support members 32.

Each drive sprocket is conveniently driven by a driven chain, the motion of which can be controlled by means familiar to those skilled in the art having the benefit of the present disclosure before them. For instance, a suitable drive assembly for driving each filling carriage in reciprocating motion comprises in substance, a cam arm attached to a bull gear for a vertically reciprocating horizontal bar whose movement is coupled to a rotatable shaft through chains and sprockets, not shown. The shaft is alternately rotated clockwise and counterclockwise as the bar is moved down and up, respectively. The alternate turning of the shaft in turn drives the chain by means of the aforementioned sprockets. By proper choice of gear ratios, each carriage can be driven synchronously with the machine and/or with the other carriages or at any desired fraction or multiple of the speed thereof. In this way, by using filling yarn of one type in carriage 28 and yarns of other types in carriages 26 and 27, a wide variety of novel fabric structures and designs can be achieved.

While the invention has been described in connection with a small number of specific embodiments, it is to be understood that these are merely illustrative of the many other specific embodiments which can also utilize the principles of the invention. Thus, numerous and varied devices and fabrics can be made by those skilled in the art without departing from the scope of the present invention as defined in the following

Claims (22)

claims. CLAIMS

1. A fabric made on a stitch-through type machine such as a Malimo machine and having a front surface and a rear surface, comprising: (a) two or more superimposed filling layers each consisting of one or more parallel continuous textile elements extending obliquely across the width of the fabric; and (b) a single system of knitting thread wales extending along the length of the fabric, each wale comprising a multiplicity of looped stitch courses which engage and secure the superimposed filling layers against relative displacement by loops of knitting thread on the rear surface of the fabric and by laps of the knitting thread courses on the front surface of the fabric.

2. A fabric according to claim 1 comprising two superimposed filling layers of textile yarn elements.

3. A fabric according to claim 2 wherein at least one of the filling layers contains a plurality of textile yarn elements.

4. A fabric according to claim 3 wherein said at least one filling layer containing a plurality of textile yarn elements is disposed rearward of the other filling layer.

5. A fabric according to claim 1 comprising three superimposed filling layers of textile yarn elements.

6. A fabric according to claim 5 wherein at least one of the filling layers contains a plurality of textile yarn elements.

7. A fabric according to claim 6 wherein said at least one filling layer containing a plurality of textile yarn elements is disposed rearward of the other filling layers.

8. A fabric according to claim 1, 2, 3, 4, 5, 6, or 7 wherein the elements of one filling layer are non-parallel to the elements of another filling layer.

9. In a method for forming a stitch-bonded type fabric on a stitch-through type machine having a comb-like sinker bar, a comb-like retainer pin bar, the sinker bar and the retainer pin bar defining an elongated work zone for fabric formation between them, means for delivering a flexible substrate to said work zone, a row of bearded sharp-pointed needles parallel to said work zone and a row of sewing thread guides co-acting with the needles for forming a single system of knitting thread wales each comprising a multiplicity of looped stitch courses along the length of the fabric, the needles piercing the substrate while moving reciprocatingly back and forth through the elongated work zone, the improvement in combination therewith comprising;; delivering the substrate to the elongated zone for fabric formation in the form comprising two or more superimposed filling layers each consisting of a group of one or more parallel continuous textile elements extending obliquely between and in engagement with two parallel endless rows of hooked leaded units by a corresponding number cf comb-like carriages each independently conveying a said group of one or more parallel continuous textile elements back and forth between and across the rows of hooked leaded units in a direction substantially transverse to the direction of delivery of the substrate to the elongated work space for fabric formation, said leaded units moving in the direction of delivery of the substrate to the elongated work zone.

10. The improvement according to claim 9 wherein the substrate is delivered to the elongated wori < zone for fabric formation in the form comprising two superimposed filling layers of textile yarn elements.

11. The improvement according to claim 10 wherein at least one of the filling layers contains a plurality of textile yarn elements.

12. The improvement according to claim 11 wherein said at least one filling layer containing a plurality of textile yarn elements is conveyed by a comb-like carriage back and forth between the rows of leaded units prior to said other filling layer being conveyed to the leaded units by the other carriage.

13. The improvement according to claim 9 wherein the substrate is delivered to the elongated space for fabric formation in the form comprising three superimposed filling layers of textile yarn elements.

14. The improvement according to claim 13 wherein at least one of said filling layers contains a plurality of textile yarn elements.

1 5. The improvement according to claim 14 wherein said at least one filling layer containing a plurality of textile yarn elements is conveyed by a comb-like carriage back and forth between the rows of leaded units prior to said other filling layer being conveyed to the leaded units by the other carriage.

1 6. The improvement according to claim 9, 10, 11, 12, 13, 14 or 15 wherein the elements of one filling layer are conveyed between and across the rows of hooked leaded units so as to be disposed on the leaded units non-parallel to the elements of another filling layer disposed on said leaded unit.

1 7. In a machine for producing textile fabrics of the stitch-through type, comprising a comb-like sinker bar, a comb-like retainer pin bar, the sinker bar and the retainer pin bar defining an elongated work zone for fabric formation between them, means for delivering a flexible substrate to said work zone, a row of bearded sharp-pointed needles parallel to said work zone and a row of knitting thread guides co-acting with the needles for forming a single system of knitting thread wales each comprising a multiplicity of looped stitch courses along the length of the fabric, the needles being adapted to pierce the substrate and being movable in reciprocating motion back and forth through the elongated work zone, the improvement wherein:: the delivery means for the flexible substrate comprises two or more comb-like carriages adapted for synchronous reciprocating movement for independently conveying the flexible substrate in the form comprising a corresponding number of superimposed filling layers each consisting of a group of one or more parallel continuous textile elements back and forth between and across two parallel endless rows of hooked leaded units in a direction substantially transverse to the direction of delivery of the substrate to the elongated work zone, said leaded units moving in the direction of delivery of the substrate to said work zone.

18. The improvement according to claim 1 7 wherein the delivery means for the flexible substrate comprises two comb-like carriages.

1 9. The improvement according to claim 17 wherein the delivery means for the flexible substrate comprises three comb-like carriages.

20. A fabric substantially as hereinbefore described with reference to Figs. 1 and 3; or Fig. 2 of the accompanying drawings.

21. A method for forming a stitch-bonded type fabric, substantially as hereinbefore described with reference to Figs. 1 and 3; Fig. 2 or Fig. 4 of the accompanying drawings.

22. A machine for producing textile fabrics of the stitch-through type, substantially as hereinbefore described with reference to Fig. 4 of the accompanying drawings.