GB2097829A - Warp knitted self-lined fabrics with woven appearance - Google Patents

Abstract

A self-lining decorative fabric especially adapted for use as a drapery, and simulating the appearance of a woven fabric includes a non-woven or other substrate fabric with weft yarns 16 disposed on a first face of the substrate and warp yarns 18 lying on top of the weft yarns, optionally with curvilinear or zig-zag paths. Stitching thread holds the warp and weft yarns in place on the substrate first face, stitch portions 20' of the stitching thread passing over the warp and weft yarn, and loops of the stitching thread being disposed in contact with the substrate second face. The stitching thread may be the same color as the substrate while the majority of the warp and weft yarns are of a different color, and at least some of the warp and weft yarns preferably are effect yarns. When used as a drapery material, a foam backing or other coating may be applied adhering to the substrate second face. <IMAGE>

Description

SPECIFICATION Warp knitted self-lined fabrics with woven appearance Background and Summary of the Invention In the production of decorative fabrics, particularly fabrics for home furnishings, such as drapery casements, it is desired to provide selflining in order to increase fabric opacity and to simulate the appearance of a separate lining. Also to allow the application of a foam backing to a type of fabric which otherwise could not be successfully foam backed utilizing conventional techniques. Further, it is desirable to produce such a self-lined fabric at minimum cost consistent with providing a desirable appearance, a simulation of a woven fabric on the face - with or without effect yarns.

According to the present invention, a self-lining decorative fabric is provided that has all of the advantages associated with self-lined fabrics, and can be produced in a simple and cost-effective manner while ultimately providing a very aesthetic appearance. The fabric according to the present invention simulates a woven fabric in appearance and dimensional stability, provides increased fabric opacity without stiffening "hand", and allows application of a foam backing utilizing conventional techniques. The fabric according to the invention is ideally suited for use as a drapery fabric because of aesthetics, cost and dimensional stability. It has enough versatility of design to be utilized for a wide variety of decorative purposes, particularly in the home furnishings area.

The dimensional stability of the compound fabric constructions make this type of manufacture important for industrial fabrics.

Similarly, an economic fabric construction achieving opacity through a substrate and controlling the tensile strength with minimum warp and filling threads make attractive for use as print fabric such as for ticking.

According to one aspect of the present invention, a self-lining decorative fabric is provided simulating the appearance of a woven fabric. The fabric includes a substrate fabric weave having first and second faces with weft yarns disposed on the first face of the substrate, and extending parallel to each other. Warp yarns are disposed on the first face of the substrate and extend in lines substantially parallel to each other and perpendicular to the weft yarns, the warp yarns laying on top of the weft yarns at all points of intersection. Stitching thread holds the warp and weft yarns in place on the substrate first face, the stitching thread including stitch portions and loops with the stitch portions operatively engaging the warp and weft yarns on the substrate first face, and the loops being disposed in contact with the substrate second face.

The fabric according to the present invention may be produced on a commercially available machine manufactured by Karl Mayer Machinery Co. of the Federal Republic of Germany. The machine is 9 warp knitting machine having pointed (piercing) stitching needles, a substrate fabric feed, a weft-insertion feed that feeds the weft yarns truly perpendicular to the warp yarns, and means for introducing decorative warp yarns, overlying the weft yarns, at the stitching needles.

Utilizing such machinery, a self-lining decorative fabric is produced by: Feeding the substrate in a first direction to the stitching needles. Feeding parallel weft yarns in the first direction, with the yarns disposed in a second direction perpendicular to the first direction, to the stitching needles, with the weft yarns in contact with the substrate first face at the stitching needles. Feeding warp yarns, extending in lines parallel to each other and perpendicular to the weft yarns, to the stitching needles substantially in the first direction, the warp yarns being laid on top of the weft yarns at the stitching needles. And, stitching through the substrate with the stitching needles to loop stitching threads stitch portions over warp and weft yarns to hold them in place on the substrate first face, and to form stitch loops on the substrate second face.

By providing the warp yarns extending in lines perpendicular to the weft yarns a woven appearance is simulated and the stability of the fabric construction improved. A wide variety of decorative effects may be obtained by using effect yarns for the warp and/or weft yarns, and by providing at least some of the warp yarns in curvilinear or zig-zag paths while extending in their lines perpendicular to the weft yarns. The stitching threads stitch portions each pass over and hold the warp and weft yarns, with the warp and weft yarns passing between a stitch portion and the substrate first face. The stitching thread stitch portions may be provided in a zig-zag configuration, straight line configuration, or the like.For some purposes, the stitching threads may be provided as the same color as the substrate (e.g., white) while the majority of the warp and weft yarns are of a different color than the substrate, simulating a woven appearance.

When used as an open type self-lining drapery casement fabric, it may be desirable to provide a foam backing to the substrate second face, the foam encapsulating the stitching thread loops.

Foam backing may be practiced as taught by U.S.

Patents 4,072,775 and 3,527,654. In such situations, the substrate fabric is a very light nonwoven fabric, such as a non-woven produced according to the teachings of U.S. Patent 3,485,706. While a non-woven is desirable as the substrate fabric for most purposes, if desired for a particular situation a woven or knit substrate film or foil may be provided.

The substrates mentioned above could be selected to increase the decorative effect, e.g., by causing pucker of the face fabric through differential shrinkage. Also the substrates could be used for functional qualities such as heat dissipation of lighted cigarette for ticking or upholstery fabrics, insulation of heat transmission or heat reflection for drapery or apparel fabrics, or sound insulation for drapery fabrics. Construction of fabrics for the desired performance could require one or several substrates inserted in a sandwich.

It is the primary object of the present invention to provide a decorative fabric simulating the appearance of a woven fabric, and particularly adapted for use as a drapery casement fabric. This and other objects of the invention will become clear from an inspection of the detailed description of the invention, and from the appended claims.

Brief Description of the Drawings FIGURE 1 is a top plan view showing the decorative face of an exemplary fabric according to the present invention; FIGURE 2 is a detailed enlarged schematic plan view of the fabric of FIGURE 1; FIGURE 3 is an enlarged schematic bottom plan view of the fabric of FIGURE 1; FIGURE 4 is a fragmentary cross-sectional view of an exemplary fabric according to the invention corresponding generally to the fabric of FIGURE 1 but also with a foam backing; and FIGURE 5 is a plan view of the decorative face of another embodiment of exemplary fabric according to the present invention.

Detailed Description of the Drawings An exemplary fabric according to the present invention is indicated generally by reference numerals 10, 10', and 10" in FIGURES 1-3, FIGURE 4, and FIGURE 5, respectively. The fabric 10, 10', and 10" comprises a self-lined decorative fabric which, as an inspection of FIGURES 1 and 5 in particular makes clear, simulates the appearance of a woven fabric, and is eminently suitable for use as a drapery casement fabric. The fabric 10, 10', and 10" is desirably produced on a commercially available warp knitting machine produced by Karl Mayer Machinery Co. of the Federal Republic of Germany, Model No. RS4(6)MSU, such a machine having a substrate fabric feed, parallel weft insertion, pointed stitch-through needles, and decorative warp yarn introducing means.

As FIGURES 2-4 make clear, the fabric 10, 10', and 10" according to the present invention includes a substrate 1 2 having a first face 13 (see FIGURE 2) and a second face 14, opposite the first face 13. Depending upon the ultimate use of the fabric 10 and substrate availabilities, the substrate 12 may be a non-woven, woven, or knit fabric film or foil. A light non-woven fabric such as that produced according to U.S. Patent 3,485,706, is preferred for most situations, especially when the fabric 10 comprises drapery casement fabric.

Weft yarns 16 are disposed on the first face 13 of the substrate 12, the weft yarns 1 6 extending parallel to each other. If desired, the weft yarns may be effect yarns, the term "effect" being a generic term to describe all types of yarns having pronounced variations in linear density, such as knops, loops, slubs, lumps, nubs, and the like. For instance, weft yarns 16', 16" illustrated in FIGURE 2 are a slub yarn (having an irregular, fuzzy configuration over the entire length thereof) and a nub yarn (having irregular configurations at spaced points therealong) respectively.

The weft yarns can be introduced singly or with two or more yarns placed in the same course simultaneously. This could be for a decorative effect, economy, or to increase the tensile strength with a yarn combination, e.g., fine filament with a coarse weak spun yarn.

The fabric 10 (10', 1 ON) further comprises warp yarns disposed on the first face 1 3 of the substrate 12 and extending in lines L (see FIGURE 2) substantially parallel to each other and perpendicular to the weft yarn 1 6, and laying on top of the weft yarns 16 at all points of intersection. While the warp yarns 1 8 extend in lines L perpendicular to the weft yarn 1 6, they may extend in curvilinear or zig-zag paths, as clearly illustrated in FIGURES 1, 2, and 5. At least some of the warp yarns 1 8 also preferably are effect yarns.

The fabric 10 (10', 10") also includes stitching thread holding the warp and weft yarns 18, 1 6 in place on the substrate first face 1 3. The stitching thread is indicated generally by reference numeral 20, and includes stitch portions 20' and loops 20". The stitch portions 20' each pass over and hold the warp and weft yarns 18, 16, with the warp and weft yarn 18, 1 6 passing between a stitch portion 20' and the substrate first face 1 3.

Preferably each stitch portion 20' holds a weft yarn 16 (although skipped picks may be provided), and at least some of the stitch portions 20' hold a warp yarn 1 8. In the embodiments illustrated in FIGURES 1, 2, and 5, warp yarns 1 8 are provided only at predetermined intervals along the fabric face, there being no provision for one warp yarn for each row of stitching thread 20. The loops 20' are disposed in contact with the substrate second face 14, conventional chain stitching being illustrated in FIGURES 2 and 3. Variations in the exact stitch configuration of the stitching thread 20 may be provided. For instance, the stitching thread portions 20' may be provided in a straight line configuration as illustrated in FIGURES 1 and 2, or they may have a zig-zag configuration as illustrated in FIGURE 5. Alternatively, tricot stitches may be provided, or any other type of conventional stitching achievable utilizing a warp knitting machine.

In order to obtain proper aesthetic effect, the stitching thread 20 may be provided having the same color as the substrate 12 (e.g., white), while the majority of the warp and weft yarns 18, 1 6 are of colors different than the substrate 12.

Especially where a white substrate 12 and white stitching thread 20 is provided with multi-color warp and weft yarns, an appearance truly simulating that of a woven fabric is provided at a distance of more than a few inches.

FIGURE 4 illustrates a fabric 10' according to the present invention which is identical to the fabric 10 only it includes a foam backing 25. An open-weave fabric normally cannot be successfully foam-backed utilizing conventional techniques, however, the self-lined fabric according to the present invention may be successfully foam backed. The foam backing 25 is applied to the substrate second face 14, and encapsulates the stitching loops 20'. After production of the fabric 10, it is fed to a conventional foam backing station, and conventional foam-backing techniques are utilized to apply the backing 25. Two conventional types of foam backing techniques are disclosed in U.S.

Patents 3,527,654 and 4,072,775.

As previously indicated, a decorative fabric 1 0, 10', and 10" according to the present invention is produced on a commercially available warp knitting machine having pointed stitching needles.

The substrate 12 is fed in a first direction to the stitching needles of the warp knitting machine, while parallel weft yarns 16 are fed in the first direction, with yarn 1 6 being disposed in a second direction perpendicular to the first direction. The weft yarns 1 6 are in contact with the substrate first face 13 at the stitching needles. Warp yarns 18 are fed, extending in lines parallel to each other and perpendicular to the weft yarns, to the stitching needles substantially in the first direction, the warp yarns being laid on top of the weft yarns 1 6 at the stitching needles.The fabric is completed by stitching through the substrate 12 with the stitching needles to loop stitching threads stitch portions 20' over the warp and weft yarns 18, 1 6 to hold them in place on the substrate first face 16, and forming stitch loops 20" on the substrate second face 14. The decorative warp yarns may be introduced by patterning bars, or with a straight lay-in bar plus patterning bars, and under some circumstances no decorative warp yarns need be provided, but rather the stitching threads themselves can provide the woven effect (in conjunction with the weft yarns). If foam backing of the fabric were desired, after formation it would be passed to a foam backing station and the backing 25 applied to the second face 14 of substrate 12.

It will thus be seen that according to the present invention an aesthetic, functional fabric has been provided which has a wide variety of uses, but is particularly adapted for use as a drapery casement. While the invention has been herein shown and described in what is presently conceived to be the most practical and preferred embodiment thereof, it will be apparent to those of ordinary skill in the art that many modifications may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent fabrics and constructions.

Claims (22)

1. A self-lining decorative fabric simulating the appearance of a woven fabric, comprising: a substrate fabric having first and second faces; weft yarns disposed on the first face of said substrate, and extending parallel to each other; warp yarns disposed on the first face of said substrate and extending in lines substantially parallel to each other and perpendicular to said weft yarns, and laying on top of said weft yarns at all points of intersection; and stitching thread holding said warp and weft yarns in place on said substrate first face, said stitching thread including stitch portions and loops, said stitch portions operatively engaging said warp and weft yarns on said substrate first face, and said loops being disposed in contact with said substrate second face.

2. A fabric as recited in claim 1 wherein said stitching thread stitch portions each pass over and hold said warp and weft yarns, said warp and weft yarns passing between a stitch portion and said substrate, each stitch portion holding a weft yarn, and at least some stitch portions holding a warp yarn.

3. A fabric as recited in claim 2 wherein at least some of said warp yarns are curvilinear or zig-zag paths while extending in said lines.

4. A fabric as recited in claims 1 or 3 wherein said stitching thread stitch portions are provided in a zig-zag configuration on said substrate first face.

5. A fabric as recited in claims 1 or 3 wherein said stitching thread stitch portions are provided in a straight line configuration on said substrate first face.

6. A fabric as recited in claims 2 or 3 wherein said stitching threads are the same color as said substrate, and wherein the majority of said warp and weft yarns are of a different color than said substrate.

7. A fabric as recited in claim 6 wherein at least some of each of said warp and weft yarns are effect yarns.

8. A fabric as recited in claims 1 or 2 further comprising a foam backing adhering to said substrate second face, encapsulating said stitching thread loops.

9. A fabric as recited in claim 8 wherein said substrate comprises a non-woven fabric.

10. A fabric as recited in claim 1 wherein said substrate comprises a non-woven fabric.

11. An open type self-lining drapery casement fabric comprising: a non-woven fabric substrate having first and second faces; weft yarns disposed on the first face of said substrate, and extending parallel to each other; warp yarns disposed on the first face of said substrate and extending in lines substantially parallel to each other and perpendicular to said weft yarns, and laying on top of said weft yarns at all points of intersection; and stitching thread holding said warp and weft yarns in place on said substrate first face, said stitching yarn including stitch portions and loops, said stitch portions each passing over and holding said warp and weft yarns, said warp and weft yarns passing between a stitch portion and said substrate first face, and said loops being disposed in contact with said substrate second face.

12. A fabric as recited in claim 11 further comprising a foam backing adhering to said substrate second face, encapsulating said stitching thread loops.

1 3. A fabric as recited in claims 11 or 12 wherein said stitching threads are the same color as said substrate, and wherein the majority of said warp and weft yarns are of a different color than said substrate.

14. A fabric as recited in claim 13 wherein at ;east some of each of said warp and weft yarns are effect yarns.

1 5. A self-lining decorative fabric including a substrate fabric having first and second faces, warp and weft yarns, and stitching thread, formed on a warp knitting machine having stitching needles, by: feeding the substrate in a first direction to the stitching needles of the warp knitting machine; feeding parallel weft yarns in the first direction, with the yarns being disposed in a second direction perpendicular to the first direction, to the stitching needles, with the weft yarns in contact with the substrate first face at the stitching needles; feeding warp yarns, extending in lines parallel to each other and perpendicular to the weft yarns, to the stitching needles substantially in the first direction, the warp yarns being laid on top of the weft yarns at the stitching needles; and stitching through the substrate with the stitching needles to loop stitching thread stitch portions over warp and weft yarns to hold them in place on the substrate first face, and to form stitch loops on the substrate second face.

16. A self-lining decorative drapery fabric, or the like, comprising: a substrate fabric having first and second faces; weft yarns disposed on the first face of said substrate, and extending parallel to each other; and stitching thread holding said weft yarns in place on the substrate first face, said stitching thread including: stitch portions and loops, said stitch portions each passing over and holding said weft yarns, with the weft yarns between a stitch portion and said substrate first face, with said stitch portions perpendicular to said weft yarns; and loops, said loops being disposed in contact with said substrate second face.

1 7. A fabric as recited in claim 1 6 further comprising a foam backing adhering to said substrate second face, encapsulating said stitching thread loops.

18. A fabric as recited in claim 16 wherein said substrate comprises a non-woven fabric.

19. A fabric as recited in claims 1, 11,or 16 wherein said weft yarns comprise a plurality of weft yarns in each course.

20. A fabric as recited in claim 1 5 wherein the feeding of parallel weft yarns in the first direction is accomplished by feeding a plurality of yarns in each course.

21. A fabric substantially as hereinbefore described with reference to the accompanying drawings.

22. A method of manufacturing a fabric, the method being substantially as described herein.