KR100752857B1 - Blister fabrics with internal connecting elements - Google Patents

Abstract

Knitted or woven blister fabric 740 may be punctured to form internal connections of filaments or fibers 741, 746 from yarns that extend into and / or between the yarns of adjacent layers. . An interconnect of fibers is created between the separate layers by a needle entering the first layer and transporting the fiber from the first layer to a second adjacent layer in the blister of the fabric. These interconnected fibers that span multiple layers of fabric or span multiple layers serve to reinforce the blister fabric, making the fabric more resistant to wear.

Description

Blister fabric with internal connection elements {BLISTER FABRICS WITH INTERNAL CONNECTING ELEMENTS}

The present invention relates to a fabric having an internal connecting element or fiber which serves to stabilize the fabric structure.

This application is a partial continuing application of US Patent Application No. 10 / 298,476, entitled "Blister Cloth with Internal Connection Element," filed November 15, 2002, in the name of Boyd et al.

Many methods and procedures have been used to stabilize the structure of a knit or woven fabric. Coatings were also applied to prevent the yarns from moving relative to each other. However, coatings alone cannot provide additional desirable features in the fabric.

Recently, a method known as hydroentanglement has been used to provide stabilization to fabrics. Hydroentangling uses fluid injection to entangle the fibers extending from the main body of the yarn with the fibers extending from the main body of another yarn. However, hydroentangling often has an undesirable effect on the aesthetic properties of fabrics because of the large number of free fibers needed to intertwine by fluid injection. There is a need for fabrics stabilized by other methods or procedures.

1 is a plan view of a blister fabric illustrating one embodiment of the present invention.

FIG. 2 is an enlarged cross-sectional view of the blister cloth taken along the cutting line 2-2 of FIG. 1.

3 is an enlarged cross-sectional view of another embodiment of the present invention, using a composite of two separate fabric layers.

4 is a partially enlarged view of a needle used in the present invention.

5A and 5B are diagrams illustrating stitches used in one embodiment of the present invention.

6 is a top view of a blister fabric.

FIG. 7 is a partial cross-sectional view of the blister fabric of FIG. 6 taken along the cutting line 7-7 of FIG. 6.

8 is another partial cross-sectional view of the blister fabric of FIGS. 6 and 7.

In the drawings, in particular FIGS. 1 and 2, a blister cloth 10 is illustrated that illustrates one embodiment of the present invention. The blister cloth 10 has an alternate band of the blister band 100 and the base band 200. The blister zone 100 has a lower blister layer 110 of the first material independent of the upper blister layer 120 of the second material. Base zone 200 is an integrated layer of material.

As shown, the blister cloth 10 consists of a basic yarn 11 and a blister yarn 12. In one embodiment, the blister cloth 10 is made of yarn having a size of about 600 denier or less. In another embodiment, the blister fabric 10 is formed of a yarn having a size of at least about 15 denier. In one preferred embodiment, the fibers forming the basic yarn 11 and the blister yarn 12 may both comprise filament yarns. As used herein, filament yarns include multiple filament yarns. In other embodiments, both the base yarn 11 and the blister yarn 12 may comprise spinning yarns. In another embodiment, the base yarn 11 may comprise a filament yarn and the blister yarn 12 may comprise a spun yarn. In other embodiments, the base yarn 11 may comprise a spun yarn and the blister yarn 12 may comprise a filament yarn. It is contemplated that the present invention will work well with yarns of combined filament fibers and staple fibers. Combined filament fiber and staple fiber yarns may be used for the base yarn 11 and / or blister yarn 12 as a substitute for the filament yarns and / or spun yarns of the combination. The fibers of the filament yarns and / or spun yarns of the invention can be made from natural materials or materials produced. For example, natural materials may include materials of animal, plant or mineral origin used as fibers. The materials produced may include polymers synthesized from compounds, modified or modified natural polymers and minerals.

As shown in FIGS. 1 and 2, the lower blister layer 10 of the blister cloth 10 is a stop knit of the basic yarn 11, and the upper blister layer 120 of the blister cloth 10. Is the jersey knit of blister yarn 12. As also shown, the base yarn 11 constitutes an integrated double layer stop knit in the base zone 200, and the blister yarn 12 is an integrated double of the base yarn 11 in the base zone 200. It is sandwiched between layer resistant knits. Although the blister fabric 10 is all shown as knitted, it is contemplated that the blister fabric can be a woven fabric or a combination of knit and textile. In addition, although the integrated base zone 200 is shown as a knitted zone, it is contemplated that the integrated base zone 200 can be formed by processes such as weaving, sewing, joining, and the like.

2 is an enlarged cross-sectional view of the blister cloth 10. As shown, a yarn in one layer of the blister zone 100 passed from a yarn in one layer of the blister zone 100 into and / or between the yarns of the other layer 110 of the blister zone 100. A portion of the blister zone connection 130 is formed between the lower blister layer 110 and the upper blister layer 120 by a fiber portion from the fiber portion. Lower blister layer 110 by the fiber portion from the yarn of the lower blister layer 110 passed into and / or between the yarns of upper blister layer 120 in the yarn of lower blister layer 110. A lower blister layer connection 131 is formed between and the upper blister layer 120. Upper blister layer 120 by the fiber portion from the yarn of the upper blister layer 120 passing into and / or between the yarns of the lower blister layer 100 in the yarn of the upper blister layer 120. An upper blister layer connection 132 is formed between and the lower blister layer 110. The lower blister layer connection 131 and the upper blister layer connection 132 provide a tie between the lower blister layer 110 and the upper blister layer 120.

In FIG. 2, the fibers forming one of the lower blister layer connections 131 protrude into the upper blister layer 120 starting from the yarns of the lower blister layer 110. The fibers from the lower blister layer 110 forming the lower blister layer connection 131 are secured by the fibers or filaments of the main body of the yarns in the upper blister layer 120. Some of the fibers that make up the lower blister layer connection 131 are secured between the fibers in the main body of the yarn in the upper blister layer 120, wherein the main body is fibers oriented in about the same direction as the yarn itself. It's a county. The other portion of the fibers forming the lower blister layer connection 131 is secured between these yarns by the fibers of the main body of the yarns of the upper blister layer 120. The fibers forming one of the upper blister layer connections 132 protrude into the lower blister layer 110 starting from the yarns of the upper blister layer 120. The fibers from the upper blister layer 120 forming the upper layer connection 132 are secured by the fibers or filaments of the main body of the yarns in the lower blister layer 110. Some of the fibers that make up the upper blister layer connection 132 are fixed between the fibers in the main body of the yarns of the lower blister layer 110, wherein the main bodies are fibers oriented in approximately the same direction as the yarns themselves. It's a county. The other portion of the fibers forming the upper blister layer connection 132 is secured between these yarns by the fibers of the main body of the yarns of the lower blister layer 110. This type of connection comprises at least partially and outwardly the fibers that normally extend outwardly and at least partially radially outwardly from one yarn, as experienced in many hydroentangling methods of treating fabric. As compared to the connection formed between the yarn and the layer by entanglement with the radially extending fibers.

Many of the lower blister layer connections 131 and the upper blister layer connections 132 are loops of fibers from individual source layers that are inserted into the corresponding receiving layers. The loop of fiber forms two connections, each one half of the loop starting from the same yarn and protruding into the same receiving layer. In some cases, upper blister layer connections 131 and / or lower blister layer connections 132 may be formed by fragments of fibers attached to individual source yarns only at one end. In some other cases, the fibers forming the upper blister layer connection 131 or the lower blister layer connection 132, attached only at one end, are hooked, bent or looped at the free end to fit by the connection. The physics can be further secured to the fibers of the corresponding layer.

In one embodiment, the blister zone of the fabric according to the present invention is at least about 275 total connections per square inch (ie, connections starting from a particular layer and the particular layer, depending on the required stability and fabric structure). Total of both connections accommodated by), and up to about 520,000 total connections per square inch to secure the lower blister layer to the upper blister layer. In one knit embodiment, the blister band may have between about 350 and about 1,050 total connections per square inch, and in another knit embodiment, the blister band may have about 750 total connections per square inch.

Since the origin of the connection starts from within the yarn and the connection also secures the yarn, it is useful to find the total number of connections per yarn distance. The sum of both the connection beginning with a particular yarn and the connection received by the particular yarn is also referred to herein as the connection "end" or point of connection. In one embodiment, such as, for example, a knit, the yarns constituting the upper blister layer or the upper blister layer in the blister zone of the fabric according to the present invention are at least about 1.1 or more total connections (or connection ends) per inch of yarn and up to about With 1,650 total connections, the yarn is fixed. In one preferred embodiment, the yarns making up the lower blister layer or the upper blister layer in the blister zone of the fabric according to the invention are from about 1.4 total connections to about 4.2 total connections, more preferably per inch of yarn. It has about 2.8 total connections.

Since the yarn of the yarn is a source of joints, different yarns have different availability of fibers for the joints and different demands on the amount of joints based on the fiber content of the yarns. The measure of filament distance is the length of the yarn with the filament (s) multiplied by the number of filaments of the yarn bundle. Thus, in some of the fabrics according to the invention, it is useful to find the total number of connections per filament distance of the yarn (the total of both the connections starting at a particular yarn and the connections accommodated by that particular yarn).

In the examples provided below, a needle punch is made on both sides of the fabric, but in another embodiment of the present invention, a fabrication method can be used which only needles on one side of the fabric.

In FIG. 2, the base zone 200 is trapped through the lower base layer portion 210, the upper base layer portion 220, and between the upper base layer portion 210 and the lower base layer portion 220. ) Is a unitary structure knitted with yarn 230. In the illustrated embodiment, the base yarn 11 forms the bottom base layer portion 210 and the top base layer portion 220, and the blister yarn 12 has the yarn 230 trapped between the two layers. To form. As shown, a base layer connection 240 is formed between the bottom base layer portion 210 and the top base layer portion 220. A trapped yarn connection 250 is also formed between the lower base layer 210 and the trapped yarn 230, and also between the upper base layer portion 220 and the trapped yarn portion 230.

In FIG. 2, the blister band connection 230 is formed by the fiber portion from one layer of yarn in the base zone 200 passing from one layer of yarn in the base zone 200 into the other layer of the base zone 200. A base layer connection 240 similar to) is formed between the bottom base layer 201 and the top base layer 220. The lower base layer connection 241 is formed by fibers starting from the yarns of the lower base layer 210 and protruding into and / or between the yarns of the upper base layer 220. The fibers from the lower base layer 210 that make up the lower base layer connection 241 are secured by the fibers or filaments of the main body of the yarns in the upper base layer 220. Some of the fibers that make up the lower base layer connection 241 are secured between the fibers in the main body of the yarn in the upper base layer 220, wherein the main body is a group of fibers oriented in substantially the same direction as the yarn itself. to be. The other portion of the fibers that make up the lower base layer connection 241 are secured between the yarns of the upper base layer 220 by the fibers of the main body of the yarns of the upper base layer 220. The upper base layer connection 242 is formed by fibers starting from the yarns in the upper base layer 220 and protruding into the lower base layer 210. The fibers from the upper base layer 220 that make up the upper base layer connection 242 are secured by the fibers or filaments of the main body of the yarns in the lower base layer 210. A portion of the fibers forming the upper base layer connection 242 is fixed between the fibers in the main body of the yarn in the lower base layer 210, wherein the main body is a group of fibers oriented in almost the same direction as the yarn itself. to be. Another portion of the fibers forming the upper base layer connection 242 is secured between the yarns of the lower base layer 210 by the fibers in the main body of the yarns of the lower base layer 210. The lower base layer connection 241 and the upper base layer connection 242 provide a fixing function between the lower base layer 210 and the upper base layer 220.

Many of the lower base layer connectors 241 and the upper base layer connectors 242, such as the lower blister layer connectors 131 and the upper blister layer connectors 132, are fibers in separate source yarns that are inserted into the corresponding receiving layer. Is a loop. In some cases, the lower base layer connection 241 and / or the upper base layer connection 242 may be formed by a piece of fiber attached to an individual source yarn at only one end. In some other cases, the fibers forming the lower base layer connection 241 or the upper base layer connection 242, attached only at one end, can be hooked, bent or looped at the free end, so that the connection becomes entangled. To the fibers of the receiving layer. The base layer connection 240 provides a more stabilized wear resistant fabric in the base zone 220 by providing a tie between the bottom base layer 210 and the top base layer 220.

In one embodiment, the base band of the fabric according to the invention is accommodated by at least about 57 total connections per square inch (connections starting from a particular layer and by that particular layer, depending on the required stability and fabric structure). Total of both connections) and up to about 109,110 total connections per square inch, more preferably about 150 total connections per square inch, connecting the lower base layer to the upper base layer. In one embodiment, the yarns constituting the lower base layer of the upper base zone of the base band of the cloth according to the invention are at least about 0.6 or more total connections per inch of yarn, up to about 11.61 total connections per inch, more preferably There are approximately 1.6 total connections per inch of yarn to secure the yarn. In one embodiment, the yarns making up the connection have between about 28.8 and about 557 connections per inch of filament.

In FIG. 2, trapped by and / or by a fiber portion from trapped yarn 230 passing into and / or between the main body of the yarn in lower base layer 210 or upper base layer 220. Between the trapped yarn 230 and the lower base layer 210 and the upper base layer 22 by fibers from the lower base layer 210 or the yarn in the upper base layer 200 passing into the yarn 230. The trapped yarn connection 250 is formed. By the fiber portion from the yarn in the lower base layer 210 passing into the main body of the yarn 230 trapped in the yarns in the lower base layer 210, and also in the trapped yarn 230 the lower base layer. The lower basic trapped yarn connection between the trapped yarn 230 and the lower base layer 210 by fibers from the trapped yarn passing into and / or between the main body of the yarn in 210. 251 is formed. The upper base layer in the trapped yarn 230 by the fiber portion from the yarn in the upper base layer 220 passing into the main body of the yarn 230 trapped in the yarn in the upper base layer 220. The upper basic trapped between the trapped yarn 230 and the upper base layer 220 by the fibers from the trapped yarn 230 passing into and / or between the main body of the yarn in 220. Yarn connection 252 is formed.

Many of the lower base trapped yarn connections 251 and the upper base trapped yarn connections 252, such as the lower base layer connections 241 and the upper base layer connections 242, are inserted into corresponding receiving yarns or layers. It is a loop of fibers within the individual source yarns. In some cases, the lower primary trapped yarn connection 251 and / or the upper primary trapped yarn connection 252 may be formed by a piece of fiber attached to an individual source yarn only at one end. In some other cases, the fibers forming the lower basic trapped yarn connection 251 or the upper basic trapped yarn connection 252, attached only at one end, can be hooked, bent or looped at the free ends The connection can be further secured to the fibers of the corresponding receiving yarn or layer where the connection is entangled.

The trapped yarn connection 25 provides a base strap between the trapped yarn 230 and the lower base layer 210 and also between the trapped yarn 230 and the upper base layer 220. Provides a more stabilized wear resistant fabric in the zone 200. In one embodiment, the yarns forming the trapped yarns of the base band of the fabric according to the invention comprise at least about 0.6 total connections per inch of yarn, up to about 11.61 total connections per inch of yarn, more preferably yarn 1 With about 1.6 total connections per inch, the yarn is fixed. In one embodiment, the trapped yarn has between about 28.8 and about 557 connections per inch of filament.

In one embodiment, the needled blister cloth 10 also includes a back coating disposed on the back side of the lower blister layer 110 and the lower base layer 210. The back coating was found to further improve the wear resistance of the opposite side of the needle-blended blister cloth 10. The back coating can be any polymeric material, such as latex, polyvinylacetate, or the like. The back coating may be applied to a knitted substrate, woven substrate or other substrate and may be applied at a level of about 0.25 oz / yd 2 to about 5 oz / yd 2. In general, a back coating may be used for knits, fabrics, or any other type of fabric used to practice the present invention.

3 is an enlarged cross-sectional view of a cloth composite 20 illustrating another embodiment of the present invention. The cloth composite 20 is a multi-layer cloth such as double cloth, triple cloth and the like. The fabric comprises at least a first layer 21 and a second layer 22. At least one of the first layer 21 and the second layer is a knit fabric. In the embodiment shown in FIG. 3, the first layer 21 is formed from the first layer yarn 23 and the second layer 22 is formed from the second layer yarn 24. In one embodiment, the first layer yarn 23 and / or the second layer yarn 24 have a yarn size of about 600 denier or less. In other embodiments, the first layer yarn 23 and / or the second layer yarn 24 have a yarn size of at least about 15 denier. In one preferred embodiment, both the first layer yarn 23 and the second layer yarn 24 comprise filaments. In other embodiments, the first layer yarns 23 are filament yarns and the second layer yarns 24 are spinning yarns. In another embodiment, both the first layer yarn 23 and the second layer yarn 24 are spinning yarns. It is also contemplated that the first layer yarn 23 and / or the second layer yarn 24 may comprise a yarn composed of a combination of filament fibers and staple fibers.

The filaments of the yarns in the two layers form a connection 25 between the first layer 21 and the second layer 22. The first layer connection 26 is formed by the fiber portion in the first layer 21 that protrudes into the second layer 22. The first layer connection 25 is secured by the fibers of the main body of the second layer yarn 24. The second layer connection 27 is formed by the fiber portion in the second layer 22 that protrudes into the first layer 21. The second layer connection 27 is fixed by the fibers of the main body of the first layer yarn 23. It is contemplated that the connections 25 of the present invention may be formed over the entire composite fabric 20 or in discrete bands.

Many of the first layer connections 26 and the second layer connections 27 are loops of fibers from individual source layers that are inserted into corresponding receiving layers. The loop of fibers creates two connections, each of which is one half of the loop starting from the same yarn and protruding into the same receiving layer. In some cases, the first layer connection 26 and / or the second layer connection 27 may be formed by a piece of fiber attached to an individual source yarn at only one end. In some other cases, the fibers forming the first layer connection 26 or the second layer connection 27, attached only at one end, are hooked, bent or looped at the free end, so that the connection is entangled. It can be further fixed to the fibers of the layer.

In one embodiment, the composite fabric or zone of composite fabric according to the present invention may comprise at least about 275 total connections per square inch (connections starting from a specific layer and the particular layer, depending on the required stability and structure of the fabric). Total of both connections accommodated by), and up to about 520,000 total connections per square inch to secure the first layer to the second layer. In one preferred embodiment, there are about 350 to about 1,050 total connections per square inch, more preferably about 750 total connections per square inch.

In another embodiment, the yarns making up the first or second layers of the composite fabric according to the present invention have at least about 1.1 or more total connections and up to about 1,650 total connections per inch of yarn to secure the yarns. In one embodiment using a knitted fabric, these yarns have from about 1.4 to about 4.2 total connections per inch of yarn, more preferably about 2.8 total connections per inch of yarn.

In one embodiment, the yarns making up the first or second layer of the composite fabric according to the invention have at least about 0.02 total connections per inch of filament and up to about 6.4 total connections per inch of filament. In one preferred embodiment, these yarns have from about 0.022 to about 0.07 total connections per inch of filament, more preferably about 0.04 total connections per inch of filament.

knitting

In one embodiment of the invention, which is a knitted fabric, the yarns making up the lower blister layer (or lower blister layer in the blister zone) may comprise at least about 0.02 total connections per inch of filament and up to about 6.4 total connections per inch of filament. Have In another embodiment, the yarns forming the upper blister layer or lower blister layer of the blister zone have from about 0.022 to about 0.07 total connections per inch of filament, in other cases about 0.04 total connections per inch of filament Has

textile

In another embodiment of the invention, which is a fabric, the yarns making up the entire (total) two-layer fabric in the blister zone may comprise at least about 9,000 total connections (connection ends) up to about 65,000 connection ends per square inch of fabric. Have

In another embodiment, the fabric includes about 4 × 10 ⁴ first and second connecting fiber ends per square inch of fabric. Another embodiment includes about 24,000 first and second connecting fiber ends per square inch of fabric.

In other applications, fabrics are produced having a two-part blister layer wherein the entire two-part blister layer provides more than about 100 connecting fiber ends per inch of yarn. In other applications, the number of connecting fiber ends per inch of yarn in the fabric is at least about 4 × 10 ² . In some embodiments, the number of connecting fiber ends per inch of filament is at least about 0.3.

Additional details

In the method of making the invention, the fabric to be further processed is made and then stabbed with a needle. In one embodiment, the fabric may be a blister fabric made by standard knitting or weaving techniques of filament yarns. The blister fabric includes a section having two separate layers of knitwear, and a section of a double layer jersey knit knitted with yarns from one of two separate layers sandwiched between the layers of the double layer stop knit. In another embodiment, the two fabrics to be processed are two layers that will be joined in a subsequent process. At least one of the layers of the multilayer fabric to be processed is a knit, and both layers may be knit. In a preferred embodiment, the yarns making up the fabric to be processed are filament yarns. However, it is also contemplated that the yarn may comprise shorter fibers or may be a spun fiber yarn with or without filament.

The manufactured fabric to be processed is fed to a needle stabbing device by inserting a needle onto the fabric. Typically, a needle sticking device inserts a needle into and out of a fabric in a direction that is generally orthogonal to the surface of the fabric. The backing plate (not shown) provides a support for the fabric on the opposite side on the needle and has holes to allow the needle to pass through the fabric completely. The needle can be inserted and removed from either side of the fabric or from both sides of the fabric. By inserting the needle on only one side, the connection is created only by the side of the fabric to be processed into which the needle is inserted. If more needle insertion is required per square area than can be provided by a single insertion on the needle, the needle phase can be inserted two or more times in a specific area of the fabric or the same area using several needle phases. Can be inserted into

In one embodiment, the needlestick device moves relative to the needle and the cloth in a linear direction (machine direction) as the cloth moves through the needlestick device and exits the needlestick device. The needle is inserted into the fabric in such a way that little or no production occurs. By moving the needle image in the direction of movement of the fabric when the needle is inserted into and removed from the fabric, there can be no relative linear movement between the needle and the fabric. After sticking the fabric with a needle, the back coating can be applied to the fabric by various known methods such as knife coating, foam coating, lamination, spray coating or other similar methods.

4 is a partial enlarged view of one embodiment of one of the needles 400 used in the present invention. Needle 400 has a pointed tip 410 and a notch 420 along the length of needle 400. The pointed end 410 of the needle 400 allows the needle 400 to easily pass through the yarn and cloth layer. The nick 420 of the needle 400 picks up or "fishes" the fibers of the yarn as the needle 400 passes through the yarn and cloth layers. As the needle 400 continues to pass through the adjacent yarns and / or cloth layers, the fibers already caught by the notches 420 of the needles 400 move into the main body of the adjacent yarns and / or cloth layers. . Due to the movement of the fiber by the needle 400, the fiber is stretched or pulled from the source yarn. In the case of a fiber with a free end near the needle 400, the fiber is notched through the notch 420 until the free end of the fiber passes through the notch 420 or until the needle 400 reaches the end of travel. Following the eye 420, the fibers eventually lie in adjacent yarns and / or cloth layers. In the case of other fibers, the fibers pass into adjacent yarns and / or layers until the needle 400 reaches the moving end point, or the fibers exit from the notch 420 due to the tension of the fibers, or the fibers Is cut off. The portion of the fiber that follows the needle and exits or breaks off the needle is placed in adjacent yarns and / or layers.

In connection with stabbing the fabric with needles, other uses of the present invention may use different needles than those shown in FIG. For example, a needle may be used that includes a non-triangular cross section, such as a "tear drop" or "pinch-blade" shape, or a cross section of another shape. Many cross-sectional shapes are known and used for needle sticking fabrics and can be used for certain applications of the present invention. In addition, the notch 420 shown in FIG. 4 is any other notch / that must be proven to be operable for a given substrate fabric or in such a way that all the notches or thorns are provided along one corner of the triangular needle. The corner combination may be of different forms in which the notches (or thorns) are provided. Thus, the number and shape of the needle's nicks can be varied to suit the particular application. The invention is not limited to the use of any particular needle or needle stabbing procedure.

6 shows a top view of the fabric 701. Fabric 701 includes a warp direction 725 (also known as the machine direction) and a vertically located weft direction 730, also known as the transverse direction. Fabric 701 includes a number of interconnected base bands, shown, for example, as base bands 702, 703 and 704 in FIG. 6. In FIG. 6, these base zones 702-704 extend from the bottom of FIG. 6 to the surface of FIG. 6 and form relatively narrow bands between blister zones 710 and 711. In the particular embodiment shown in FIG. 6, the blister zones 710, 711 have a length shown along the bottom edge of FIG. 6 and a width indicated by “W” at the bottom left of FIG. 6. Thus, FIG. 6 contains about four blister zones from the surface to the bottom, as shown in FIG. 6, and contains about three blister zones in total from left to right. In addition, these blister bands shown in FIG. 6 include gratings of base bands interconnected therein. Thus, blister bands 710 and 711 are located within the interconnected grating. In FIG. 6, the warp direction 725 is typically oriented perpendicular to the weft direction 730, with the base bands 702, 703, 704 extending along the warp direction and the weft direction, with the base bands connected to each other in the grating. And blister zones 710 and 711 are located within the grating.

The particular fabric 701 shown in FIG. 6 is a fabric having two plies or layers. These two layers or layers can be seen in FIG. 7. FIG. 7 shows a partial cross-sectional view of the fabric 701 represented by the cuts 7-7 shown in FIG. 6. In FIG. 7, the fabric 701 is shown in an enlarged view with the blister zone 711 shown in the center of the figure. This particular embodiment includes a lower base layer 715 and an upper blister layer 716 that make up or form two layers, ie, blister zone 711. The upper blister layer 716 is made of yarn 718 and the lower base layer 715 is made of yarn 717. Also shown is a relatively large number of connecting fibers 720 extending from the lower base layer 715 to the upper blister layer 716. In this particular embodiment, the fabric 701 was needled on both sides, so that the connecting fibers 720 ran out of the upper blister layer 716 and extended down into the lower base layer 715; The other connecting fibers also deviate from the lower base layer 715 and extend up into the upper blister layer 716. Other embodiments of the present invention may also include a needle poke on only one side of the fabric 701.

FIG. 8 is another enlarged view of the fabric 701 showing the insert 740 seen from the left side of FIG. 7. This insert 740 shows an enlarged cross-sectional view of the fabric 701 and reveals in detail the base zone 704 lying adjacent to the blister zone 711. Also, the cut end 722 of the warp is visible in the center of FIG. 8. The cut end 721 of the warp in the blister zone 711 is shown in FIG. 8. Also shown is interconnected fiber 741 in FIG. 8, which includes a first end 742 and a second end 743, respectively. In FIG. 8, the first end 742 lies or is positioned in the lower base layer 715, while the second end 743 is located in the upper blister layer 716.

Near the left side of FIG. 8, another fiber 746 is shown including connecting ends 745a and 745b as shown in the figure. In general, the use of interconnected fibers 741, 746 serves to reinforce the entire fabric 701 so that the fabric 701 is reinforced against wear, and uses such textiles in a variety of applications, including for example, automotive seat applications. The chances of passing the strict standards required can be much higher.

In the use of the invention in which the base fabric is woven, or when using so-called "pocket" fabric or blister cloth, several different types of weaving machines can be used. For example, Example 2 uses a jacquard loom to form two plies together into a pocket fabric or a blister cloth. In other uses of the invention, other types of weaving machines, such as dobby-type weaving machines, or any other weaving machine capable of obtaining pocket fabrics, blister-like fabrics, may be used. The invention is not limited to any particular loom type or weaving procedure.

With regard to the types of yarns that can be used in the present invention, package dyed filament yarns as shown in Example 2 can be used while spinning yarns can be used in other applications. Example 1 below uses a package dyed yarn. In some applications, a piece dyed yarn may be used that dyes the yarn after weaving the fabric. Package Dyed Yarn In the examples, the yarns are dyed before they are woven. It is also possible to use solution dyed yarns which dye yarns before weaving.

With regard to the chemical composition of the yarns used, any other composition or substrate of the yarns used to make polyester, rayon, cotton, wool or industrial yarns can be used.

In some applications of the present invention, other means may be used to form interconnects (or connections) between adjacent layers. In essence, any mechanical or hydraulic means may be used to move the fibers from one layer and place them in an adjacent layer.

The result obtained by needle-punching the multilayer fabric of the present invention is typically achieved by positively moving or moving a portion of the fibers or filaments of a particular yarn from one layer directly into the main body of the adjacent yarn or adjacent fabric layer. It can then be fixed directly in the main body of the adjacent yarn or cloth layer. The fibers or filaments migrated into adjacent yarns form a connection between the fabric layer or the yarns of the fabric layer.

Counting procedure

Using the following interconnect or joint coefficient estimation procedures, the number of fiber connection ends formed by needle stitching the fabric was estimated according to the practice of the present invention. First, it should be noted that it may be impractical and even impossible to actually count the number of interconnects within a given square portion of the cloth using currently known techniques. However, by using the following estimation method, it has proved convenient to measure the desired effect obtained by sticking the cloth with a needle, which estimates the actual number of such interconnects (or connection ends) occupying a given space. to provide.

Fabrics made according to the invention and which have been needled can be cut, for example in the weft direction. After cutting, the needle-punched fabric is examined under a scanning electron microscope (SEM) with a suitable magnification, which in some cases is found to be about 20 to 40 times. The joints (fiber ends moved into the subsequent layer) are then actually counted along one straight edge of the fabric resulting from the cut. In some cases, it has been found to be convenient to count these fiber connections resulting from moving from the first layer to the second layer along a straight length of about 20 to 25 mm.

In general, the equations that can be used in the estimation method for determining the number of interconnects in unit square and area are:

Example 1

knitting

The present invention may be better understood by reference to the following examples. The fabric is a blister fabric consisting of two 1/200/48 yarns of different colors for the base yarns and 2/150/50 yarns for the yarns used in the blister zone of the fabric. Fabrics with blisters are made in a two-phase annular knitting machine having the knitting pattern shown in FIGS. 5A and 5B. The back of the fabric uses two basic yarns to create two different colors, alternately knitted, each yarn having about 18 courses per inch (combined to make about 36 noses per inch). , About 13 bones per inch (combined to make about 26 bones per inch). The back of the fabric does not knit blister yarns. On the surface of the fabric in the blister zone, the blister yarns form a jersey knit with about 32 noses per inch and about 28 valleys per inch. Also on the surface of the base zone, two base yarns are knitted alternately, each yarn having about 18.25 noses per inch (combining about 36.5 noses per inch) and about 14 valleys per inch. (Combined to make about 28 goals per inch).

The blister cloth was then punctured with a needle to form a joint in the cloth. Using the Dilo Hyperpunch double needle weaving machine (Dilo Manufacturing Co.), the fabric is needled with a needle movement with little or no relative movement in the machine direction between the fabric and the needle. Stabbed with The needle phase contained the Groz-Beckert F222 needle, a triangular needle with six notches (two per corner of the needle). The needle phase was inserted into the fabric for a time sufficient to produce approximately 900 needle inserts per cm 2. This needle-sticking process has been shown to produce about 350 connections per square inch in the blister zone, corresponding to about 1.4 connections per inch of yarn and about 0.022 connections per inch of filament. The needle-stick cloth was back coated with about 3 oz / yd ² of latex.

The surface of the fabric was tested by Taber snag testing according to SAE J948, using an H-18 wheel weighing 1000 g to run 200 times on needle and non-needle samples. For non-stick cloths, the surface of the cloth was rated 3.0. In the case of needle-stitched fabric, the surface of the fabric obtained a rating of 3.5.

Example 2

textile

With reference to the following description, this additional embodiment can be understood. In this embodiment, the fabric is not knitted but woven. The fabric is a blister fabric consisting of warp and weft 2/300/136. In this embodiment, other embodiments may be provided in which the warp and weft are the same, but the yarns are not the same. In general, the present invention is not limited to any particular form or type of yarn. In this particular embodiment, the warp and weft are both made of two plies with 300 denier per ply. Each ply was provided with 136 filaments. Filament yarns were used which were package dyed (ie meaning yarn dyed before weaving). The fabric was woven in a jacquard loom.

The fabric had about 38 picks per inch and about 60 ends per inch. In the blister area of the fabric, the two layers remained essentially separate after weaving (pocket area). In the base zone or the surrounding zone (also known as the "coupled" zone), the two layers were tightly woven together.

Pushing the needle into the blister zone, partially leaving the fibers to extend the fibers between the two layers of fabric or to a position that spans the two layers, thereby stitching the "pocket weave" fabric into the needle stabbing process to form the interconnect. Was added. Using a dilo hyper punch double needle weaving machine (Diro Manufacturing Company), the fabric was needled with a needle movement that contained little or no relative movement in the machine direction between the fabric and the needle.

In this particular type of needle stabing method, the needle moves in an elliptical motion to move along the fabric for a period of time while allowing the needle to engage into the fabric. This allows for faster working speeds in the manufacture of fabrics.

The needle phase contained F222 needles manufactured and distributed by Groz-Beckert Company, which included triangular needles with about 6 (2 per corner of needles) indentations. In this particular example the needle phase was inserted into the fabric for a time sufficient to form about 300 inserts per cm 2.

Using the counting procedure detailed herein, it was found in this example that the needle-sticking process produced about 40,854 connections per square inch in the fabric in the blister zone (also known as the pocket weaving zone) (about 40 Under SEM magnification of 2x). Counting under a magnification of about 22 times, it was estimated that there were about 27,530 connections per square inch. This number is somewhat less than the coefficient made at higher magnifications and is believed to be less because at lower magnifications the ability to observe the actual interconnected fibers is low. Therefore, it is believed that the coefficient obtained under higher magnification will be more accurate.

Obviously, in this embodiment using a pocket fabric, the needle stabbing process produces a significant amount of more connections per unit square, in this embodiment 100 times (or more) per unit square than the knit described in Example 1 You can see that more connections have been created.

In this example, estimates of yarn were obtained to estimate the number of connections (connection ends) formed on the fabric per inch of yarn in the fabric, and the number of connections (connection ends) formed on the fabric per inch of filament. In this particular example, it can be seen that there are about 60 warp ends per inch of fabric and about 38 picks per inch, resulting in a total of about 98 yarn ends per square inch of final fabric. Thus, in this particular example, 272 filaments were used for each single yarn strand, thus the estimated total amount was about 26,656 filament connection ends per square inch of fabric.

The number of connections per inch of filament was estimated to be about 1.53 in this particular example. In addition, there were about 417 connections per inch of yarn in the final fabric.

Using an H-18 wheel weighing about 1000 g to run 1000 times on needle and non-stick samples, the surface of the final fabric was tested by the Torch Hang Test according to the SAE J948 test procedure. For fabrics not sticked with needles, the surface of the fabrics was rated around 3.0. For fabrics needled in accordance with this example and the method of the present invention, the surface of the fabric has a rating of about 6.0. This higher grade is believed to be due, at least in part, to the formation of fiber ends in adjacent layers, which serve to stabilize and reinforce the entire fabric against wear.

Claims (13)

(a) a plurality of interconnected base bands having a single layer; (b) the base, comprising: i) a lower base layer consisting of a plurality of bundled yarns, and ii) an upper blister layer consisting of a yarn consisting of a plurality of fibers bundled. A plurality of blister bands located between the bands; And (c) a fabric comprising connecting fibers extending between the lower base layer and the upper blister layer. The method of claim 1, Further comprising a transition warp direction and a weft direction, wherein the warp direction is oriented normally perpendicular to the weft direction; A base band extends longitudinally along the warp direction and the weft direction, and is connected by a lattice; Fabric in which a blister zone is located in the grating. (a) two or more interconnected base bands having a single weave layer; (b) (i) a lower base layer consisting of a woven yarn composed of a plurality of first fibers; And (ii) an upper blister layer composed of a woven yarn made of a plurality of second fibers, wherein the plurality of blister zones are located between the base zones; And (c) a connecting fiber extending between the lower base layer and the upper blister layer, wherein Wherein the connecting fiber has a first end and an opposing second end, wherein the first end is located in the lower base layer and the second end is located in the upper blister layer. The method of claim 3, wherein Consisting of a two-ply fabric, wherein the two plies include the lower base layer and the upper blister layer, A fabric providing between 9,000 and 65,000 first connecting fiber ends and second connecting fiber ends per square inch of fabric. The method of claim 4, wherein A fabric providing more than 24,000 first and second connecting fiber ends per square inch of fabric. The method of claim 5, A fabric providing 4 × 10 ⁴ first connecting fiber ends and second connecting fiber ends per square inch of fabric. The method of claim 4, wherein Fabrics capable of achieving a Taber snag test rating according to SAE J948, higher than 3. The method of claim 3, wherein Fabrics with more than 100 connecting fiber ends per inch of yarn. The method of claim 8, A fabric having at least 4 × 10 ² connecting fiber ends per inch of yarn in the fabric. The method of claim 3, wherein A fabric having at least 0.3 connecting fiber ends per inch of filament in the fabric. (a) providing a plurality of interconnected base bands having a single weave layer; (b) located between the base zones, (i) a bottom base layer consisting of a first woven yarn having a plurality of first fibers, and (ii) a top consisting of a second woven yarn having a plurality of second fibers Providing a plurality of blister zones further comprising a blister layer; (c) pushing a needle into the blister zone of the fabric; And (d) moving the fibers from one of the layers to the other of the layers. (a) providing a plurality of base bands partially or wholly interconnected and having a single layer; (b) i) a lower base layer consisting of a first yarn consisting of a plurality of bundles of fibers; And ii) an upper blister layer comprised of a second yarn of a plurality of bundles of fibers, the one or more blister zones positioned between the base zones; (c) applying a needle to the blister zone; (d) transferring fibers from one of the lower base layer or the upper blister layer to another of the layers, wherein the migrated fibers are defined as interconnect fibers having a first end and a second end; And (e) forming a fabric in part comprising the interconnect fiber, wherein the interconnect fiber is at the first end in the lower base layer and also at the second end in the upper blister layer. Supported, A method of making a multilayer fabric in which the fabric is provided with a blister band. The method of claim 12, Moving the fabric in the machine direction during fabric manufacture and moving the needle in the machine direction during step (c) of applying a needle to minimize relative movement of the needle and the fabric while the needle is engaged with the fabric. .

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