MXPA05005077A

MXPA05005077A - Blister fabrics with internal connecting elements.

Info

Publication number: MXPA05005077A
Application number: MXPA05005077A
Authority: MX
Inventors: L Tucker John Jr
Original assignee: Milliken & Co
Priority date: 2002-11-15
Filing date: 2003-10-24
Publication date: 2005-07-01
Also published as: KR20050086568A; JP2006506557A; BR0316354A; EP1583856A4; CN1711379B; CN1711168A; JP4599589B2; EP1583856B1; CN1296198C; AU2003287211A8; EP1581680A4; AU2003284934A1; EP1581680A2; WO2004046437A1; WO2004046446A2; MXPA05005075A; CA2505391A1; CA2505388A1; AU2003287211A1; WO2004046446A3

Abstract

A blister fabric (740) of a knit or woven construction may be needle punched to produce internal connections of filaments or fibers (741, 746) from yarns extending into, and/or between, the yarns of an adjacent layer. Interconnections of fibers among separate layers are produced by needles which enter a first layer and then carry fibers from the first layer to a second adjacent layer within the blister of the fabric. Such interconnected fibers which bridge or span multiple layers in the fabric serve to strengthen the blister fabric, making the fabric more resistant to abrasive forces.

Description

ROUGH TISSUE WITH INTERNAL CONNECTING ELEMENTS REFERENCE TO RELATED REQUESTS This application is a continuation request in part of serial application No. 10 / 298,476 filed on November 15, 2002 entitled "Rugged fabrics with internal connecting elements" for Boyd et al.

BACKGROUND The present invention relates to fabrics having internal connecting elements or fibers that serve to stabilize the construction of the fabric.

Many methods and procedures have been used to stabilize the construction of a woven fabric or knitted fabric. Coatings have been applied to prevent one thread from moving in relation to another. However, the coatings alone do not provide the desired additional characteristics in the fabric.

Recently a process known as hydroentanglement has been employed to provide stabilization to flat weave fabrics. The hydroentangling uses jets of fluid to cause the fibers extending from the main body of a yarn to become entangled with the fibers extending from the main body of another yarn. However, hydroentangling processes sometimes affect the aesthetic characteristics of the fabric undesirably due to the large number of free fibers necessary to create the entanglements or swirling by the fluid jets. There is a need for fabrics that have been stabilized by other methods or procedures.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a top view of a rough cloth illustrating one embodiment of the present invention.

Figure 2 is an enlarged, cross-sectional view of the rough fabric of Figure 1 taken around the lines of section 2-2.

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

Figure 4 is an enlarged partial view of a needle that is used in the present invention.

Figures 5a and 5b are diagrams showing the seams that are used in an example of the present invention.

Figure 6 is a top plan view of a rough cloth of flat weave.

Figure 7 is a cross-sectional view of a portion of the rough woven fabric of Figure 6, taken along line 7-7 of Figure 6; Y Figure 8 shows another view of a portion of the cross section of the rough woven fabric of Figures 7.

DETAILED DESCRIPTION Now in relation to the figures, and in particular to Figures 1-2, there is shown a rough cloth 10 showing one embodiment of the present invention. The rough fabric 10 has alternate areas of rough areas 100 and support areas 200. The rough areas 100 have a lower rough layer 110 of a first material independent of a rough upper layer 120 of a second material. The support zones 200 are a layer of unified material.

As shown, the rough fabric 10 is formed of support yarns 11 and the roughened yarns 12. In one embodiment, the roughened cloth 10 is formed of yarns having a size of up to about 600 denier. rough 10 is formed of yarns having at least about 15 denier In a preferred embodiment, the fibers forming the supporting yarns 11 and the roughened yarns 12 may consist of filament yarns When used herein, filament yarns includes multiple filament yarns In another embodiment, the support yarns 11 and the roughened yarns 12 may consist of spun yarns In yet another embodiment, the yarns of support 11 may consist of filament yarns and the roughened yarns 12 may consist of yarns of filaments. In another embodiment, the support yarns 11 can consist of spun yarns and the roughened yarns 12 can consist of filament yarns.It is also contemplated that the present invention works with filament yarns and short fibers combined. The combined filament and short fiber yarns can be used in the support yarns 11 and / or the rough yarns 12 as a substitute for the filament yarns and / or the spun yarns in the above combinations. The fibers of the filament yarns and / or spun yarns of the present invention may be formed from natural or manufactured material. For example, natural materials may consist of materials of animal, vegetable or mineral origin that are used as fibers. The materials manufactured can consist of synthesized polymers of chemical compounds, natural or processed polymers and minerals. Still with reference to figures 1-2, as shown, the lower rough layer 110 of the rough fabric 10 is an unbreakable jersey fabric of the rough yarns 12. Also as shown, the support yarns 11 form a fabric knitted double-layer knitted sweater, unified in the support zones 200, and the rough yarns 12 are sandwiched between the double-layer knitted jersey fabric of the support threads 11 of the support zones 200. Although the rough cloth 10 shown as a knitted fabric, it is contemplated that the rough fabric may be a flat woven fabric or a combination of knitted fabric and flat fabric. Furthermore, although the unified support areas 200 are shown as a section of knitted fabric, it is contemplated that the unified support zones may be formed by processes such as weaving, sewing, adhesion or the like.

Now with reference to Figure 2, there is shown an enlarged cross-sectional area of the rough cloth 10 · As shown, connections of the rough zone 130 are formed between the lower rough layer 110 and the upper rough layer 120 by parts of fibers of the threads of a layer of the rough zone 100 which passes from these threads towards and / or between, the threads of the other layer of the rough zone 110. The connections of the lower rough layer 131 are formed between the rough layer lower 110 and upper rough layer 120 by portions of the fibers coming from the threads of the lower rough layer 110 passing from these threads towards, and / or between, the threads of the upper rough layer 120. The connections of the rough layer upper 132 are formed between the upper rough layer 120 and the lower rough layer 110 by portions of the fibers of the upper rough layer yarns 120 that pass from these yarns to, and / or between the yarns of the lower rough layer 100. The connections of the c lower rough surface 131 and connections of upper rough layer 132 provide a secure bond between lower rough layer 110 and upper rough layer 120.

Still, with reference to Figure 2, a fiber forming one of the connections of the upper rough layer 131 comes from a yarn of the lower rough layer 110 and then onto the upper rough layer 120. The fibers coming from the lower rough layer 110 forming the connections of the lower rough layer 131 are secured by the fibers or filaments of the main body of the threads of the upper rough layer 120. A part of the fibers forming the connections of the lower rough layer 131 is they secure between the fibers within the main body of the threads of the upper rough layer 120, the main body being the fiber body which is oriented in approximately the same direction as the thread itself. Another part of the fibers forming the connections of the lower rough layer 131 are secured between the threads of the upper rough layer 120 by the fibers of the main body of these threads. A fiber forming one of the connections of the upper rough layer 132 comes from a thread of the upper rough layer 120 and then protrudes towards the lower rough layer 110. The fibers coming from the upper rough layer 120 forming the connections of the upper layer 132 are secured by the fibers or filaments of the main body of the threads in the lower rough layer 110. A part of the fibers forming the connections of the upper rough layer 132 are secured between the fibers within the main body of the threads of the lower rough layer 110, the main body being the group of fibers that is oriented in approximately the same direction as the thread itself. Another part of the fibers forming the connections of the upper rough layer 132 is secured between the threads of the lower rough layer 110 by the fibers of the main body of these threads. These connection wires contrast with the connections that are formed between the threads and the layers by entanglement of the fibers that extend outwardly and at least partially radially of a thread with the fibers extending in a direction usually outward and at least partially radial from another thread, as observed with multiple methods of hydroentanglement of the treatment of a fabric.

Many of the connections of the lower rough layer 131 and the connections of the upper rough layer 132 are loops of the fibers from the respective origin layers that are inserted into the corresponding receiver layers. The loops of the fibers create two connections, "each of the connections is one half of the loop that originates in the same thread and then protrudes into the same receiving layer, in some cases, the connections of the upper rough layer 131 and / or the connections of the lower rough layer 132 may be formed by sections of the fibers which are attached to only one end of the respective feed wires, In some other cases, a fiber attached to only one end and forming a connection of the upper rough layer 131 or a connection of lower rough layer 132 can be hooked, bent or form curls or meshes at the free end to make it more secure with the fibers of the corresponding layer to which the connection is connected.

In one embodiment, the rough area of a fabric embodying the present invention has a total of at least about 275 total connections (i.e., the total of connections coming from a specific layer and the connections received by this specific layer) per inch. square, assuring the rough layer inferior to the upper rough layer, and a maximum of approximately 520,000 total connections per square inch, depending on the necessary stability and structure of the fabric. In a knitted fabric mode, the rough area has a total of about 350 total connections per square inch to approximately 1050 total connections per square inch, and in other embodiments of the knitted fabric may have approximately 750 connections totals per square inch.

Because the origin of the connections comes from within the wires, and the connections also secure the wires, it is useful to understand the number of total connections per wire distance. The total connections from a specific wire and the connections received by this specific wire are also described here as connection "ends" or connecting points. In one embodiment, for example a knitted fabric, the yarns forming the upper rough layer or the upper rough layer of the rough area of the fabric embodying the present invention have a minimum of at least about 1.1 total connections ( or connection end) per inch of thread securing the thread, and a maximum of approximately 1650 total connections per inch of thread. In a preferred embodiment, the yarns forming the lower rough layer or the upper rough layer of the rough area of the fabric embodying the present invention, have from about 1.4 total connections per inch of yarn to about 4.2 total connections per inch of yarn , and more preferably about 2.8 total connections per inch of thread.

Because the yarn fibers are the source of the connections, different yarns will have different fiber availability for the connection, and different demands of the number of connections, based on the fiber content of the yarn. A measure of the distance of the filaments is the length of a yarn that has filament (s) multiplied by the number of filaments in this yarn bundle. Therefore, it is useful to understand the number of total connections (the total of the connections from a specific wire and the connections received by the specific wire) by filament distance of the wires for the part of the fabric that is incorporated in the present invention. .

In the examples given below, the fabric was perforated with needles from the sides, but other embodiments of the invention can use construction methods that pierce with needle from only side of the fabric.

Referring again to Figure 2, a knitted fabric is shown in which the support zone 200 has a unitary construction with a lower part of the supporting layer 210 an upper part of the supporting layer 220 and yarns retained 230 passing between the lower part of the support layer 210 and the upper part of the support layer 220. In the embodiment shown, the lower part of the support layer 210 and the upper part of the support layer 220 are formed by the support yarns 11, and the rough yarns 12 form the retained yarns 230 between the two layers. As shown, the connections of the support layer 240 are formed between the lower part of the support layer 210 and the upper part of the support layer 220. Likewise, the connections of the retained yarns 250 are formed between the layer of lower support 210 and the retained yarns 230 and the upper part of the support layer 220 and the part of the retained yarns 230.

Still with reference to Figure 2, like the connections of the rough area 230, the connections of the support layer 240 are formed between the lower support layer 210 and the upper support layer 220 by portions of the fibers of the threads of a layer of the support zone 200 that pass from these threads towards the other layer of the support zone 200. The connections of the lower base layer 241 are formed by the fibers coming from a yarn of the lower support layer 210 and then protrude towards, and / or between, the yarns of the support layer upper 220. The fibers from the lower support layer 210 forming the connections of the lower support layer 241 are secured by the fibers or filaments of the main body of the yarns in the upper support layer 220. A part of the fibers which form the connections of the lower support layer 241 are secured between the fibers within the main body of the threads of the upper support layer 220, the main body being the group of fibers which is oriented in about the same diameter. the thread itself. Another part of the fibers forming the connections of the lower support layer 241 is secured between the threads of the upper layer 220 by the fibers of the main body of these threads. The connections of the upper support layers 242 are formed by the fibers coming from a yarn of the upper support layer 220 and then protrude towards the lower support layer 210. The fibers coming from the upper support layer 220 forming the connections of the upper support layer 242 are secured by the fibers or filaments of the main body of the yarns in the lower support layer 210. A portion of the fibers forming the connections of the upper support layer 242 are secured between the fibers within the main body of the threads in the lower support layer 210, the main body being the group of fibers that is oriented in approximately the same direction as the thread itself. Another part of the fibers forming the connections of the upper support layer 242 is secured between the threads of the lower support layer 210 by the fibers of the main body of these threads. The connections of the lower support layer 241 and the connections of the upper support layer 242 provide a secure tie-down between the lower support layer 210 and the upper support layer 220.

As with the connections of the lower rough layer 131 and the connections of the upper rough layer 132 ,. many of the connections of the lower support layer 241 and the connections of the upper support layer 242 are loops or curls of the fibers in the respective supply yarns which. they are inserted into the corresponding receptor layer. In some cases, the connections of the lower support layer 241 and / or the connections of the upper rough layer 242 may be formed by sections of the fibers that are attached to only one end of the respective supply wires. In some other cases, a fiber attached to only one end and forming a connection of the lower support layer 241 or a connection of the upper support layer 242 can be hooked, bent or crimped to the free end to be further secured with the fibers of the corresponding receiving layer to which the connection is attached or linked. The connections of the support layer 240 provide a secure tie-down between the lower support layer 210 and the upper support layer 220, thereby giving the support zone 200 an abrasion-resistant and more stabilized fabric.

In one embodiment, the support zone embodying the present invention has a total of at least about 50 total connections (the total of connections originating from a specific layer and the connections received by this specific layer) per square inch, ensuring the lower support layer to the upper support layer, and a maximum of about 109,110 total connections per square inch, and more preferably about 150 total connections per square inch, depending on the necessary stability and construction of the fabric. In one embodiment, the yarns forming the lower support layer of the upper support area of the support zone of the fabric embodying the present invention have a minimum of at least about 0.6 total connections per inch of yarn securing the yarn, and a maximum of about 11.61 total connections per inch, and more preferably about 1.6 total connections per inch of thread. In one embodiment, the wires forming the connections have from about 28.8 connections per inch of filament to about 557 connections per inch of filament.

Still in relation to Figure 2, the retained thread connections 250 are formed between the retained wires 230 and the lower support layer 210 and the upper support layer 220, by portions of the fibers coming from the retained thread 230 passing to, and / or between, the main body of the threads of the lower support layer 210 or the upper support layer 220, and / or the fibers coming from the threads of the lower support layer 210 or the upper support layer 200 which pass to the stopped thread 230. The connections of the retained thread of the lower support 251 are formed between the retained wires 230 and the lower support layer 210 by parts of the fibers of the wires of the lower support layer 210 passing from these wires towards the main body of the retained threads 230, and by figures from the retained threads passing from the retained threads 230 towards, and / or between, the main body of the threads of the lower support layer 210. The connections d The retained upper support yarns 252 are formed between the retained yarns 230 and the upper support layer 220 by portions of fibers from the yarns of the upper support layer 220 that pass from these yarns to the main body of the retained yarns. 230, and by the fibers of the retained yarns 230 that pass from the retained yarns 230 towards, and / or between, the main body of the yarns of the upper support layer 220.

As with the connections of the lower support layer 241 and the connections of the upper support layer 242, many of the connections of the retained threads of the lower support 251 and the connections of the retained threads of the upper support 252 are loops of the fibers in the respective feed yarns that are inserted into the corresponding receiving strands or layer. Sn some cases, the connections of the retained threads of the lower support 251 and / or the connections of the retained threads of the upper support 252 can be formed by sections of the fibers that are attached to only one end of the respective supply threads. In some other cases, a fiber that is attached to only one end and forms a retained thread connection of the lower support 251 or a retained thread connection of the upper support 252 may be hooked, bent or crimped at the free end to be more secure with the fibers of the corresponding receiving strand or layer to which the connection is connected.

The connections of the retained yarns 250 provide a secure mooring between the retained yarns 230 and the lower support layer 210, and the retained yarns 230 and the upper support layer 220, thereby giving the support zone 200 a resistant fabric abrasion and more stable. In one embodiment, the yarns forming the yarns retained from the support zone of the fabric embodying the present invention have a minimum of at least about 0.6 total connections per inch of yarn securing the yarn, a maximum of about 11.61 total connections per inch of thread, more preferably about 1.6 total connections per inch of thread. In one embodiment, the retained wires have from about 28.8 connections per inch of filament to about 557 connections per inch of the filament.

In one embodiment, the needle-punched rugged fabric 10 also has a backing coating placed on the back side of the lower rough layer 110 and the lower backing layer 210. It has been found that a backing further improves the abrasion resistance of the opposite side of the needle-like rugged fabric 10. The backing can be any polymeric material such as vinyl polyacetate latex, or the like. The backing can be applied to the knitted, flat woven or other substrate, and can be applied in a concentration from about 0.25 oz / yd 2 to about 5 oz / yd2. In general, the backing can be used in knitted fabrics, flat woven fabrics or any other type of fabric used in the practice of the invention.

Now with reference to Figure 3, there is shown an enlarged cross section of a fabric composite 20 showing another embodiment of the present invention. The fabric composite 20 is a multilayer bath, such as a double cloth, a triple cloth, etc., the fabric consists of at least a first layer 21 and a second layer 22. At least the first layer 21 or the Second layer is a knitted fabric. In the embodiment shown in Figure 3, the first layer 21 is formed from the yarns of the first layer 23, and the second layer 22 is formed from the yarns of the second layer 24. In one embodiment, the yarns of the first layer 23 and / or the yarns of second layer 24 have a yarn size of up to about 600 denier. In another embodiment, the yarns of the first layer 23 and / or the yarns of the second layer 24 have a yarn size of at least about 15 denier. In a preferred embodiment, the yarns of the first layer 23 and the yarns of the second layer 24 consist of filaments. In another embodiment, the yarns of the first layer 23 are filament yarns and the yarns of the second layer 24 are spun yarns. In still another embodiment, the yarns of the first layer 23 and the yarns of the second layer 24 are spun yarns. Furthermore, it is contemplated that the yarns of the first layer 23 and / or the yarns of the second layer 24 may consist of yarns formed from the combination of filaments and short fibers.

The connections 25 are formed between the first layer 21 and the second layer 22 by the filaments of the yarns of the two layers. The connections of the first layer 26 are formed by parts of the fibers of the first layer 21 that project onto the second layer 22. The connections of the first layer 25 are secured by the fibers of the main body of the strands of the second layer. 24. The connections of the second layer 27 are formed by parts of the fibers of the second layer 22 that project onto the first layer 21. The connections of the second layer 27 are secured by the fibers of the main body of the wires of the second layer. first layer 23. It is contemplated that the connections 25 of the present invention may be formed through the entire composite fabric 20, or in small areas.

The connections 25 are formed between the first layer 21 and the second layer 22 by the filaments of the threads of the two layers. The connections of the first layer 26 are they form by parts of the fibers of the first layer 21 projecting towards the second layer 22. The connections of the first layer 25 are secured by the fibers of the main body of the threads of the second layer 24. The connections of the second layer 27 they are formed by parts of the fibers of the second layer 22 projecting towards the first layer 21. The connections of the second layer 27 are secured by the fibers of the main body of the threads of the first layer 23. It is proposed that the connections 25 of the present invention can be formed throughout the composite fabric, or in small areas.

Many of the connections of the first layer 26 and the connections of the second layer 27 are loops of the fibers from the respective feed layers that are inserted into the corresponding receiving layers. The loops of the fibers create two connections, each of the connections being one half of the loop that comes from the same thread and then protrudes towards the same receiving layer. In some cases, the connections of the first layer 26 and / or the connections of the second layer 27 can be formed by sections of the fibers that are attached to only one end of the respective supply wires. In some other cases, a fiber attached to only one end and forming a connection of the first layer 26 or a connection of the second layer 27 can be hooked, folded or crimped at the free end to be further secured with the fibers of the corresponding layer to which the connection is linked.

In one embodiment, the composite fabric, or the area of the composite fabric incorporating the present invention, will have a total of at least about 275 total connections (the total of both connections exiting from a specific layer and the connections received by this specific layer). ) per square inch ensuring the first layer to the second layer, and a maximum of approximately 520,000 total connections per square inch, depending on the necessary stability and construction of the fabric. In a preferred embodiment, open a total of from about 350 total connections per square inch to about 1050 total connections per square inch, and more preferably about 350 total connections per square inch.

In still another embodiment, the yarns forming the first layer or the second layer of the composite fabric embodying the present invention have a minimum of at least about 1.1 total connections per inch of yarn securing the yarn, and a maximum of about 1650 total connections per inch of thread. In a modality employing the knit fabric, these yarns have from about 1.4 total connections per inch of yarn 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 forming the first or second layer of the composite fabric incorporating the present invention have at least about 0.02 total connections per inch of filament, and a maximum of about 6.4 total connections per inch of filament. In a preferred embodiment, these yarns have from about 0.022 total connections per inch of filament to about 0.07 total connections per inch of filament, and most preferably about 0.04 total connections per inch of filament.

Knitted fabrics In one embodiment of the invention, which is a knitted fabric, the yarns that form the lower rough layer (or the lower rough layer of the rough area) have at least about 0.02 total connections per inch of filament, and a maximum of about 6.4 total connections per inch of filament. In yet another embodiment, the yarns forming the upper rough layer or the lower rough layer of the rough area have from about 0.022 total connections per inch of filament to about 0.07 total connections per inch of filament, and in other cases about 0.04 connections total per inch of filament.

Flat woven fabrics In yet another embodiment of the invention, which is a flat woven fabric, the yarns forming the entire (double) bilayer fabric in the rough area have at least about 9,000 total connections (connecting ends) and up to about 65,000 connector ends per square inch of woven fabric.

In yet another embodiment, the flat ejido fabric includes approximately 4 x 104 first and second fiber connecting ends per square inch of the fabric. Other embodiments include approximately 24,000 first and second ends of connective fibers per square inch of woven fabric.

Other applications give rise to a flat woven fabric with a two-part rough layer, in which the total two-part rugose layer as a whole provides more than about 100 fiber connector ends per inch of yarn. In other applications, the number of fiber connecting ends per inch of yarn in the fabric is at least about 4 x 10z. In some embodiments, the number of fiber connector ends per inch of filament is at least about 0.3.

Another detailed description In a method for manufacturing the present invention, the fabric to be further processed is formed and then subjected to a needling process. In one embodiment, the fabric can be a rough fabric that is formed by the normal knitting or plain weave techniques of the filament yarns. The rough fabric consists of areas with two separate layers of knitted fabric material, and areas of an unbreakable double layer jersey knit with yarns from one of the two separate layers sandwiched between the layers of the double layer jersey knit fabric. In another embodiment, the fabric to be processed is two layers that are joined in the further processing. At least one of the layers in a multilayer fabric to be processed is a knitted fabric, and both layers could be a knitted fabric. In a preferred embodiment, the yarns forming the fabric to be processed are filament yarns. However, it is considered that the yarns could include shorter fibers or they could be spun fiber strands with or without filaments.

The cloth formed to be processed is fed to a needle-punched machine that pierces the fabric by inserting a bed of needles into the fabric. Usually, the piercing machine inserts the needles in the fabric and removes the needles, in an injection usually perpendicular to the surface of the fabric. The backing plates (not shown) provide support for the fabric on the opposite side of the needle bed, and have holes to allow the needles to pass completely through the fabric. The needles can be inserted and removed from either side of the fabric, or both sides of the fabric. When inserting the needles from only one side, only connections will be made on the side of the fabric to be processed by which the holes are inserted. If more needle inserts per square area are needed compared to those that can be provided by a single insertion of the bed of needles, then the needle bed can be inserted more than once into an area of the specific fabric, or it is possible to use Multiple needle beds to be inserted in the same area.

In one embodiment, the piercing machine inserts the needles into the fabric in a way that produces little or no relative movement between the beds of the needles and the fabric in the linear direction (the direction of the machine) as the fabric moves. to, cross and exit the machine. The absence of relative linear movement between the beds of the needles and the fabric can be carried out by moving the beds of the needles with the direction of travel of the fabric as the needles are inserted into the fabric and leave the fabric. After the fabric has been punched it is possible to apply a backing to the fabric by different known methods, such as knife coating, foam coating, lamination, spray coating or other similar methods.

Now with reference to Figure 4 there is shown an enlarged partial view of an embodiment of one of the needles 400 that is used in the present invention. The needle 400 has a pointed end 410 and the notches 420 along the length of the needle 400. The pointed end 410 of the needle 400 facilitates the passage of the needle 400 through the threads and layers of the fabric. The notches 420 of the needle 400 pick up or "hook" fibers of the yarns when the needle 400 passes through the yarns and the layers of the fabric. As the needle 400 continues to pass through contiguous yarns and / or fabric layers, the fibers previously hooked by the notches 420 of the needle 400 move towards the main body of the adjoining threads and / or the fabric layers, the movement of the fibers by the needles 400 that will stretch or pull the fibers of the threads of destiny. For fibers with free ends near the needle 400, the fiber will follow the notch 420 of the needle 400 until the free end of the fiber passes through the notch 420 or the needle 400 reaches the end of its path, and the fiber it is deposited in the adjoining yarn and / or fabric layer. For other fibers, the fiber will pass into the yarn and / or adjoining layer until the needle 400 reaches the end of its path, or the fiber board causes the fiber to be released from the groove 420, or the fiber is broken. The part of the fiber that follows the needle and is released from the needle or breaks, will deposit this part of the fiber in the thread and / or adjoining layer.

With respect to the needle piercing the fabric, other applications of the invention could employ needles that are different from that shown in Figure 4. For example, it is possible to use needles that include a non-rectangular cross section, as to be transverse sections that are in the form of "tear" or "in the form of a goat foot blade" or other shape, in their cross section. Multiple configurations of cross section are known and used in the application of the needles for fabrics, which could be used in applications of the invention. Moreover, the samples 420 as seen in Figure 4 could be of a different configuration in which the notches (or grapples) are provided with all the notches or hooks along one edge of the triangular needle or in any other combination of notches / edge that must work for a given substrate fabric. Thus, the number and configuration of the notches (hooks) on the needle can be varied to suit a specific application. The invention is limited to the use of a specific needling needle or method.

Referring now to Figure 6 there is shown a top plan view of a flat weave fabric 701. The flat weave fabric 701 has a warp direction 725 (also known as the machine direction) and a weft direction placed perpendicularly 730, also known as the transverse direction. The flat weave fabric 701 consists of a plurality of interconnected support areas which is seen for example in Figure 6 as the support areas 702, 703 and 704. In Figure 6 these support areas 702-704 extend from the base of figure 6 to the upper part of figure 6, and form a relatively narrow band between the rough areas 710, 711. In the particular embodiment shown in figure 6, the rough areas 710, 711 have a length as it is shown along the lower edge of figure 6, and a width as shown by "W" in the lower left part of figure 6. Thus, figure 6 contains approximately 4 rough areas from the upper part to the lower one, and a total of 3 rough areas from left to right as shown in figure 6. Furthermore, these rough areas as shown in figure 6 include within these a grid of interconnected support zones. Therefore, the rough areas 710, 711 are placed within an interconnected grid. In Figure 6, the direction of the warp 725 is oriented generally perpendicular to the direction of the weft 730, and the support areas 702,703 and 704 extend along the directions of the warp and weft, with the support areas connected within a grid between them, and the rough areas 710, 711 placed within the grid or grid.

The particular woven fabric 701 shown in Figure 6 is a fabric having two layers. These two layers can be seen in figure 7. Figure 7 shows a cross-sectional view of a part of the flat fabric 701 indicated by section 7-7 shown in figure 6. In figure 7 the flat weave fabric 701 it is shown in an extended view where the rough area 711 is shown in the center of the figure. This specific embodiment consists of two layers, a lower support layer 715 and an upper rough layer 716 that constitute or comprise the rough area 711. The upper rough layer 716 is composed of yarns 718, and a lower support layer 715 is composed of 717. In addition, a relatively large number of connector fibers 720 are observed extending from the lower support layer 7154 to the upper rough layer 716. In this specific embodiment, the flat weave fabric 701 was pierced on both sides, and therefore the connector fibers 720 were displaced from the upper rough layer 716 to extend downward to the lower support layer 715; further still, other connecting fibers were displaced from the lower support layer 715 to extend upwards and towards the upper rough layer 716. Other embodiments of the invention may include a needle piercing only from one side of the flat weave fabric 701.

Figure 8 shows yet another extended view of the flat weave fabric 701 showing the insert 740 shown on the left side of Figure 7. This insert 740 shows an extended view of the flat weave fabric 701 in the cross section, and shows a detailed view of the support area 704 which is adjacent to the rough area 711. Furthermore, the cut end of a warp yarn 722 is shown in the center of figure 8. The cut end of a warp yarn 721 within the rough zone 711 is seen in Figure 8. In addition, the interconnected fibers 741 are shown in Figure 8, each of which includes a first end 742 and a second end 743. In Figure 8 the first end 742 is deposited or placed within the lower support layer 715, while the second end 743 is placed within the upper rough layer 716.

Near the left side of Fig. 8 is another fiber 746 which includes connector ends 745a, b as shown in the figure. In general, the use of interconnected fibers 741, 746 contributes to reinforcing the total flat weave fabric 701 so that the fabric is reinforced against abrasion, and it may be much more likely to pass the stringent standards for the use of these textiles in different applications. , which includes for example the applications for car seats.

In applications of the invention for which the substrate fabric is knitted, or when a fabric of flat or rough weave called "alveoli" is used, it is possible to use some different types of weaving machines. Example 2 employs a type of jacquard loom forming the two layers together in the material of the alveolar rugose flat fabric. In other applications of the invention it would be possible to use other types of looms. For example, a dobby-type loom or any other loom that can achieve a fabric of alveolar flat fabric or rugged type flat fabric. The invention is not limited to any particular type of loom, or weaving process.

With respect to the types of yarns that can be employed in the invention, it would be possible to use a filament yarn dyed in a winder as shown in Example 2, while other applications would be possible to use a spun yarn. Example 1 below uses a yarn dyed in a wire feeder. In some applications it would be possible to use a yarn dyed per piece in which the yarn is dyed after the fabric is woven. In the example of the yarn dyed in a winder, the yarn is pre-dyed prior to weaving. In addition, it would be possible to employ a yarn dyed in solution, in which the yarn is dyed before weaving.

With respect to the chemical composition of the yarn used, it would be possible to use polyester, rayon, cotton, wool or any other composition or substrate in the yarn used to manufacture the yarn in the industry.

In some applications of the invention it may be possible to use other means to form interconnections (or connections) between adjacent layers. Practically any mechanical or hydraulic means could be used to move the fibers of a deposit layer in the adjacent layer.

The result achieved by the needle piercing of the multilayer fabric of the present invention usually includes a positive movement or displacement of a part of the fibers or filaments of some yarns from one layer directly to the main body of the adjacent yarns or yarns. layers of contiguous fabrics, whereby these fibers or filaments can then create an anchor directly within the main body of the adjoining fabric strands or layers. The fiber or filament displaced within the adjacent yarn forms the connection between the fabric layers or the yarns of a fabric layer.

Counting procedure The following procedure for estimating the interconnection or connection count is used to calculate the number of fiber connecting ends formed by needling of the fabric according to the practice of the invention. First, it is possible to observe that it is impractical, and it may even be impossible, to use the currently known techniques to obtain a real account of the number of interconnections in a given square part of the fabric. However, it has been found convenient to measure the desired effect from the needling of the fabric using the following estimation method, which provides an estimate of the actual number of interconnections (or connecting ends) occupying a given space.

A fabric that has been prepared and perforated with needles according to the invention can be cut in the direction of the weft, for example. After cutting, the flat tissue fabric punctured with needles is examined under a scanning electron microscope (SEM) having a convenient amplification, which in some cases has been found between approximately 20x and 40x. Then a real count is made of the connections (the ends of the fibers that have been moved to a subsequent layer) along a linear edge of the fabric along the cut. In some cases it has been found convenient to cut such fiber connections resulting from the displacement of a first layer to a second layer along a linear length of about 20-25 mm.

In general, the formula that can be used in the estimation method to determine the number of interconnections in a square unit and area is as follows: Number of interconnections = (connections with all reals) 2 (SEM amplification) 2 Unit area (linear distance in which the counts are made) 2 Example 1 Knit Fabric The present invention can be better understood with reference to the following example. The fabric is a rough fabric formed of two threads 1/200/48 of different color for the support threads and threads 2/150/50 for the threads that are used in the rough area of the fabric. The fabric having wrinkles or vesicles is formed in a two-bed circular knitting machine with the design of the knitted fabric as shown in Figures 5a and 5b. On the back of the fabric the two support yarns are used to make two different colors in alternating horizontal strips, each yarn having approximately 18 alternating stripes per inch each (combined making approximately 36 horizontal stripes or rows per inch) and approximately 13 columns per inch (combined making approximately 26 columns or longitudinal rows per inch). The rough yarn is not woven in the back of the fabric. On the face of the fabric in the rough area, the rough yarn forms a jersey knit fabric with approximately 32 horizontal rows per inch and approximately 28 longitudinal rows per inch. Likewise on the face, but in the support area, the two support yarns are woven in alternating horizontal rows, each yarn having approximately 18.25 horizontal rows per inch each (combined making approximately 36.5 horizontal rows per inch) and approximately 14 rows longitudinal per inch (combined making approximately 28 longitudinal rows per inch).

The rough cloth is then subjected to a needling process to form the connections in the fabric. A double needle loom Dilo Hyperpunch (Dilo Manufacturing Co.) was used to pierce the fabric with a pricking movement that had little or no relative movement in the machine direction between the fabric and the needle bed. The needle bed contained Groz-Beckert F222 needles, which are triangular needles with 6 notches (2 per angular edge of the needle). The needle bed was inserted into the fabric enough times that approximately 900 needle inserts were made per square centimeter of the fabric. It was found that this pricking process gives rise to approximately 350 connections per square inch of the cloth in rough area, which was approximately 1. connections per inch of thread and approximately 0.022 connections per inch of filaments. The needle-coated fabric was then coated on the backing with approximately 3oz / yd of latex.

The face of the fabric was subjected to a Taber rub test in accordance with SAE JB 8, using H-18 wheels with 1000 grams of weight during 200 cycles for the samples that were not punched, and the samples that were punched. For the fabric that was not pierced, the face of the fabric received a rating of 3.0. For the fabric that was punched, the face of the fabric obtained a 3.5 rating.

Example 2 Knit Fabric This other example can be understood with reference to the following description. In this example, the fabric is woven flat, not knitted. The fabric is a rough fabric formed of warp and weft threads, 2/300/136. In this example, the threads of the warp and weft are identical, but other examples can be provided in which the threads are not identical. In general, the invention is not limited to any specific configuration or identity of threads. In this specific example, the warp and weft threads consist of two layers, having 300 denier per layer. Each layer had 136 filaments. I know I use a filament thread that was a yarn dyed in a wire feeder, which means that the yarn was dyed before weaving. The fabric was woven with knitting in a jacquard weaving machine.

In the cloth there were approximately 38 passes or weft threads per inch and approximately 60 ends per inch. In the area of the vesicle for the fabric, the two layers remained practically separated after the tissue (in the alveolar area). In the support zone or the perimeter area (also known as the "mooring" area) the two layers were woven tightly together. The "woven" fabric was subjected to a needling process in which the needles were pushed towards the rough areas to form interconnections in part displacing the fibers moving these fibers in positions in which they extend between or span two layers of the flat weave fabric. To perforate the flat woven fabric, a double needle loom Dilo-Hyperpunch (Dilo Manufacturing Co.) was used with a movement of the needles that caused little or no relative movement in the direction of the machine between the fabric and the bed of the needles. needles In this particular type of piercing method the needle moves in an elliptical movement, so that the needle travels together with the fabric for a while while the needle is inserted into the fabric. This allows faster process speeds in the manufacture of the fabric.

The needle bed contained F222 needles manufactured and distributed by the Groz-Beckert company, which included a triangular needle with approximately 6 notches (2 per angular edge of the needle). The needle bed was inserted into the plain weave fabric enough times that approximately 300 inserts were made per square centimeter of the fabric for this specific example.

Using the detailed counting procedure in this specification, it was found in this example (under an SEM amplification of approximately 40x) that the tapping process resulted in approximately 40,854 connections / square inch in the flat weave fabric within the rough area ( also known as the alveolar tissue area). Under amplification of only about 22x, the count gave an estimate of approximately 27,530 connections per square inch.

This number is somewhat lower than the score obtained at higher amplification, and in this way less life is considered to be the less ability to observe the real fibers interconnected in low amplification. Therefore, the account obtained in greater amplification is considered more accurate.

As it is evident, it can be observed that in this example a fabric of alveolar flat weave is used the pricking process produces a significant amount of more connections per square unit, and in this example it produced more than 100 times (or more) connections per unit square then a knit fabric as seen in Example 1.

In this example an estimate was made of the yarns to calculate the number of connections (connector ends) formed in the fabric per inch of yarn inside the fabric, and also the number of connections (connector ends) formed in the fabric per inch of yarn. filament. In this specific example, it can be seen that there were approximately 80 warp ends per inch in the woven fabric, and approximately 38 strokes per inch, giving a total of approximately 98 yarn ends per one square inch of the finished fabric . Thus, in this particular example, 272 filaments were used per single strand thread, which resulted in an estimated total amount of approximately 26,656 filament / inch connectors per square inch of the fabric.

The number of connections per inch of filament, then, was calculated at approximately 1.53 in this specific example. Moreover, there were approximately 417 connections per inch of thread in the finished fabric.

The face of the finished fabric was subjected to the Taber rub test in accordance with SAE J848, using H-18 tests with approximately 1000 grams of weight and 1000 cycles for samples that had not been punctured and for samples that were punched. For the fabric that was not punched, the face of the fabric received a rating of only about 3.0. For the fabric that was punched according to the example and the process of this invention, the face of the fabric obtained a classification of approximately 6.0. The higher classification is considered to be due at least in part to the formation of fiber ends within adjacent layers which serves to stabilize and reinforce the total fabric against the abrasion forces.

Claims

A fabric consisting of: (a) a plurality of interconnected support zones, the support zones have a single layer, and (b) a plurality of rough areas located between the support zones, the rough areas comprise at least the following i) a lower support layer composed of yarn, the yarn being composed of a plurality of fibers in clumps; and ii) an upper rough layer composed of yarn, the yarn being composed of a plurality of fibers in clumps; and (c) connecting fibers extending between the lower support layer and the upper rough layer.
The fabric of claim 1, characterized in that the fabric further consists of a warp direction and a weft direction, the warp direction oriented generally perpendicular to the weft direction, wherein the support areas extend in the longitudinal direction along the directions of the fabric and the weft, the support areas being connected in a grid, the rough areas being placed inside the grid.
A flat woven fabric composed of: (a) at least two interconnected support zones, the support zones have a single layer of flat weave; and (b) a plurality of rough areas located between the support zones, the rough areas further comprising: i) a lower support layer composed of flat woven yarn, the flat woven yarn being composed of a first plurality of fibers; and ii) An upper rough layer composed of flat dewoven yarn, the flat woven wire being composed of a second plurality of fibers (c) connecting fibers extending between the lower support layer and the upper rough layer, the connecting fibers having a first end and a second opposite end, the first end located within the lower support layer and the second end being located within the upper rough layer.
The flat woven fabric of claim 3, characterized in that the flat woven fabric consists mainly of a two-layer fabric, the two layers comprising the lower support layer and the upper rough layer, wherein the flat woven fabric provides between approximately 9000 and approximately 65,000 first and second ends of connective fibers per square inch of the woven fabric.
The flat woven fabric of claim 4, characterized in that the flat woven fabric provides more than about 24,000 first and second ends of connecting fibers per square inch of the woven fabric.
The flat woven fabric of claim 5, characterized in that the fabric provides approximately 4 x 10 first and second ends of connector fibers per square inch of the
7. The fabric of claim 4, characterized in that the flat weave fabric is capable of achieving a classification in the Taber gall test in accordance with SAE J848 of more than 3.
8. The fabric of claim 3, characterized in that the number of ends of connective fibers per inch of yarn is greater than about 100.
9. The fabric of claim 8, characterized in that the number of ends of connective fibers per inch of yarn in the fabric is at least 2 about 4 x 10.
10. . The fabric of claim 3, characterized in that the number of ends of connective fibers per inch of filament in the fabric is at least about 0.3.
11. A method for manufacturing a flat, needle-punched fabric consisting of: (a) having a plurality of interconnected support zones, the support zones having a single layer of flat fabric; and (b) having a plurality of rough areas located between the support areas, the rough areas further consist of: i) a lower support layer composed of a first flat woven thread, the first flat woven thread having a first plurality of fibers; and ii) an upper rough layer composed of a second flat woven thread, the second flat woven thread having a second plurality of fibers (c) pushing needles toward the rough area of the flat woven fabric; (d) moving the fibers from one of the layers to another of the layers. A method for manufacturing a multilayer fabric wherein the fabric provides rough areas on the fabric, the method consists of: (a) having a plurality of support zones, the support zones being at least partially interconnected, and wherein the zones of support have a single layer, and (b) have at least one rough area located between the support areas, the rough area comprises: i) a lower support layer composed of a first thread, the first thread being composed of a plurality of fibers in clumps; ii) an upper rough layer composed of a second thread, the second thread being composed of a plurality of fibers in solid, and (c) applying the needles to the rough area (d) Moving the fibers of the lower support layer or the a rough layer superior to the other of the layers, the displaced fibers being defined as connecting fibers with a first end and a second end, and (e) forming a fabric composed in part of connecting fibers, the connecting fibers being maintained at the first end within the lower support layer and the second end within the upper rough layer. The method of claim 12, wherein the fabric moves in a machine direction during the manufacture of the fabric, furthermore wherein during the application of step (c), the needles move in the machine direction, so that the relative movement of the needle to the fabric is minimized while the needle is inserted into the fabric.