US2137203A

US2137203A - Pile fabric

Info

Publication number: US2137203A
Application number: US167515A
Authority: US
Inventors: Willis G Mccullough
Original assignee: Collins and Aikman Corp
Current assignee: Collins and Aikman Corp
Priority date: 1937-10-06
Filing date: 1937-10-06
Publication date: 1938-11-15
Anticipated expiration: 1955-11-15

Description

Npv. l5, 1938. A I w, G, MccuLLoUGH 2,l37,z"..( )3v PILE FABRIC Filed Oct. 6,l 1957 2 Sheets-Sheet 1 PILE INVENTOR W/LL/s G. M? Cagol/6H.

ATTORNEY I Nov. 15., 1938.

w. G. MccuLLouGl-l 2,137,203v

PILE FABRIC Filed oct. 6, 1957 2 sheets-sheet 2 .IAN .QNRN

INVENTOQ.. WILL/5 G. MQ C0 oz/6H.

` ATTORNEY.

Patented Nov. 15, 1938 UNITED STATES PATENT OFFICEA ford, Conn., assignor to Collins & Aikman Co'rporation, Philadelphia, Pa., a, corporation of Delaware Application October 6, 1937, Serial No. 167,515

12 Claims.

My invention is directed to a woven pile fabric and it comprises al method of producing an indistinct but visual pattern effect on the pile face of the fabric, even .then pile yarns of the same color are used and when the pile height is uniform throughout the fabric. This result may be accomplished in accordance with my invention, with the use of a loom reed having equal dent spaces', by grouping the backing and pile warp l0 yarns during weaving in said dents and by so interlacing the said backing and pile warps that after weaving, these warps will re-align themselves to form an indistinct pattern on the face of the pile fabric. anchored in this re-aligned position by a normally insoluble adhesive such as properly Icompounded latex or other rubber compositions.

Pile fabrics and particularly those having animal fibre yarn such as mohair and wool, or. a mixture of animal fibre yarn, cotton and/or synthetic :libres to form the pile are highly desirable for upholstery which is subject to rough and hard treatment, for example, use in automobiles. The use to which such fabrics are put backing and for the pile, be of substantial diameter and strength, and this, aswell as manufacturing economy,'has made it necessary tol use in practice a relatively small number of wefts or picks per inch, say. between 25 and 40. My invention contemplates features of economy by the use of commercially practicable yarns because as the size of the pile yarn is increased, its cost per pound decreases. In fabrics woven according to a preferred practice of my invention, the pile tufts are made from yarns of greater diameter than the backing threads and are each supported at their sides and at their ends to give complete coverage of the ground threads, not- 40 withstanding the shortness ofv the pile.

An object o f my invention is to provide, without the use of conventional pattern shedding mechanism, a cut pile fabric in which the pile tufts are anchored in position by an adhesive and which has an indistinct pattern.

A further object of my invention is to provide a method of weaving whereby a reed having equal dent spaces may be instrumental in producing pattern` effects in the finished pile fabric.

A further object of my invention is to provide a porous or air-permeable cut pile fabric having an indistinct pattern, the tuftsof which are formed from pile yarns of substantial size which effectively conceal the ground warps and wefts The pile tufts may then be requires that lthe yarn used therein,l both forwthe,

kand thereby avoids the objectionable grinning a pattern pile fabric by drawing through some of the reed dents of a double plush loom a plurality of pile warp yarns, each having a diameter larger than the maximum diameter of pile warp yarn-which with the customary knots therein, can be drawn inpractical weaving through reed dents having one-half the width of said reed dents and associating a plurality of pairs of upper ground warps and a plurality cf pairs of lower ground warps and subsequently impregnating the fabric locally to keep the face of the fabric free of impregnating material.

' These and other objects of my invention will become readily apparent from a considerationA of the following description and claims.

In accordance with my invention in the emin the accompanying drawric Ia is illustrated as comprising warps 2 interlacing with the wefts 3 in ats to support the pile tufts 4. In the practice of my invention, I may utilize a double shuttle loom (Fig. IV) come prising al frame 5 on which is mounted a lay 6 driven through a pitman 'l and crank shaft 8. Ground warps 9 are drawn from a warp beam I0 and form superposed and converging sheds Il and I2. Pile yarn I3 is drawn about rolls I4 from an independent source of supply and together with the backing warps form the fabric I after passing through the harnesses I 5 and the reed I6. The double fabric'moves forwardly during weaving and is cut apart into single webs by the cutter I1, one of which webs is directed around the roll I8 and the reversing roll I9, and the other of said webs is guided over the roll 20. Both of said webs are then taken up by conventional mechanism not shown.

In weaving pile fabric in accordance with my invention, (Fig. III) eight ground warps and two pile' warps may be drawn through some of the dents and four backing warps and one pile warp may be drawn through other of the reed dents.

Each of said pile warps may have a diameter larger than the maximum diameter of pile warp yarn, which with the customary knots therein, can be drawn in practical weaving through reed dents having one-half the Width of said reed dents. Fig. III illustrates a repeat of the drawing in of warp threads through the dents to form a pattern in Vaccordance with my invention. It should be understood, however, that I do not wish to be confined to the use of the eight ground threads and two pile warps in two adjacent dents, and the four backing threads and one pile warp yarn in the third dent. The grouping in the reed dents may be alternate or the set of four backing threads and one pile yarn may be in every fourth, fifth or sixth dent. This invention contemplates broadly that all the pairs of ground warps of a pile fabric be woven in flats and that the ground warps in a dent carrying a pile warp should interlace with the wefts in fiats in the identical manner and over the same wefts as the next adjacent ground warps of a next adjacent reed dent, whether the pile be V, W, or uncut in the finished fabric. .When the fabric is removed from the loom, it will be seen that the original reed grouping will have been destroyed and that the said adjacent ground warps and tufts have crowded together in part and re-aligned themselves, as illustrated in Figs. I and II of the drawings. As can clearly be seen on Figs. I and II, all the ground warps 2 interlace with the filling threads 3 in fiats and in each instance pass over the filling about which the V-tufts are looped. This crowding and 'an indistinct and attractive pattern is formed on the face of the fabric. A suitable fabric within the scope of my invention has been woven with a 56 inch reed having approximately 67 per cent. of free space and 868 equal dent spaces, said fabric comprising 2/30s cotton backing warps, 2,/24s worsted count blend pile warps containing animal fibre and 1/8s cotton count weft yarn inserted 32 to the inch.

As will be seen in Figs. III and IV, some of the pile warps are shed to interlace in the upper ground while others of the pile warp are being interlaced with the lower ground on one rotation of the crank shaft 8 and are at all times spaced from one another by four ground warps during Weaving. On the next revolution of the crank "shaft, the pile warps are shed oppositely to introduce the first group of pile warps in the lower ground and the other group in the upperground as illustrated in the weaving and shedding diagram, (Fig. III)` Y In Fig. III, the dots depict the ground warps and the cross-sections the pile warps in their respective raised positions, whereas the blank spaces indicate that the pile or backing thread. as the case may be, is in the down position. The backing warp harnesses I5 are shown in pairs for weaving in flats. Reading from left to right in Fig. IlI, the four rectangles under B show the position of a bottom backing or ground yarn during four successive picks. T denotes a top backing or ground yarnand P the pile yarns. It is to be understood that Fig. III illustrates all the backing and pile yarns in a repeat of three dents fo-r two fabrics which are cut apart on Athe loom after fabrication. l

Prior to impregnation for the purpose of anchoring the tufts to the backing, the fabric may be scoured to remove the water-repellent oils naturally carried thereby or artificially incorporated therein, and any excess of water incorporated in the fabric as a result of the scouring and rinsing may be removed by a suction or blowing apparatus. mayl have collected in the relatively large interstices between the single rows of tufts and between the single rows of tufts and the double rows, and as just sufcient adhesive is applied to the back of the fabric to anchor the tufts, the pile face remains free of adhesive and the fibres of the backing yarn are thoroughly permeated and surrounded by adhesive which confines itself substantially to the backing thread and adjacent pile tuft area and does not fill the interstices between the ground threads.

'I'he tips of the pile bights, passing as they do around a single weft thread over which the warps pass in fiats, are exposed on the back of the fabric. 'I'he tips of the pile bights may be scraped and all excess adhesive thereby removed.l This scraping operation may be done with the impregnating blade concurrently with or immediately following impregnation, and is so effective that the presence of adhesive in the fabric is in most cases diiiicult to determine.l must be sufficient adhesive material deposited and suiiicient concentration'and viscosity of the compound to securely anchor the pile tufts without the adhesive contacting the pile face. It has been found, by the removal of the water-repellent oils, that the anchoring power of the adhesive is so increased that a very short tuft may be used and the distinctiveness of the design increased.

Having described my invention, I claim 1. In the manufacture of pile fabrics having warp-wise extending groups of a plurality of rows of pile, the steps which comprise guiding a plurality of ground warp threads and a pileforming Warp yarn through reed dents separated from one another by a wire, interweaving the ground warp threads with filling threads in flats to form a ground fabric, interlacing some of the pile yarns with the ground between two ground warps forming fiats and about only those filling threads over which the ground warps lie when the fabric is face up, interweaving others of the pile yarns with the ground between pairs of next adjacent ground warps in next adjacent reed dents in the same manner and over the same filling threads and interweaving ground warp threads, which do not support the said pile yarns, with lling threads and over those filling threads about which the said pile yarns are not looped whereby the original reed spacing will have been lost and the warps re-aligned.

. 2. In themanufacture of pile fabrics having Warp-wise extending groups of a plurality of rows of pile and single rows of pile spaced from the groups, the steps which comprise guiding a plurality of ground warp threads and pile-forming warp yarns through reed dents separated from one another by a wire, interweaving the ground Warp threads with filling threads in flats to form a ground fabric, interlacing some of the pile yarns with the ground between two ground warps forming iiats and about only those filling threads over which the ground warps lie when the fabric is face up, interweaving others of the pile yarns with the ground between pairs of next adjacent This latter step removes any water which There ground warps in next adjacent reed dents in the which none of the group pile-forming yarn is looped whereby the original reed spacing will have been lost and the warps re-aligned, and securing the pile to theV ground by an adhesive which does not fill the interstices of the interwoven threads.

3. In the face' to face manufacture of pile fabrics having warp-wise extending groups of a plurality of rows of pile, the steps which comprise providing'a, set of ground warps for each fabric, guidingl a plurality of ground warp threads and a pile-forming warp yarn through reed dents separated from one another by a wire, interweaving the ground warp threads with filling threads in flats to form ground fabrics, interlacing some of pile yarns with the grounds between two ground warps forming ats and about only those filling threads in each ground over which the ground warps lie when the fabrics are face up, interweaving others of the pile yarns with the ground between pairs of next adjacent ground warps in next adjacent reed dents in the same manner and over the same filling threads and interweaving ground warp threads, which do not support the said pile yarns, with filling threads and over those filling threads about which the said pile yarns are not looped.

4. In the face to face manufacture of pile fabrics having warp-wise extending groups of a plurality of rows of pile and single rows of pilespaced from the groups the steps which comprise providinga set of ground warps for each fabric, guiding a plurality of ground warp threads and pile-forming yarns through reed dents separated from one another by a wire, interweaving the ground warp threads with filling threads in flats to form ground fabrics, interlacing some of the pile yarns with the grounds between two ground warps forming flats and about only those filling threads in each ground over which the ground warps lie when the fabrics are face up, interweaving others of the pile yarns with the ground between pairs of next adjacent ground warps in next adjacent reed dents in the same manner and over the same filling threads of the respective fabrics, interlacing still others of the pile yarns with the ground and about-those filling threads about which none of the group pile-forming yarn is looped, and cutting the fabric into webs.

5. In the manufacture of V-pile fabrics having warp-wise extending groups of a plurality of rows of pile, lthe steps which comprise guiding a plurality of ground warps threads and a pileform ing warp yarn through reed dents separated from one another by a wire, interweaving the ground warp threads with iling threads in flats to form a ground fabric, interlacing some of the pile yarns with the ground between twoground warps forming ats and about only those filling threads over which the ground warps lie when the fabric is face up, interweaving others of the pile yarns with the ground between pairs of next adjacent warps in next adjacent reed dents in the same manner and over the same filling threads andinterweaving ground warp threads, which do not support the said pile yarns, with filling threads and over those filling threads about which the said pile yarns are not looped whereby the original reed spacing will have been lost and the warps re-aligned.-

6'. vIn the manufacture of- V-plle fabrics having Warp-wise extending groups of a plurality of rows of pilev and single rows of pile spaced from the groups, the steps which comprise guiding a plurality of ground warp threads and pile-forming warp yarns through reed dents separated from one another by a wire, interweaving the ground warp threads with filling threads'in iiats to form a ground fabric, interlacing some of the pile' yarns with the ground between two ground warps forming iiats and about only those filling threads over which the ground warps lie when the fabric is face up, interweaving others of the pile yarns with the ground between pairs of next adjacent warps in next adjacent reed dents in the same manner and over the same filling threads and interlacing still others of the pile yarns with the ground and about those filling threads about which noneof the group pileforming yarn is looped whereby the original reed spacing will have been lost and the warps realigned, and securing the pile to the ground by an adhesive which does not lill the interstices of the interwoven threads.

7. In the face to face manufacture of V-pile fabrics having warp-wise extending groups of a `plurality of rows of pile and single rows of pile spaced from the groups, the steps which comprise providing a'set of ground warps for each fabric, guiding a plurality of V ground warp threads and pile-forming warp yarns through reed dents separated from one another by a wire, interweaving the ground warp threads with filling threads in flats to form ground fabrics, interlacing some of the pile yarns with the grounds between two ground warps forming iiats and about only those, filling threads in each ground over which the ground warps lie when the fabrics are face up, and interweaving others of the pile .yarns with the ground between pairs of next adjacent ground warps in next adjacent reed dents in the same manner and over the same filling `threads and interlacing still others of the the ground warp threads with filling threads in flats to form ground fabrics, interlacing some of the pile yarns with 'the grounds between two ground warps forming flats and about only those filling threads in each ground over which the ground warps lie when the fabrics are faceupf interweaving others of the pile yarns with the ground between pairs of next adjacent Vground warps in next adjacent reed dents in the same manner and over the same Ifilling threads, inter lacing still others of the pile yarns with the ground and about those filling threads about which none of the group pile-forming yarn is looped, cutting the fabric into webs, and securing thepile to the ground by an adhesive which does not fill the interstices of the interwoven threads.

9. In the manufacture of pile fabrics having warp-wise extending groups of a plurality of rows of pile and single rows of pile spaced from the groups, the steps which comprise guiding a plurality of ground warp threads and a pileforming warp yarn through a reed dent and twice the number of ground warp threads and two pile yarns in the next adjacent reed dent, said dents being separated by a reed wire, interweaving all .75

the ground warp threads with filling threads in ats to form a ground fabric, interlacing each of the pile yarns with the ground between two ground warps forming flats about on1y" those lling threads over which the ground warps lie when the fabric is face up, and interweaving pairs of next adjacent ground warps in the two dents with the ground in the same manner and over the same filling threads and interlacing the others of the pile yarns with the ground and about those filling threads about which none of the group pile-forming yarn is looped.

10. In the face to face manufacture of pile fabrics having warp-wise extending groups of a plurality of rows of pile and single rows of pile spaced from the groups, the steps which comprise providing a set of ground warps for each fabric, guiding a plurality of ground warp threads and a pile-forming warp yarn through a reed dent and twice the number of ground warp threads and two pile yarns inthe next adjacent reed dent, said dents being separated by a reed wire, interweaving all the ground warp threads with filling threads in flats to form ground fabrics, interlacing each of the said pile yarns with the grounds between two ground warps forming ats and about only/those filling threads over which the ground warps lie whenthe fabrics are face up, interweaving pairs of next adjacent ground warps in the two dents with the ground in the same manner and over the same filling threads and interlacing the others of the pile yarns with the ground and about those filling threads about which none of the group pile-forming yarn is looped.

11. An impregnated 4porous pile fabric. the tips of the pile of which are free of irnpregnating material, which consists of a ground of interwoven warp and weft threads, said Warp threads being interwoven with the wefts in` pairs which form ats, pile tufts positioned between warps of each of the adjacent pairs and looped about and secured only to weft threads over which pairs of warps pass when the fabric is face up, at least four of the next adjacent of said ground warpsy and the pile tufts they support being aligned in groups in which said last-named ground warps pass over the samewefts, additional'pile tufts positioned between other single pairs to form single rows of tufts and being looped about and secured only to weft threads over which said last-named pairs of warps pass when the fabric is face up, said additional pile tufts and their supporting warps also forming groups which are spaced from the first-named groups, adhesive- Securing means which does not fill the interstices between the groups and which secures the pile tufts to the ground.

12. An impregnated porous pile fabric, the tips of the pile of which are free of the-impregnating material, which comprises a ground of interwoven warp and weft threads, said warp threads being interwoven with the weft in' pairs which form flats, pile positioned between pairs of ground warps and looped about and secured only to weft threads over which pairs of warps pass when the fabric is face up, at least four of the next adjacent of s aid ground warps and the pile they support being aligned in warp-wise extending groups in which the pile bights are looped in pairs around the same wefts, additional pile positioned between other singlepairsof ground warps to form single rows of pile and being looped about and secured to weft threads over which said last-named pa'irs of warps pass when the fabric is face up, said additional pile and their supporting warpsforming groups which are spaced from the first said named groups, adhesive-securing means which does not ll the interstices between the groups and which secures the pile to the ground.

WILLIS G. MCCULLOUGH.