US2175733A

US2175733A - Elastic fabric and its process of manufacture

Info

Publication number: US2175733A
Application number: US157504A
Authority: US
Inventors: Schwartz Fernand Frederic; Chavannes Marc Alfred
Original assignee: AMERICAN ECLA CORP
Current assignee: AMERICAN ECLA Corp
Priority date: 1937-04-16
Filing date: 1937-08-05
Publication date: 1939-10-10
Anticipated expiration: 1956-10-10

Description

Ct. 10, 1939. I F F, SCHWARTZ ET AL 2,l'u75,733

ELASTLC FABRIC AND ITS PROCESS OF MANUFACTURE Filed Aug. 5, 1937 Agg 3b' K l 7159.4 illy@ @9.45

3,9 lNvENToRs Frederi Schwartz rc Alfred avannes Patented Oct. 10, 1939 UNITED STATES PATENT OFFICE ELASTIC FABRIC AND ITS PROCESS F MANUFACTURE Application August 5, 1937, Serial No. 157,504 In France April 16, 1937 19 Claims.

This invention relates to an elastic fabric and its process of manufacture and deals particularly with elastic fabrics possessing great extensibility and consisting of a basis of textile material and a coating of rubber applied for example in the form of an aqueous dispersion such as rubber latex. Such rubber coatings may be applied by spraying in such a way that the constituent threads of the fabric are able to slide relatively to one another at their points of intersection.

When used for certain purposes it is desirable that such elastic fabrics should possess a very high degree of extensibility. Woven fabrics, however, are not in general very extensible.

Knitted fabrics are usually more lextensible but normally their extensibility is in one direction onlyand their'extensibility in a direction at right angles to the above-mentioned direction is limited.

It is an object of the present invention to provide an improved elastic product formed of textile material and rubber in which the extensibility in a predetermined direction is greatly increased.

We have found that this result may be achieved by employing a textile material which is formed of threads or yarns of two different natures, the threads or yarns of one kind beingof such a nature that they may be removed from the fabric altogether by chemical means at some stage of 80 the manufacture of the elastic product. The

threads or .varns of the other kind are such that they resist the attack of the chemical agent employed and remain in the finished fabric. 'Ihe threads or yarns which are capable of being removed are hereinafter referred to as destructible threads while the threads or yarns which remain in the finished fabric are hereinafter referred to as indestructible threads.

The indestructible threads are normally arranged so that they run in one direction and the destructible threads so that they run in a direction at vright angles to the indestructible threads. The indestructible threads are preferably arranged so that they form loops (as for example Y in the case of knitted fabrics) or form windings ric is made on an ordinary loom or frame, the warp threads of the fabric being of wool and the weft threads, cotton. Rubber is applied to this fabric by spraying rubber latex on to its surface in a very finely divided state and the conditions 5 `of application may be those described in cepending United States VApplication Serial No. 112,972.

In general the latex is applied only to one side of the fabric so that the threads of the fabric are not completely encased in rubber. The -rubberl0 coated fabric is then threated with a 3% solution of caustic soda at a temperature of about C. and the woollen threads are thereby dissolved leaving the rubber previously deposited thereon in the form of rubber threads. It will be underl5 stood that the treated fabric possesses such extensibility in the direction of the original woollenA y threads as is possessed by the rubber threads p which nally remain.

Instead of forming certain of the threads of 20 the fabric of destructible threads it is within the scope of this invention to form the threads of .a combination of destructible and indestructible fibres. The final product may possess very considerable extensibility providing care is taken to 25 arrange the indestructible fibres in pronounced loops, windings or sinuosities. The employment of indestructible threads as described above limits the extensibility of the rubber. Y

In one form of fabric employed in the present 30 invention the threads or certain of the threads are composed of a core of woollen fibres wrapped in cotton fibres. After the woollen fibres'have f been destroyed the cotton remains in the vform of helices which are capable of considerable elongation. Such tlneads may be placed either in one g direction of the fabric only or in both directions. Y

In the preferred method of carrying the invention into effect fabrics knitted on special frames 'i are employed. 'Ihese fabrics consist of a series 40 of parallel warp threads and a series of threads connected with the warp threads with the formation of numerous loops. Such a fabric possesses little extensibility along the warp threads but the extensibility at right angles to the warp threads 45 may be very considerable, for examp1e,up to 800% of the original length of the fabric. The warp threads are preferably made of wool or other destructible material capable of being removed by chemical treatment and the remaining threads i 0f the fabric are made of cotton. By treating the rubber-coated fabric with a solution of alkali for example a solution of caustic `soda the warpj threads are dissolved and the cotton threads remain. '111e final product s considerable-2..-

extensibility both along the warp threads and in a direction perpendicular to the warp threads. According'to a further feature of the invention the fabric may be so designed that the rubber threads possess a reinforcement of textile bres which prevents the rubber from being stretched beyond its safe limits.

In a modified form of extensible fabric two pieces of rubber-coated fabric are prepared. the extensibility of the fabric in one direction being considerable (but limited by the arrangement of the threads running in that direction) and the extensibility of the fabric in the other direction being limited only by the safe extensibility of the rubber threads running ln that direction. The two pieces of fabric are stuck together with their rubber threads crossing. Such a fabric possesses great extensibility in all directions, but the extensibility is limited in all directions by the textile threads.

Following is a description with. reference to the accompanying diagrammatic drawing (in which similar reference numerals denote similar parts) of extensible fabrics formed in accordance with the present invention.

In the drawing:

Fig. 1 is a diagrammatic plan view in an enlarged scale of a fabric consisting of sinuous threads;

Figs. 2, 2A, 2B and 2C respectively represent successive steps in one process for the treatment of the fabric;

Figs. 3, 3A and 3B show to an enlarged scale portions of the fabric before, during and after treatment respectively;

Figs. 4, 4A and 4B show a short portion of a composite textile fabric before, during and after treatment;

Fig. 5 illustrates a further modification of a fabric to be used in the practice of the invention;

Fig. 5A is a piece of fabric similar to that shown in Fig. 5, to be used in conjunction with thejabric used in Fig. 5;

Fig. 5B is a composite fabric made by superimposing a fabric shown in Figs. 5A and 5B; and

Fig. 6 is a view in elevation to an enlarged scale of the fabric shown in Fig. 5B.

In Fig. 1 there is shown a small section to an enlarged scale of a fabric consisting of sinuous threads. All threads, such as II, which run in one direction, are made of wool and all threads such as I2 running in a direction substantially at right angles to the threads il are made of cotton so that by treatment of the fabric with a solution of alkali the wool may be dissolved, leaving only the cotton threads l2.

In Figs. 2, 2A, 2B and 2C there is illustrated a process for the manufacture of elastic fabrics in accordance with the present invention. Fig. 2 shows diagrammatically a fabric I3 composed of cotton and woolen threads similar to the fabric shown in Fig. 1. Fig. 2A shows fabric I3 being sprayed with rubber latex I4 from a spray gun I5. Fig. 2B shows the sprayed fabric I3 being dried under a hood I6. Fig. 2C shows a sprayed and dried fabric I3 being passed through a bath I I containing a suitable alkali liquid I8 for dissolving the wool threads from the fabric. The vessel I'I is provided with a steam jacket I9 for maintaining the liquid I8 at a desired temperature. The fabric may be passed in a continuous web through the alkaline solution I1, under and over rollers 2D, the time of passage of the fabric I3 through the solution being that necessary to dissolve thewool threads II.

Fig. 3 shows a plan View on an enlarged scale of a piece of woven fabric consisting of cotton threads 2I running in one direction and wool threads 22 substantially at right angles to threads 2|. In Fig. 3A there is shown the same portion of the fabric shown in Fig 3 sprayed with rubber latex, the coating of rubber being indicated for the sake of Vclearness by the band between the

lines

23 and 24. It will be observed that the rubber forms a connected network overlying the threads of the fabric. Fig. 3B shows the section of fabric shown in Fig. 3A after it has been treated with a solvent for the wool threads 22. The fibers of the threads 22 have been dissolved away, leaving continuous rubber threads 25 while the cotton threads 2 I remain undissolved but bearing the coating of latex rubber.

Fig. 4 shows a short portion of a composite textile fabric thread consisting of a core 26 of wool fibers surrounded by a helical winding of cotton bers 2l. Fig. lA shows the same thread to which a coating of latex 2d has been applied. Fig. 4B shows the same portion of fabric after treatment of a solvent for the wool fibers 2E. The core of woolen bers has been dissolved, leaving the wound core of cotton fibers 2'! and the layer of latex rubber 28 attached thereto.

Fig. 5 shows a small portion of fabric consisting of woolen threads 29 substantially parallel to one another and substantially parallel cotton threads 30 running in a direction at right angles to the threads 29. Fig. 5A shows a similar fabric in which the woolen threads 29 run in a direction at right angles to the woolen threads 29 of Fig. 5, i. e., in the same direction as the cotton threads 3U of Fig. 5. The fabrics shown in Fig. 5 and the cotton threads 3d run in the same direction as the woolen threads 29 of Fig 5. The fabrics, after being sprayed with rubber latex, are treated with a solvent for the woolen nbers and the fabrics are superimposed with the layer of rubber coating of each fabric in contact. The fabrics are pressed together and the resulting fabric is shown in Fig. 5B in which the coated cotton fibers 30 run at right angles to each other and are interspersed with the threads of sprayed rubber which remain after the core of wool threads have been treated with a solvent for the wool.

In Fig. 6 there is shown a section through the fabric illustrated in Fig. 5B and this section can be either along the warp or the weft of the fabric since the two sections would be identical In the drawing the cotton threads 3I are substantially parallel to one another and are crossed at sub stantially right angles by the cotton threads 32. In between the cotton threads 3| and 32 lie a rubber network of threads 33 which are parallel and spaced apart from the threads 3l and the rubber threads 34 which are parallel to and spaced apart from the cross threads 32. Itwill be observed that neither the rubber threads 3| nor the cotton threads are interwoven but all threads lie in a horizontal plane, passing through the longitudinal axis of threads 3I and will be substantially parallel to the horizontal plane passing through the longitudinal axis of threads 32.

We claim:

l. A process for the manufacture of an elastic fabric consisting of textile material and rubber which consists in weaving or knitting a fabric from textile threads some of which can be dissolved in a solvent and the remainder of which are under the same conditions insoluble in the said solvent, applying rubber latex to the said fabric in the form of a finely-divided spray the coating of latex being insuflicient to enclose the threads of the fabric completely and thereafter treating the coated fabric with a solvent to dissolve the soluble threads and to leave the insoluble threads intact.

2. A process for the manufacture of an elastic fabric consisting of textile material and rubber which consists in weaving or knitting a fabric from textile threads some of which can be dissolved in a solvent and the remainder of which are under the same conditions insoluble in the said solvent, applying rubber latex to the said fabric in the form of a finely-divided spray so that the threads remain capable of sliding one on the other at their points of intersection and thereafter treating the coated fabric with a solvent to dissolve the soluble threads and to leave the insoluble threads intact.

3. A process for the manufacture of a` fabric which is extensible in all directions and which consists of textile material and rubber which process consists in weaving or knitting a fabric wholly from textile threads some of which can be dissolved in a solvent and the remainder of which are under the same conditions insoluble in the said solvent, the insoluble textile threads running in the direction in which the fabric is freely extensible and the soluble textile threads running in that direction in which the fabric is not freely extensible, applying rubber latex to the said fabric in the form of a finely-divided spray, the coating of latex being insufficient to enclose the threads of the fabric completely, and

, thereafter treating the coated fabric with -a solvent to dissolve the said soluble textile threads and to leave the said insoluble textile threads intact.

4. A process for the manufacture of an elastic fabric consisting of textile material and rubber which process consists in weaving or knitting a fabric wholly from textile,yarns some of which can be dissolved in a solvent and the remainder of which are under the same conditions not completely soluble in the said solvent, applying rubber latex to the said fabric in the form of a finely-divided spray, the coating of latex being insuillcient to enclose the threads of the fabric completely, and thereafter treating the coated fabric with a solvent to dissolve the said soluble textile threads and to leave the said insoluble textile fibres intact.

5.' A process for the manufacture of an elastic fabric consisting of textile material and rubber which process consists in weaving or knitting a fabric wholly from textile threads some of which can bedissolved in a solvent and the remainder of which are under the same conditions insoluble in the said solvent, the said soluble textile threads running in the general direction in which the fabric is not normally extensible, applying rubber latex to the said fabric in the form of a finely-divided spray, the coating of latex being insufficient to enclose the threads of the fabric completely and thereafter treating the rubber coated fabric with a solvent to dissolve the soluble textile threads and to leave the insoluble threads intact.

6. A process for the manufacture of an elastic fabric consisting of textile material andrubber which process consists in weaving or knitting a fabric wholly from textile threads some of which ing arranged in sinuous form, applying rubber latex to the said fabric in the form of a finelydivided spray, the coating of latex being insufficient to enclose the threads of the fabric completely, and thereafter treating the rubber coated fabric with a solvent to dissolve the soluble threads and to leave the insoluble threads inthereafter treating the rubber coated fabric with f a solvent to dissolve the wool and to cotton intact.

8. A process for the manufacture of an elastic fabric consisting of textile material and rubber as claimed in claim 7 wherein the solvent for the wool is a solution of -caustic soda.

9. A process for the manufacture of an elastic fabric consisting of textile material and rubber as claimed in claim 7 wherein the wool is dissolved by treatment with a caustic soda solution of substantially 3% strength at about 70 C.

l0. A process for the manufacture of an elastic fabric consisting of textile material and rubber whichv process consists in Weaving or knitting Vleave the a fabric wholly from textile threads consisting of y which under the same conditions are insoluble in the said solvent, applying rubber latex to the said fabric in the form of a nely-divlded spray, the coating of latex being insufficient to enclose the threads of the fabric completely, and thereafter treating the coated fabric with a solvent to dissolve the fibres forming the core of the threads and leaving the wrapping threads undissolved.

11. A process for the manufacture of an elastic fabric consisting of textile material and rubber which process consists in weaving or knitting a fabric wholly from textile threads consisting of a core of wool, the said core being wrapped round with helices of cotton fibres, applying rubber latex to the said fabric in the form of a nelydivided spray, the coating of l ex being insumcient to enclose the threads of he fabric completely, and thereafter treating the coated fabric with a solvent for the wool.

l2. A process for the manufacture of an elastic fabric consisting of textile material and rubberl which process consists in weaving or, knitting a fabric from threads some of which can be dissolved in a solvent and the remainder of:

which have a core the fibres whereof are soluble in the said solvent under the same conditions and are wound with fibres which are insoluble in the said solvent, applying rubber latex to one face of the said fabric in the form of a finelydivided spray, and thereafter treating the rubber coated fabric with a solvent to dissolve the soluble parts thereof and to leave the insoluble parts intact.

13. A process for the manufacture of a composite elastic fabric consisting of textile material and rubberwhich process cor. ists in weaving or knitting a fabric from threads some of which 5 can be dissolved in a solvent and the remainder of which are insoluble in the said solvent, the soluble threads all running in one direction and the insoluble threads all running in a direction at right angles to the soluble threads, applying rubber latex to the said fabric in the form of a finely-divided spray, the coating of latex being insuicient to enclose the threads of the fabric completely, and thereafter treating the rubber coated fabric with a solvent to dissolve the soluble threads and to leave the insoluble threads intact and uniting two Vsimilarly treated sheets of fabric so that the insoluble threads on one fabric are at right angles to the insoluble threads of the other fabric.

14. An elastic fabric consisting of a textile material the threads whereof are covered with a closely adhering coating of porous rubber and coherent built-up threads of porous rubber interspersed therewith.

15. An elastic fabric some of whose elements have a core of textile fibre coated with a porous but continuous layer of closely adhering rubber and other elements whereof consist wholly of such porous rubber.

16. An elastic fabric some of whose elements have a core of textile fibre coated with a porous but continuous layer of closely adhering sprayed 17. An elastic fabric which consists of threads of extensible textile material with an adherent coating of porous rubber thereon and interwoven elements of porous rubber built up on textile threads which limit the extensibility of said rubber threads.

18. A process for the manufacture of a fabric consisting of textile material and rubber which comprises treating with rubber latex in the form of a finely divided spray, so that its constituent textile elements are not completely enclosed by rubber, a knitted or woven fabric some of the textile elements whereof are soluble in a solvent and the remainder whereof are insoluble in said solvent and subsequently treating the rubberized fabric with the solvent to dissolve the said soluble textile elements and to leave intact those textile elements which are insoluble.

19. An elastic fabric formed by the association of rubber coated fabric extensible threads and intersecting rubber threads, the rubber threads and the rubber of the coated threads being integral and forming a single thickness at the f intersections.

FERNAND FREDERIC SCHWARTZ. MARC ALFRED CHAVANNES.