US2235732A

US2235732A - Pile fabric

Info

Publication number: US2235732A
Application number: US257228A
Authority: US
Inventors: Sudell Frank
Original assignee: FRANCE IND
Current assignee: FRANCE IND; LA FRANCE INDUSTRIES
Priority date: 1939-02-18
Filing date: 1939-02-18
Publication date: 1941-03-18
Anticipated expiration: 1958-03-18

Description

March 18, 1941. F. s'uDELL 2,235,732

PILE FABRIC March 18, 1941- F. suDELL PILE FABRIC Filed Feb. 3.8, 1959 2 Sheets-Sheet 2 0,0 0,0 0g @nl s@ @bww IHR Patented Mar. 18, 1941 UNITED STATES PILE FABRIC Frank Slidell, Philadelphia, Pa., assignor to La France Industries, Philadelphia, Pa., a corporation of Pennsylvania Application February 18, 1939, Serial No. 257,228

2 Claims.

This invention relates to textile fabrics of the pile-face type, such as carpets, rugs, bath mats, stool covers, etc., including, for example, articles of the types disclosed in my prior U. S. Patent No. 2,144,555, dated January 17, 1939, wherein a Cal base fabric of substantially plain weave commonly employed in the making of canvas or heavy duck is provided with longitudinally extending pile yarns spaced apart a substantial distance laterally, and formed into longitudinally extending rows of pile tufts respectively which spread laterally until the tips of the marginal filaments of the laterally spaced rows of pile tufts lie substantially in abutting relation to each other and cover relatively narrow areas of nonpile fabric lying intermediate the rows of pile tufts and give the surface of the fabric a more or less corrugated or wavy appearance. Under normal conditions of use, the marginal filaments of adjacent rows of pile tufts occasionally become separated to some extent and expose the base fabric between the rows, which'more or less detracts from the esthetic effect of the pile face as a whole, particularly in articles where the base fabric is of a different color from the pile, which is normally the case, the base fabric usually being unbleached or of a neutral color, while the pile tufts are of any desired color intended to blend with other furnishings or draperies of the room in which the fabric is used.

The object of the present invention is to provide a fabric of the general type noted above, wherein the yarns which form the pile tufts float across the normally non-pile areas lying intermediate the rows of pile tufts and cover the neutral colored base fabric`at all points intermediate the frows of pile tufts, thus eliminating any and all exposure of the base fabric between the pile tufts should displacement of the pile tufts along the marginal edges thereof occur.

The present invention more particularly relates to a fabric of the type noted but with the rows of pile tufts definitely spaced apart a suilicient distance to provide open 0r non-pile areas between the rows of pile tufts at all times. and wherein the pile yarns float across the non-pile areas intermediate the rows of pile tuftsand.

cover the neutral -base fabric, resulting in a fabric having a face composed of laterally spaced rows of out pile tufts alternating with narrow nonpile areas composed of the same yarns as the pile tufts, which gives the face `of the fabric a spaced bar appearance. The twisted yarn of the floats in the non-pile areas will reflect the light rays differently from the cut ends of the yarn filaments in the rows of pile tufts.

In the fabric disclosed in said prior patent, the rows of pile tufts extended longitudinally, i. e. warpwise of the fabric, whereas in the fabric of the present instance the rows of pile tufts extend transversely, Le. weftwise of the fabric, with the pile yarn floats between the transverse bars extending warpwise of the fabric and hiding the underlying base fabric.

The pile tufts, according to the present invention, may be of the V type or of the- W type, without departing from the spirit of the invention.

In the accompanying drawings:`

Fig. 1 is a plan view of a swatch of fabric made in accordance with the principles of the present invention;

Fig. 2 is a longitudinal or warpwise sectional view taken on the line 2 2, Fig. l;

Fig. 3 is a view similar to Fig. 2 and showing a slightly modified arrangement with the pile tuft rows spaced a greater distance apart than in the fabric of Fig. 2;

Fig. 4 is a longitudinal sectional View showing the fabric of Fig. 3 as being woven double, prior to splitting in a median plane intermediate the upper and lower fabrics;

Fig. 5 is a view similar to Fig. 3 showing one form of w type tuft:

Fig. 6 is a view similar to Fig. 4, illustrating the weaving of the fabric of Fig. 5;

Fig. 7 is a view similar to Fig. 5, showing a somewhat different arrangement of the W tufts; and

Fig. 8 is a view similar to Fig. 6, showing the manner of 'weaving the fabric of Fig. '7.

As shown in Fig. 2, the base fabric l is of the ordinary plain weave commonly employed in the making of heavy duck and comprises the usual series of transversely extending weft threads or iilling-

shots

2, 2 bound together in the usual one and one weave by binder threads or

warp chains

3, 3.

Interwoven with relatively spaced groups 4, 4 of the weft threads or filling

threads

2, 2 are

pile warp threads

5, 5, which are disposed in close laterally abutting relation to each other, as shown in Fig. 2. The

pile warps

5, 5 are formed into pile tufts 6, B, with two or more tufts preferably arranged in succession longitudinally of the fabric and cooperating with similar tufts formed from the laterally abutting pile warps to collectively produce transversely extending rows or bars l, l which alternate with open non-pile areas 8, 8 on the pile face of the fabric.

Extending from one bar 'i to the next adjacent `bar 1 across the open spaces 8. 8, are floats 9, 9. These floats El are formed of the

pile warps

5, 5 and cover the underlying areas l0, i0 of the base fabric I which are composed of groups of weft threads 2. 2, lying intermediate the groups 4, 4

`of the weft threads with which the pile warps 5 are interwoven to form the tufts 6, 6 of the transverse bars or ribs 1. 1.' u e From the above it will beclear that the spaces 8 between the rows or courses i of pile tufts are bridged by floats 9 of the pile forming warp threads arranged in close laterally abutting relation to each other and covering the base fabric i, thus givingthe face of the fabric a very attractive appearance.

Fig. 3 illustrates a similar fabric to that shown in Figs. 1 and 2, with the exception that the bars or rows la, `la are respectively wider than 10 those shown in Figs. l and 2 but are composed of V tufts 6a, the same as the tufts t of Figs. l and 2. The spaces Ba in the fabric of Fig. 3 are considerably wider than the spaces t of the fabric of Figs. il and 2 and are also wider in proportion to the widths of the bar la, la, which makes the floats @a of the pile threads 5a considerably longer than the floats 9 of the pile threads 5 of Figs. l. and 2. The areas @0a of the base fabric ia which lie intermediate the groups fla, la of the wef-ts 2a, 2a around which the tufts ila, Se are formed, are correspondingly ,wider than the areas it of the base fabric i in Figs. 1 and 2. Zin the fabric of Fig. 3 the wefts 2a are tied together in pairs by the binder or warp chains 3a. The general eiect of the fabric of Fig. 3 is, therefore, the same as the general effect of the fabric shown in Fig. 1, except as to the greater spacing of therows or bars of pile tufts and the greater width of each baror row 'of pile tufts.

In order to insure against the ends of the floats 9a being pulled loose, the

pile yarns

5, 5 are interwoven with a, plurality of the wef-ts 4a, 4a, at each of the opposite sides of each row of pille tufts, as indicated at I9a, lila, in Fig. 3.

Fig. 4 shows the fabric of Fig. 3, as being woven double, i. e. with one complete fabric B superimposed above a corresponding fabric A, with a space C therebetween, the two fabrics being separated, after weaving, by cutting the pile yarns 5a, 5a on a median plane :c equidistant from the fabrics A and B, said cutting on the line a: producing the cut pile tufts 6a, 6a, which would be the same in each of the fabrics A and B respectively.

In the fabrics shown in Figs. 1, 2, 3, and 4, the

simple form of V type tuft is produced, i. e, rela.- tively short portions of the pile yarns 5 or 5a of which the pile tufts 6 or 6a are formed, pass under single Wef-t threads or filling shots 2 or 2a,

to whereas in the fabrics shown in Figs. 5, 6, 7`and 8 the W type of tuf't is provided, i. e. the yarn portion forming each tuft passes under one weft thread 2b, as shown in Fig. 5, over the next weft thread 2b, and then under a third weft thread 2b,

55 to produce the pile tutt Eb with the free ends of the piece of yarn projecting upwardly beyond the base fabric i.

The opposite ends of eac-h of the longer pieces or sections of the pile yarns 5b which con- 00 sti-tute the oats 9b are interwoven with a. plurality of wefrts 2b, to secure these opposite ends of the floats against being pulled out during normal usage of the fabric.

As shown in Fig. 6, each pile yarn 5b asso- 55 ciated with the lower fabric Ai is interwoven with a number of the weftrthreaids 2b of the lower fabric, and then passes upwardly across the space CI between the fabrics AI and Bl into the fabric BI Iwhere it is interwoven with a. plu- 70 ral-ity of the wet-ts 2b of the upper fabric BI,

as indicated at lib. It then passes downwardly again across the space CI into the lower fabric Al where it is interwoven with a. plurality of the wefts 2b of the lower fabric AI, as indicated at i912. in a. similar manner each of the pile warns 5b of the upper fabric BI is interwoven .with a plurality of the Wefts 2b of the upper fabric Bi, then passes downwardly across the space Ci into the lower fabric Ai, and is interwoven with a plurality of the wefts 2b of the lower fabric, as indicated at lb. The pile warp then passes upwardly Iagain across the space CI into the fabric Bi where it is interwoven with 2.10 plurality of the wefts 2b of the upper fahr-tc Bl,

as indicated at lh.

The pile warp yarns 5b, 5b, in the upper and Ilower fabrics Bi and Ai float in the space Ci adjacent the upper and Liower fabrics respective- 15 ly, as indicated at ib, Sb, between the places where the yarns pass from one to the other of the upper and lower fabrics.

When the two fabrics are separated as disclosed above by splitting the doubly woven fabric on a 20 median plane midway between the fabrics Ai and Bi, lthe lower fabric, in each of the transversely extending pile tuft bars '.lb, will include a W tuft formed of the pile yarn normally interwoven lwith the upper fabric and two part 25 tufts 90b formed of the .pile yiarn normally, interwoven rwith the lower fabric, while the upper fabric Bi, in each of the bars 1b, will include a W tuft formed of the pile yarn 5b, which is normally associated with the lower fabric AI 30 and two part tufts, corresponding to the `part tufts ib of the lower fabric, composed of the pile yarn normally associated lwith the upper fabric Bi.

Figs. 7 and 8 show fabrics similar to Figs. 5 35 and 6 respectively, with a slight variation in the manner in which the

yarns

5c, 5c of the upper and [lower fabrics B2 and A2 respectively Iare led from the one Ito the other of the fabrics across the space C2 therebetweenthe pile tufts in this in- 40 stance being of thewtype, the same as in the fabrics of Figs. 5 and 6, the tuft parts in vthe fabrics of Figs. 7 and 8 in some instances passing between two adjacent wefts 2c, 2c instead of at opposite sides of the wefts as shown in Figs. 45 5 and 6: otherwise, the fabrics are substantially the same.

I claim:

l. A 'textile fabric comprising a base fabric composed of interwoven warps and wefts, pile warps interwoven with predetermined wefts at relatively spaced points Wmpwise of the fabric and formed into pile tufts projecting above one face of 'the base fabric in transversely extending longitudinally spaced continuous .rows of substantially equal uniform width, with said -pifle warps floating warpwise of said fabric continuously on and covering said Ibase fabric in the spaces between said rows of pile tufts.

2. A textile fabric comprising a. base fabric comped of interwoven warps and wefts, pile warps interwoven with predetermined relatively spaced groups of said wefts and formed into pile tufts projecting lfrom said groups of -wefts upwardly above one face of said Ibase fabric in longitudinal-ly spaced continuous rows of substantially equail uniform width, with non-pile areas therebetween, said pile war-ps floating continuously on and covering said face of said .base fabric between said relatively spaced rows of pile 7o tufts and interwoven with other predetermined wefts adjacent said groups of wefts.

FRANK SUDELL.