US2272317A - Decorated composite fabric - Google Patents

Description

Feb. 10, 1942 c. J. DAVIES DECORATED COMPOSITE FABRIC Filed June 5, 1939 FIG.3.

FIG.2.

FIGJ.

FIG.7.

FIG.8.

INVEN TOR.

CLARENCE J.DAVIES BY W? W ATTORNEYS Patented Feb. 10, 1942 DECORATED COMPOSITE FABRIC Cla en e Da i s, D t o t, Mich, assi nc t National Automotive- "Fibres, Inc, Mich, a corporation of Delaware Detroit,

Application June 5 1939, Serial No. 277,556

9 Claims. 1 91. 15447 T res nt in e i n rel tes to decera ien and more particularly to a decorated fabric and n a icl f manufa tu m lo ed the decoration of fabric.

n th r or application; of Cunnin t n. Serial 72.256 fi May 6. .939. en led Dec on, he e s d s losed the deccratiecof cloth y fo ming em ssed desi ns therein ev r an a uttin ay r of unvu lcan aed ru ber, and subs quent y vulcau a n th rubber to caus it to retain its embossed or molded shape and to cause it to adhere permanently to the fabric. lnisaid application there was further disclosed the use fa re nf rcing sheet material, su h for examp as paper era Wov n sh etin a ainst the'r a f su face f the rubber. The purpose of th inforcing material was to. permit the decorated fabric to be tensioned without pulling out, or flattening the design. i

The useof' reinforcing material as disclosed in the Ciunnington] application aforesaid, has been adopted with excellent results generally, but under articular circmnstances'it has been found that certain disadvantagesaccrua; Thus for example, when thecloth to be decorated has a certain: amountof stretch therein and when the-cloth is used in a tensioned condition, asfor example in some applications of upholstery t0 automotive trim interiors, it is found that the presence of the reinforcing material referredto prevents uniform stretch of thefabric. This result is most marked in devices where the fabric employed has a symmetrical design therein, as for example when the fabric is striped.

It is accordingly an object of the present invention to provide a decorated fabric formed by correspondingly embossed fabric and rubber vulcanized together, in which reinforcing means are provided which permit tensioning of the fabric without pulling out or reducing; the height or effectiveness of the design, and at the same time which will permit uniform stretching of the decorated fabric.

It is a further object of'the present invention to providea material to be employed in the decoration of fabric which lends itself to the accomplishment of the first mentioned object.

It is a further object of the present'inventi'on' to provide a strip material for decorated fabric which is reinforced against transverse stretching in a manner which permits longitudinal stretching. V l p 7 It is a further object of the present inven tion to provide a material to be employed in rubber reinfor ed against stretchin n n rection only. 1

Other objects of the invention will be apparent as the description proceeds, and when taken in conjunction with the accompanying drawing Figure 2 is a section on the line 2-4, Figure 1;

Figure 3 is a plan view of a somewhat modified form of decorated material;

Figure 4 is a section on the line 4-4, Figure 3;

Figure 5 is a fragmentary section through an embossed decoration illustrating the cooperation of elements;

' Figure 6 Is a' fragmentary sectional view similar to Figure 5, illustrating the result of omitting reinforcing material;

Figure 7- is a view of a tensioned decorated fabric illustrating the condition encountered when ncprovision is made for longitudinal stretch; and I 1 v Figure 8 is a View of a deQorated-tensioned fabric when manufactured in accordance with the present invention.

' The'present invention deals with decorated fabrics which are decorated by themethod and apparatus illustrated in prior Cunnington applications; Serial Nos; "231,811 and 272,256.

Briefly reviewed, to render'the present disclosure complete, this method of-de'corating a fabric comprises placing a strip, sheet, or area of uncured rubber adjacent the rear face of a fabric to be decorated. By the rear face is meant the face which is not normally exposed in use. For example, in pile fabrics the face is, of course, the face opposite the pile or nap face. The rubber stock which is employed may be either a rubber stock compounded to blow or becomeporous on heating, or it may be a nonblowing stock which remains dense throughout the decorating operation. In either case, the fabric 'is decorat'ed'and has a predetermined relief design imparted thereto by applying pressure to the dress or-front face of the fabric and at the same time applying heat to vulcanize the rubber. The pressure is applied to the frontface of thefabricin whatever predetermined design it is desired to reproduce. It has been found that by this method of decoration it is possible to reproduce a limitless variety of designs, including the reproduction of designs containing a large amount of fine detail. The simultaneous application of heat and pressure causes the rubdecorated fabric comp i a strip of u u d at her to mold or flow into the form of the desired formity to corresponding risers I2 formed in a rubberous material I3. As previously stated, the rubberous material in the completed article may be substantially dense, or may be of a spongy character, resulting from blowing of the rubber. A reinforcing material I4 is provided, permanently attached to the rubber I3. As will be noted in this figure, the fabric I is separated from the reinforcing material Id at points a by only a very thin film of rubber. In other words, at the points a. the fabric I0 is vulcanized substantially directly to thereinforcing material I4. I I

The importance of the reinforcing material I4 will be better appreciated by reference to Figure 6. in which I have illustrated a decorated fabric III and a rubber strip I3. In this figure the decorated fabric I 0 was initially formed in exact conformity with the showing of Figure 5, with the exce tion that the reinforcing material I l was omitted. Figure d-illustrates the condition w ich occurs u on tensioning of the fabric ID transversely of the beads II. The rubber which forms the basis of the decoration is, as will be appreciated. relatively soft and flexible. When vulcanized it tends to retain its initial shape. but

the tendency to retain this shape is not sufficient to resist even moderate tension of the fabric I0. When the fabric I0 is tensioned, therubber is displaced so that the beads are'flattened out substantially as indicated in Figure 6, with the result that the effectiveness of the design, asviewed from the dress face of the fabric I0, is largely lost.

As will be appreciated, in Figure 5 tension of the fabric I0 is transmitted to" the reinforcing sheet material I 4 at the points a, and particularly at the points of attachment between the fabric I0 and the reinforcing material I4 at the edges of the decorated design. The fabric Ill, when'it is provided with the reinforcing material I4, is therefore capable of withstanding relatively great tension without any substantial loss of effectiveness of the design.

While the provision of the reinforcing material I4 has been'found to solve the problem of providing a design which will resist tension of the cloth, another difficulty has arisen. In many applications the fabric which is decorated is in use subjected to substantial tension in both directions. Furthermore, in many cases the fabric has considerable give or stretch thereto. In fact, in all cases, the fabric, if sufliciently tensioned, will stretch or elongate sufficiently to give an undesirable result, which will now be outlined.

Referring to Figure 7, I have illustrated a decorated fabric II) the decoration being in the form of a plurality of parallel straight beads II.

In order to emphasize the problem which is overcome by the present invention, I have shown the fabric II) as a striped cloth, the stripes being indicated at I5. Purely as a matter of illustration, I have'shown the fabric ID in Figures 7 and 8 as strongly tensioned in both directions and appliedto a board, such for example as a panel board, to be employed in upholstery of automobile interiors.

Tension of the fabric in the direction of the arrow b, it will be noted, does not reduce the effectiveness of height of beads II where a reinforcing material, such as shown at I4 in Figure 5, is employed. However, where this reinforcing material is employed, the tension of the fabric in the direction of the arrow c produces an undesirable result. As previously stated, all fabrics will stretch somewhat if tensioned, and particularly in the case of a striped or figured fabric, the unequal stretching which results is undesirable. If the reinforcing material I 4 is an ordinary paper or a textile fabric, a uniform tensioning of the fabric ID in the direction of the arrow 0 will cause more stretch or give in the fabric along the edges of the panel than it does adjacent the decorated beads II. As a result of this, where the fabric has stripes, such as I5, or is otherwise symmetrically figured, there is a distortion of the design of the cloth.

According to the present invention, the rubber which is employed in decorating the fabric is provided with a reinforcing medium which prevents stretching in one direction and which permits stretching of the rubber in the other direction. It will be appreciated that the present invention is applicable both to elongated strips, such as will be employed in the design shown at II in Figures 7 and 8, or in applying other designs, such for example as separated design areas.

Referring to Figures 1 and 2, I have illustrated a strip of thin uncured rubber stock 20, having secured to one surface thereof a reinforcing material 2|. According to this embodiment of my invention this reinforcing material may take the form of a strong creped paper. The paper is provided with a unidirectional creping. In other words, the folds are provided, all extending substantially parallel and are indicated by the lines at 22. It will be readily understood that a paper of this nature is readily stretchable in one direction, as for example longitudinal of the strip, and that it will strongly resist stretching in the opposite direction, as in this case, transversely of the strip.

A somewhat diiferent'embodiment of my invention is illustrated in Figures 3 and 4 in which the strip area of uncured rubber is indicated at 30 and has embedded therein transverse threads 3|. These threads reinforce the rubber 30 against transverse stretching but, as will be readily evident, are ineffective to prevent longitudinal stretching of the strip.

Instead of embedding thethreads 3I in the rubber 30, they may be applied to one surface thereof. Instead of threads, other transversely extending elongated reinforcing members of any nature may be employed.

As an alternative it is also possible to obtain the same result by applying anordinary strong paper or fabric to the rubber' and then scoring or cutting the same transversely at close intervals to permit longitudinal stretching of the strip.

Referring now particularly to Figure 8, I have illustrated the appearance of a decorated fabric when made with my improved decorating material and when subjected to sufficient tension in both directions I) and c to substantially stretch the cloth. In this case the stretching of the cloth in the direction of the arrow 1) will not cause the design to lose its effectiveness by reason of red c i n of the height of beads or risers II.

siblelengthwise upon stretching of said fabric,'

In the event that thecreped paper H is em-' and meansstron'gly resisting transverse stretch-1 ployed, the paper will strongly resist stretching transversely of the longitudinal direction of the decorations I L In theevent that the rubberous material is in the form illustrated in Figures 3 and 4, the threads or transverse elements 3| prevent transverse stretching of the reinforcing ma terial and the rubber and serve the same purpose as the creped paper.

Tensioning of the cloth ii) in Figure 8 in the direction of the arrow does not unequally stretch the cloth and thus distort the designs or figures therein. The rubber which forms the basis of the decorations is relatively thin and is quite easily stretched. The reinforcing material, if it is in the form of creped paper as illustrated in Figure l, is effective to permit elongation of the rubber in conformity with the natural exten-- sion of the fabric. Elongation of the design in this instance is accompanied by a corresponding unfolding or loosening of the folds 22 of the creped paper. In the event that the reinforcing material is in the form of transverse threads or the like, it will be apparent that these threads, since they are not interconnected, have no tendency to resist the normal stretching of the fabric. As a result, strips l5, if such are provided in the cloth, will extend parallel after tensioning of the cloth. 1

It will be noted in Figure '7 that tension of the cloth in the direction of the arrow 0 results in distortion of the design and unequal spacing of the stripes. It will be readily evident that if the reinforcing material takes any of the other forms suggested in the foregoing, the result will be the same.

While I have illustrated and described several specific embodiments of my invention, it will be apparent to those skilled in the art that various additions, modifications, omissions, combinations and substitutions may be made which will be within the spirit and scope of my invention as defined by the appended claims.

What I claim as my invention is:

1. A decorated slightly elastic fabric adapted to be tensioned in use, having a rubber strip provided with a riser at its front surface secured to the rear face of said fabric in a manner to provide a bead on the front face of said fabric corresponding to said riser, a reinforcing layer adhered to the rear of said rubber strip, said layer adapted to resist transverse stretching but permitting lengthwise elongation of said strip, thereby providing for uniform stretch of said fabric under tension applied thereto uniformly in adirection parallel to said rubber strip.

2. A decorated slightly elastic fabric having a pattern therein adapted to be tensioned in use, having a rubber strip provided with a riser at its front surface secured to the rear face of said fabric in a manner to provide a bead on the front face of said fabric corresponding to said riser, a reinforcing layer adhered to the rear of said rubber strip, said layer adapted to resist transverse stretching but permitting lengthwise elongation of said strip, thereby providing for uniform stretch of said fabric under tension applied thereto uniformly in a direction parallel to said rubber strip.

3. A decorated slightly elastic fabric adapted to be tensioned in use, having a rubber strip provided with a riser at its front surface secured to the rear face of said fabric in a manner to provide a bead on the front face of said fabric corresponding to said riser, said strip being extening of said strip,- while permitting'longitudinal stretching of said strip' and fabric along. said risers, thereby providing for uniformstretch of said fabric under tension applied thereto uni-- formly in a direction parallel to. said rubber strip. 4. A decorated composite fabric adapted to be tensionedin use comprising a facing fabric, a

strip of rubber vulcanized to the rear of said. facing fabric, and a strip of reinforcing sheeting secured to. the rear of said strip of'rubber, said facing fabric being slightly stretchable under. the tension applied'to said 'fabricin use, said reinforcing sheeting being substantially nonstretchable in a transverse direction and being stretchable longitudinally, said composite fabric being embossed Jtoform beads longitudinally of said strip of rubber and reinforcing material,

said reinforcingstrip serving to prevent. flattening of said beads under tension applied to said fabric transversely of. said strip, while permitting longitudinal stretching. of said composite fabric along said embos'smen't under, tension applied ,to said fabric longitudinally of said strip.

5. A decorated composite fabric adapted to be tensioned in use comprising a facing fabric, a strip of rubber vulcanized to the rear of said facing fabric, and a strip of reinforcing sheeting secured to the rear of said strip of rubber, said facing fabric being slightly stretchable under the tension applied to said fabric in use, said reinforcing sheeting being substantially nonstretchable in a transverse direction and being stretchable longitudinally, said composite fabric being embossed to form beads longitudinally of said strip of rubber and reinforcing material, said reinforcing strip serving to prevent flattening of said beads under tension applied to said fabric transversely of said strip, while permitting longitudinal stretching of said composite fabric along said beads under tension applied to said fabric longitudinally of said strip, said facing fabric having a symmetrical pattern therein, whereby upon stretching of said composite fabric in the direction of said strip, the original symmetry of reinforcing strip serving to prevent flattening of said beads under tension applied to said fabric transversely of said strip, while permitting longitudinal stretching of said composite fabric along said beads under tension applied to said fabric longitudinally of said strip, said facing fabric having a pattern including parallel stripes generally perpendicular to said rubber and reinforcing strip, whereby upon stretching of said composite fabric longitudinally of said strip, said stripes tend to remain in parallel relationship.

'7. A decorated composite fabric comprising a facing fabric of slightly stretchable material, an intermediate strip of rubber vulcanized to the rear of said facing fabric, a longitudinal embossment provided in said composite fabric along said rubber strip, and reinforcing means cooperating with said rubber strip and said facing fabric adapted to permit substantially free stretching of said composite fabric longitudinally of said strip, said reinforcing means being substantially non-extensible transversely of said strip whereby to prevent flattening of said embossment under tension appliedto said fabric transversely of said strip.

8. A decorated composite fabric comprising a facing fabric of slightly stretchable material, an intermediate strip of rubber vulcanized to the rear of said facing fabric, a longitudinal embossment provided in said composite fabric along said rubber strip, and said facing fabric adapted to permit substantially free stretching of said fabric longitudinally of said strip but preventing flattening of said embossment under tension applied to said fabric transversely of said strip, said reinforcing means comprising one-way creped material secured to said rubber strip, the crepeing extending transversely of said strip.

9. A decorated composite fabric adapted to be tensioned in use comprising a facing fabric, a strip of rubber vulcanized to the rear of said facing fabric, and a strip of reinforcing sheeting secured to the rear of said strip of rubber, said facing fabric being slightly stretchable under the tension applied in use, said reinforcing sheeting being substantially non-stretchable in a transverse direction and being stretchable longitudinally, said composite fabric being embossed to form beads in said facing fabric longitudinally of said strip of rubber and reinforcing material, the embossment resulting in the formation of thickened risers in the rubber, and the reinforcing strip being united substantially directly to said facing fabric by said rubber at the sides of said risers, said reinforcing strip serving to prevent flattening of said embossment under tension applied to said fabric transversely of said strip, while permitting longitudinal stretching of said composite fabric along said embossment under tension applied to said fabric longitudinally of said strip.

CLARENCE J. DAVIES.

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