US2800149A

US2800149A - Embossed pile fabric

Info

Publication number: US2800149A
Application number: US444521A
Authority: US
Inventors: Henry F Nowicki
Original assignee: Individual
Current assignee: James Lees and Sons Co
Priority date: 1954-07-20
Filing date: 1954-07-20
Publication date: 1957-07-23
Anticipated expiration: 1974-07-23

Description

July 23, 1957 H. F. NOWlCKl EMBOSSED PILEI FABRIC Filed July 20, 1954 nited States Pa 2,800,149 nrvmossnn PILE FABRIC Henry F. Nowicki, Bridgeport, Pa., assignor to James Lees and Sons Company, Bridgeport, Pa., a corporation of Pennsylvania Application July 20, 1954, Serial No. 444,521

Claims. (Cl. 139-406) The present invention relates to an improved fabric and method of making the same and has particular application to pile fabrics having having an embossed surface.

Prior to the present invention, fabrics having an embossed surface were formed by weaving varying heights of pile loops over wires which vary in height according to the desired pattern. It has also been proposed to produce embossed pile surfaces by simply omitting pile projections from certain parts of the surface. The first method, while producing a satisfactory fabric, is very expensive in that it requires a special wire set and also entails a higher power output to withdraw the wires. The latter method, on the other hand, is very economical to perform since wires of uniform height may be used and in addition, a minimum amount of power is required to withdraw the wires from the fabric. However, the latter method does not produce the desired quality of pile surface since the conventional method of weaving exposes the upper weft shots in the area of the pile surface wherein no pile loops are raised. The exposure of the weft shots gives the carpet a cheap and undesirable surface appearance which is to be avoided in the manufacture of quality pile fabrics.

With the foregoing in mind, a primary object of the present invention is to provide a pile fabric and method for producing the same in which the embossed pile surface comprises loops of uniform height in selected areas of the fabric, the remaining areas comprising a groundwork of pile yarn lying over the upper weft shots in relaxed condition. The relaxed pile yarns efiectively cover the upper weft shots to hide the base fabric, and at the same time, provide a contrast from the pile loops in the selected portions of the surface.

Another object of the present invention is to provide a novel method of forming an embossed pile surface in a fabric which is highly economical and which produces a fabric having the desired luxuriant pile characteristics.

These and other objects of the invention and the various features and details of the operation thereof are more fully set forth hereinafter with reference to the accompanying drawing wherein:

Fig. 1 is a warpwise sectional view of a fabric made in accordance with the present invention;

Fig. 2 is a sectional view taken on the line 22 of Fig. 1;

Fig. 3 is a detached elevational view of a preferred yarn used in the formation of the fabric shown in Fig. 1; and,

Fig. 4 is a view similar to Fig. 1 showing a modified form of the invention.

Referring now to the drawing, Fig. 1 shows a fabric comprising a base fabric having

opposed chain warps

11, 11 passing over and under upper and lower weft shots 2,800,149 Patented July 23, 1957 12 and 13 respectively. A stuifer warp passes intermediate the upper and lower weft shots as shown at 14. Pile yarn P is looped between selected upper weft shots 12 as indicated at 16, and passes over the remaining upper weft shot to form a float as indicated at 17.

As shown in Fig. 3, the pile yarn P is preferably formed with a slight pucker or crimp so that it providescover for the base fabric when it is floated over the upper weft shots, for example, as indicated at 17.. To preserve this pucker or crimp in the pile yarn, it is threaded in the conventional loom under a minimum of tension so that it is substantially relaxed when it is woven into the fabric. Thus, the relaxed float 17 provides adequate coverage for the base fabric. 7

When weaving the fabric, pile wires are inserted between successive upper weft shots and the loops 16 are raised over selected pile wires. The float 17, on the other hand, is raised over the upper weft shot but passes under the wires disposed on opposite sides of the weft shot. Preferably, the wires are inserted with the lower weft shots in a split shed loom, the lower weft shots being inserted in the lower shed and the wires in the upper shed. The upper weft shots are inserted in alter nation with the lower weft shots, the upper weft shot being inserted in the lower shed and nothing being inserted in the upper shed. Thus, the pile yarn P may be retained in the intermediate position to pass over the upper weft shot 12 and under the wires to form a float. The absence of tension in the pile yarn P retains the pucker in the yarn and provides a soft pleasing appearance to the fabric in the areas where there are no pile projections.

A modified fabric is shown in Fig. 4 wherein a single chain warp 21 passes alternately above and below upper and

lower weft shots

22 and 23. The stuifer warp 24 passes between the upper and

lower weft shots

22 and 23 as indicated. The pile yarn P in this modification of the invention is composed similarly to the pile yarn P, having a pucker or crimp. In this modification, the

pile yarn P is tied under alternate upper weft shots, and

the embossed pile surface is obtained by forming pile loops over the intermediate upper weft shots in a selected area of the fabric and floating the pile yarn P over the intermediate upper weft shots in the remaining area of the fabric. This fabric exhibits the same desirable characteristics as the aforedescribed fabric.

While certain embodiments of the present invention have been illustrated and described, it is understood that changes and modifications may be made thereto. For example, a single chain warp may be employed in fabrics having the pile yarn tied under every weft shot or double chain warps may be employed in fabrics having the pile yarn tied under alternate upper weft shots. In addition, double upper and lower weft shots may be employed in lieu of the single upper and lower weft shots shown. Still other changes and modifications may be made within the scope of the following claims.

I claim:

1. A pile fabric having a plurality of weft shots, a raised pile area in said fabric comprised of pile projections of face yarn, and a ground pile area in said fabric comprised of relaxed pile yarns floated over at least one of said weft shots to provide maximum weftwise coverage of said weft shot.

2. A fabric in accordance with claim 1 in which the relaxed pile yarn in the ground pile area is crimped.

3. A fabric in accordance with claim 1 having a series of upper weft shots, a series of lower weft shots, a stufi'er warp between said shots, and .chain warps for binding the upper and lower weft shots and the stutfer to form a base fabric.

is one pile yarn end between each pair of chain warps.

5. The method of weaving a pile fabric which cornprises controlling a face pile yarn to form raised pile projections in predetermined areas of a fabric, controlling said pile yarn to form ground pile areas in said fabric, and substantially removing tension from said face pile yarn in said ground pile areas to permit natural puckering of the yarn to cover a maximum weftwise areav References Cited in the file of this patent UNITED STATES PATENTS 467,633 Bollentin Jan. 26, 1892 4 Hope Oct. 28, 1919 Underwood Oct, 9, 1951 Jackson Dec. 15, 1953 Dacey June 15, 1954 Parlin Aug. 10, 1954 Hoeselbarth May 31, 1955.

OTHER REFERENCES The Modern Textile Dictionary (Linton), published 10 by Little, Brown and Co. (New York), 1954, page 200.