WO2003080914A2

WO2003080914A2 - A method for manufacturing multiple ply fabric and a multiple ply fabric obtained through use of such a method

Info

Publication number: WO2003080914A2
Application number: PCT/TR2003/000020
Authority: WO
Inventors: Mehmet Arif GÖGÜS
Original assignee: Tekerekoglu Tekstil Sanayi Ve Ticaret A.S.
Priority date: 2002-03-22
Filing date: 2003-03-21
Publication date: 2003-10-02
Also published as: AU2003219646A8; WO2003080914A3; TR200402386T1; AU2003219646A1

Abstract

This invention is related to a multiple ply fabric manufacturing method characterized by loading the software of the pattern into fabric embroidery machine (101); stretching base fabric (14) and one or more upper ply fabrics (15) on to each other over the machine bench (102); fixing fabrics to each other by sewing loose stitches (18) along the pattern (19)(103); embroidering (17) along these lines (108); mounting racks (3) on machine bench (9)(105), if the pattern comprises a section extending only in the direction of a specific width (104); stretching over other fabrics (14and 15) of a pattern fabric (16) of appropriate width on such a section after attaching this latter to racks (3)(106); attaching pattern fabric (16) from the top by means of shears (0)(107); embroidering the pattern (19) with embroideries (17)(108); cutting out parts of the pattern fabric (16) extending outside the pattern borders and moving the same out (109); cutting one or more upper ply fabrics (15) from zero or more covered area (20) formed by pattern and taking them out (110).

Description

METHOD FORMANUFACTURINGMULTI-LAYERFABRICAND FABRIC MANUFACTURED THEREOF

The present invention is related to a method regarding manufacturing of multiple ply fabrics having two or more than two plies utilized in the making of curtains, covers and similar household textile products, apparatuses used in the carrying out of such a method and multiple ply fabric obtained as a result of putting into use such a method.

In the prior art, various methods which consider laying different fabrics over other ones and making embroidery works and designs on such fabrics are known. In one of such methods, the main lines of the design or of the embroidery are put by straight stitching tread on the bottom fabric following which a second ply of fabric having appropriate sizes and of colour and texture characteristics as desired is laid and fixed over the bottom one so as to allow making embroidery works or plain stitching along lines set beforehand

The process is deemed completed by the cutting of fabric parts extending outside limits set by embroidery or design.

However, this method which was known to be in use in the former art is no longer practicable when use is intended to be made of industry type machines. If the process has to be completed by manual work, this takes too much time and effort and causes loss of precious time. Moreover, as the quality of the product thus obtained depends to a large extent to the skill owned by the manufacturer, it becomes difficult to catch a standard level of quality.

The object of the present invention is the attainment of a fabric, which bring into being various colour, light and texture effects, which presents new opportunities to designer.

Another object of the invention is the obtainment of a fabric of long life and endurable quality.

Another object of the present invention may be saving time and costs. Drawing 2b- is the cross-sectional view of the rack used the manufacturing method.

Drawing 3- is the front view of the shear used in the manufacturing method. Drawing 4-is the schematical view of the application of the method in an industrial machine.

Drawing 5 a -is the front view of multiple ply fabric.

Drawing 5b- is the sectional view taken along D-D' line of the multiple ply fabric. Drawing 6a- is the front view of multiple ply fabric sewn by loose stitches in another embodiment.

Drawing 6b-is the sectional view along the line C-C'of multiple ply fabric after sewn by loose stitches.

Drawing 6c-is the rear view of the multiple ply fabric after sewn by loose stitches.

Drawing 7a- is the front view of another embodiment of the multiple ply fabric of this invention.

Drawing 7b- is the cross sectional view taken along the line A-A'.

Drawing 7c- is the cross sectional view taken along the line B-B'.

Parts shown in the drawings are numbered, as follows:

1. Multiple ply fabric manufacturing method

2. Industrial fabric processing machine

3. Rack

4. Rack gear

5. Rack handle 6. Shear

7. Shear cavity

8. shear ring

9. Bench

10. Movable frame

11. Control panel

12. Embroidery handle

13. Multiple ply fabric

14. Base fabric

15. Upper fabric

16. Pattern fabric

17. Embroidery

18. loose stitch

19. Pattern

20. Covered area

Steps of the method for the manufacturing of multiple ply fabric are numbered as follows:

101 Loading pattern software to the machine

102 Stretching base fabric and one or more upper ply fabris over the rear of the bench

103 Fixing fabrics together by loose stitches applied over pattern lines.

104 Deciding whether the pattern should comprise a section extending along a specific line to be embroidered on a different fabric or not. 105 Mounting racks onto the machine bench

106 Stretching a patterned fabric of appropriate size onto other fabrics after placing the former on the racks

107 Attaching the pattern fabric by shears from top

108 Embroidering along the pattern

109 Cutting out parts of the pattern fabric extending outside borders of the pattern

110 Cutting one or more upper ply fabrics from covered area formed by the pattern.

Y yes

N no

In a preferred embodiment, the method of multiple ply fabric manufacturing (1) of this invention is characterized by loading the software of the pattern into fabric embroidery machine (101); stretching base fabric (14) and one or more upper ply fabrics (15) onto each other over the machine bench (102); fixing fabrics to each other by sewing loose stitches (18) along the pattern (19) (103); embroidering (17) along these lines (108), mounting racks (3) on machine bench (9)(105), if the pattern comprises a section extending only in the direction of a specific width (104); stretching over other fabrics(14 and 15) of a pattern fabric (16) of appropriate width on such a section after attaching this latter to racks (3)(106); attaching pattern fabric (16) from the top by means of shears (6) (107); embroidering the pattern (19) with embroideries (17) (108); cutting out parts of the pattern fabric (16) extending outside the pattern borders and moving the same out (109); cutting one or more upper ply fabrics (15) from zero or more covered area (20) formed by pattern and taking them out (110) (Figure 1)

The subject multiple ply fabric (13) manufactured by means of the above mentioned method is characterized by a base fabric (14); one or more upper ply fabrics (15) of the same size with the bottom fabric (14) placed on this latter by stretching the same; one or more pattern fabric (16) stretched over such base and upper ply fabrics in specific regions; a loose stitching sewn along the lines formed by the pattern (19) in order to join the said fabrics (14,15 and 16); embroideries (17) made over such loose stitches; and zero or more covered areas (20) are trimmed out from one or more upper ply fabrics which the pattern (19) covers.

Base fabric (14) is a fabric of any size, having any type of texture and any colour.

Upper ply fabric (15) is a fabric of the same size and form with the base fabric. Preferably, this fabric has different characteristics than the base fabric.

The pattern (19) which forms lines along which base fabric (14), upper ply fabric (15) and pattern fabric (16) are seamed together by loose stitches and which promotes aesthetical effect of such fabrics consists of covered areas (20) scattered with a specific order without any overlap and having at least one edge point in common. Of such covered areas, zero or more areas may comprise patterns formed of curves overlapping with each other inside their own limits.

Loose stitching is used to determine the borders of the pattern (19) to be embroidered on fabrics (14 and 15) and to prevent formation of wrinkles or folds on fabrics.

Embroider (17) is made along loose stitches to promote fabrics (14,15, and

16) appearance and moreover to seam the fabrics solidly.

In the state of the art, industrial fabric manufacturing machine (2), consists essentially of a control panel (11), to control mechanical and pneumatical parts and accessories in accordance with a pattern software to be used, a frame (10) acting according to the commands of panel, a bench (9) acting in and with the said frame onto which fabric is stretched from all of its edges, and a handle (12) moving fore and aft towards the fabric laterally to make embroidery on the fabric stretched onto the bench having needles inserted at intervals with a specific pattern. Curved teeth are placed to the rear of the vertical walls of the bench extending outwardly. To these teeth fabric is secured. Fabrics are fastened to the bench by placing on these teeth and by wrapping them on rollers. The bottom and top edges of the bench (9) are of a structure to enable wrapping of fabric around A. Rack (3) utilized in stretching the pattern fabric (16) which is narrower than the base fabric to the two vertical sides of the bench comprises curved, pointed teeth (4) facing outwardly and placed closely in two rows and handles in the form of hooks curved backwardly to secure to the sides of the bench.

A Shear (6) in C form having a cavity (7) to fasten to the rollers on the upper portion of the bench comprises a holding ring (8) at each of its two tips to ease fabric rollers being attached to and remove from bench. These rings are formed by curving the two tips so as to form a circle. Such curves prevent the tips to damage the fabrics (Figure 3).

In the course of implementation of the method for manufacturing of multiple ply fabric, which is the subject of this invention, firstly the pattern software is loaded to the industrial fabric embroidery machine. Then, taking the trimmed out fabric area into consideration attention is focused on the pattern (19) being formed of closed curves. Next, base fabric (14) and upper ply fabric (15) in desired number are stretched over the bench. The machine is operated and loose stitching (18) is performed by following pattern lines. After this, embroidering is made onto the loose stitches. A fabric of different type than the fabrics utilized heretofore is mounted over the previous ones. If it is desired to embroider a pattern (19) forming an area closed in respect of its external limits but consisting of various curves overlapping with each other inside that closed area, since no set- up was available for stretching design fabric (16) on the front of the bench in industrial type embroidering machines according to prior art, to the two vertical edges of the bench, a rack to each edge on which to fasten design fabric (16) is fixed. To prevent wrinkles and folds as a result of pattern fabric sagging down, shears are utilized (6) to secure upper edge of the pattern fabric (16) to the upper edge of the bench (9) (Figure 4). The remaining part of the pattern (19) is embroidered. The machine is shut off and fabrics joined by loose stitching and embroidery (14,15 and 16) are removed from the bench. The part of the pattern fabric which remains outside the pattern is trimmed out. If desired, from some of the covered areas of the pattern upper ply fabrics in number as desired are trimmed out. In this way, appearance of upper ply fabrics and base fabrics which remained in the intermediate plies is ensured which enables viewing fabrics of different colour and texture characteristics. (Figure 5a to 7c).

In the event the base fabric and the upper ply fabrics are entirely chosen from coloured and transparent fabrics such as tulle, the light coming from rear of the multiple ply fabric (13) causes fabric to be seen in a combination of the two colours and an effect much richer than visual effect of a single fabric is obtained. Parts from which fabrics are removed increase such an effect owing to different colour fabrics.

When non-transparent fabrics for base and upper plies are used, a multiple ply fabric displaying colour and textural characteristics different if looked at from front and rear is obtained. By means of trimmed out areas in the front of multiple ply fabrics, various colored and textured windows are obtained.

Removal of upper ply fabrics or base fabrics in accordance with a specific pattern or removal of the same randomly creates various visual effects. According to the planned use of household textile products where multiple ply fabrics are utilized, one or more of such effects may be preferred.

Since the method of multiple ply fabric manufacturing of the present invention (1) and the multiple ply fabric obtained thereof is consisted of two or more fabrics having different characteristics as to colour, texture, design and transparency, the finished product creates colour and light effects which are impossible for a single fabric to create.

A large spectrum of opportunities are offered to designers as the invention enables joining fabrics in any desired number and extracting parts of the fabrics thus utilized from any desired areas. Moreover, in case the pattern is fastened not only by loose stitches but by embroidery on two or more lines, the end products is more durable.

Special apparatus (3 and 6) used in this method enables various combinations for joining fabrics, which were not provided in the prior art.

Since the method of the present invention (1) can be used in industrial machines, the invention saves time and money.

Claims

1. In a preferred embodiment, the method of multiple ply fabric manufacturing (1) of this invention is characterized by loading the software of the pattern into fabric embroidery machine (101); stretching base fabric (14) and one or more upper ply fabrics (15) on to each other over the machine bench (102); fixing fabrics to each other by sewing loose stitches (18) along the pattern (19) (103); embroidering (17) along these lines (108), mounting racks (3) on machine bench (9)(105), if the pattern comprises a section extending only in the direction of a specific width (104); stretching over other fabrics (14 and 15) of a pattern fabric (16) of appropriate width on such a section after attaching this latter to racks (3)(106); attaching pattern fabric (16) from the top by means of shears (6) (107); embroidering the pattern (19) with embroideries (17) (108); cutting out parts of the pattern fabric (16) extending outside the pattern borders and moving the same out (109); cutting one or more upper ply fabrics (15) from zero or more covered area (20) formed by pattern and taking them out (110) (Figure 1)

2. A method of manufacturing multiple ply fabric according to claim 1, characterized by a base fabric (14) of any size, colour and textural characteristics.

3. A method of manufacturing multiple ply fabric according to claims 1 and 2 characterized by an upper ply fabric (15) having different characteristics than of the base fabric though it may have size form colour and texture characteristics identical with this latter.

4. A method of manufacturing multiple ply fabric according to claims 1 to 3 characterized by having a pattern which forms lines along which base fabric (14), upper ply fabrics (15) and design fabric (16) are secured to each other by loose stitching (18), which promote aesthetical effect of such fabrics and which comprise covered areas (20) having at least one point on the edges in common without overlapping with each other distributed on fabric surface in accordance with a predetermined pattern.

5. A method of manufacturing multiple ply fabric as claimed in claims 1 to 4 and characterized by a rack (3) utilized in stretching the pattern fabric (16) wherein is narrower than the base fabric to the two vertical sides of the bench comprises curved, pointed teeth (4) facing outwardly and placed closely in two rows and handles in the form of hooks curved backwardly to secure to the sides of the bench.

6. A method of manufacturing multiple ply fabric as claimed in claims 1 to 5 and characterized by a shear (6) in C form having a cavity (7) to fasten to the rollers on the upper portion of the bench comprises a holding ring (8) at each of its two tips to ease fabric rollers being attached to and remove from bench, formed by curving the two tips so as to form a circle.

7. A multiple ply fabric obtained by using the method according to claims 1 to 6 characterized by a base fabric (14); one or more upper ply fabrics (15) of the size same as the base fabric (14) placed on this latter by stretching the same; one or more pattern fabrics (16) stretched over such base and upper ply fabrics in specific regions; a loose stitching made along the lines of the pattern (19) to secure said fabrics (14,15 and 16); embroideries (17) made over such loose stitches; and zero or more covered area (20) trimmed out from one or more upper ply fabrics which the pattern (19) covers.