WO2004046437A1

WO2004046437A1 - Blister fabrics with internal connecting elements

Info

Publication number: WO2004046437A1
Application number: PCT/US2003/033846
Authority: WO
Inventors: William O. Boyd, Jr.; John L. Tucker, Jr.; Iain R. Taylor; David M. Brown; Derek A. Sharp
Original assignee: Milliken & Company
Priority date: 2002-11-15
Filing date: 2003-10-24
Publication date: 2004-06-03
Also published as: KR100752857B1; KR20050086568A; AU2003284934A1; AU2003287211A1; EP1581680A2; WO2004046446A3; EP1583856A4; EP1581680A4; MXPA05005077A; JP4599589B2; CA2505388A1; CN1711379A; CN1711168A; HK1086229A1; KR20050086561A; WO2004046446A2; EP1583856A1; MXPA05005075A; CN1296198C; BR0316354A

Abstract

A blister fabric (740) of a knit or woven construction may be needle punched to produce internal connections of filaments or fibers (741, 746) from yarns extending into, and/or between, the yarns of an adjacent layer. Interconnections of fibers among separate layers are produced by needles which enter a first layer and then carry fibers from the first layer to a second adjacent layer within the blister of the fabric. Such interconnected fibers which bridge or span multiple layers in the fabric serve to strengthen the blister fabric, making the fabric more resistant to abrasive forces.

Description

BLISTER FABRICS WITH INTERNAL CONNECTING ELEMENTS

CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part application of application Serial No.

10/298,476 filed on November 15, 2002 entitled "Blister Fabrics With Internal Connecting Elements" to Boyd et al.

BACKGROUND

The present invention relates to fabrics having internal connecting elements or fibers which serve to stabilize the fabric construction.

Many methods and procedures have been used to stabilize the construction of a knit or woven fabric. Coatings have been applied to prevent the yarns from moving relative to each other. However, coatings alone may not provide within the fabric the additional desired characteristics. Recently, a process known as hydroentanglement has been employed to provide stabilization to woven fabrics. Hydroentanglement uses fluid jets to force fibers extending from the main body of a yarn to entangle with fibers extending from the main body of another yarn. However, hydroentanglement processes sometimes affect undesirably the aesthetic characteristics of the fabric due to the large number of free fibers needed to create entanglements by the fluid jets. There is a need for fabrics that have been stabilized by other methods or procedures.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a top view of a blister fabric illustrating one embodiment of the present invention;

Figure 2 is an enlarged cross sectional view of the blister fabric from Figure 1 taken about the section lines 2-2; Figure 3 is an enlarged cross sectional view of another embodiment of the present invention, using a composite of two separate layers of fabric; Figure 4 is an enlarged partial view of a needle used in the present invention; 2

Figures 5A and 5B are diagrams illustrating stitches used in one example of the present invention; Figure 6 is a top plan view of a woven blister fabric; Figure 7 is a cross-section view of a portion of the woven blister fabric of

Figure 6, as taken along lines 7-7 of Figure 6; and Figure 8 shows a further view of a portion of the cross-section of the woven blister fabric of Figures 6-7.

DETAILED DESCRIPTION Referring now to the Figures, and in particular Figures 1-2, there is shown a blister fabric 10 illustrating one embodiment of the present invention. The blister fabric 10 has alternating zones of blister zones 100 and base zones 200. The blister zones 100 have a lower blister layer 110 of a first material independent of an upper blister layer 120 of a second material. The base zones 200 are a unified layer of material.

As illustrated, the blister fabric 10 is formed of base yarns 11 and blister yarns 12. In one embodiment, the blister fabric 10 is formed from yarns having a size of up to about 600 denier. In another embodiment, the blister fabric 10 is formed from yarns having a size of at least about 15 denier. In one preferred embodiment, the fibers forming the base yarns 11 and the blister yarns 12 can both comprise filament yarns. As used herein, filament yarns includes multifilament yarns. In another embodiment, the base yarns 11 and the blister yarns 12 can both comprise spun yarns. In yet another embodiment, the base yarns 11 can comprise filament yarns and the blister yarns 12 can comprise spun yarns. In yet another embodiment, the base yarns 11 can comprise spun yarns and the blister yarns 12 can comprise filament yarns. It is also contemplated that the present invention will work with yarns of combined filament and staple fiber. The combined filament and staple fiber yarns can be used in the base yarns 11 and/or the blister yarns 12 as a substitute for either the filament yarns and/or spun yarns in the above combinations. The fibers of the filament and/or spun yarns in the present invention can be formed from natural or manufactured material. For example, natural materials can include materials of animals, vegetable, or mineral origin which are used as fibers. Manufactured materials can include polymers synthesized from chemical compounds, modified or transformed natural polymers and minerals.

Still referring to Figures 1-2, as illustrated, the lower blister layer 110 of the blister fabric 10 is a jersey knit of the base yarns 11 , and the upper blister layer 120 of the blister fabric 10 is a jersey knit of the blister yarns 12. Also as illustrated, the base yarns 11 form a unified double layer jersey knit in the base zones 200, and the blister yarns 12 are sandwiched between the unified double layer jersey knit of the base yarns 11 in the base zones 200. Although the blister fabric 10 is illustrated as an all knitted fabric, it is contemplated that the blister fabric can be a woven fabric, or a combination of knit and woven fabric. Additionally, although the unified base zones 200 are illustrated as a knitted together section, it is contemplated that the unified base zones could be formed by processes such as weaving, stitching, bonding, or the like.

Referring now to Figure 2, there is shown an enlarged cross sectional area of the blister fabric 10. As illustrated, blister zone connections 130 are formed between the lower blister layer 110 and the upper blister layer 120 by portions of the fibers from the yarns in one layer of the blister zone 100 passing from those yarns into, and/or between, the yarns of the other layer of the blister zone 110. Lower blister layer connections 131 are formed between the lower blister layer 110 and the upper blister layer 120 by portions of the fibers from the yarns in the lower blister layer 110 passing from those yarns into, and/or between, the yarns of the upper blister layer 120. Upper blister layer connections 132 are formed between the upper blister layer 120 and the lower blister layer 110 by portions of fibers from the yarns in the upper blister layer 120 passing from those yarns into, and/or between, the yarns or of the lower blister layer 100. The lower blister layer connections 131 and the upper blister layer connections 132 provide a securing tie between the lower blister layer 110 and the upper blister layer 120.

Still referring to Figure 2, a fiber forming one of the lower blister layer connections 131 originates from a yarn in the lower blister layer 110 and then projects into the upper blister layer 120. The fibers from the lower blister layer 110 forming the lower blister layer connections 131 are secured by the fibers or filaments in the main body of the yarns in the upper blister layer 120. A portion of the fibers forming the lower blister layer connections 131 are secured between fibers within the main body of the yarns in the upper blister layer 120, the main body being the group of fibers which are oriented in about the same direction as the yarn itself. Another portion of the fibers forming the lower blister layer connections 131 are secured between yarns of the upper blister layer 120 by the fibers in the main body of those yarns. A fiber forming one of the upper blister layer connections 132 originates from a yarn in the upper blister layer 120 and then projects into the lower blister layer 110.

The fibers from the upper blister layer 120 forming the upper layer connections 132 are secured by the fibers or filaments in the main body of the yarns in the lower blister layer 110. A portion of the fibers forming the upper blister layer connections 132 are secured between fibers within the main body of the yarns in the lower blister layer 110, the main body being the group of fibers which are oriented in about the same direction as the yarn itself. Another portion of the fibers forming the upper blister layer connections 132 are secured between yarns of the lower blister layer 110 by the fibers in the main body of those yarns. These types of connections contrast with connections formed between yarns and layers by the entanglement of fibers extending generally outward and at least partially radial from one yarn with the fibers extending in a direction generally outward and at least partially radial from another yarn, as experienced with many of the hydroentanglement methods of treating a fabric. Many of the lower blister layer connections 131 and the upper blister layer connections 132 are loops of the fibers from the respective source layers that insert into the corresponding receiving layers. The loops of fibers create two connections, each of the connections being one half of the loop that originates in the same yarn and then project into the same receiving layer. In some instances, the upper blister layer connections 131 and/or the lower blister layer connections 132 can be formed by sections of the fibers that are attached at only one end to the respective source yarns. In some further instances, a fiber attached at only one end and forming an upper blister layer connection 131 or a lower blister layer connection 132 can be hooked, bent, or looped at the free end to further secure with the fibers of the corresponding layer to which the connection engages.

In one embodiment, the blister zone of a fabric incorporating the present invention, has a total of at least about 275 total connections (i.e. the total of both the connections originating from a particular layer and the connections received by that (

5 particular layer) per square inch securing the lower blister layer to the upper blister layer, and a maximum of about 520,000 total connections per square inch, depending on the stability needed and the construction of the fabric. In one knitted fabric embodiment, the blister zone has a total of from about 350 total connections per square inch to about 1 ,050 total connections per square inch, and further in other knitted fabric embodiments may have about 750 total connections per square inch.

Because the source of the connections originates from within yarns, and the connections also secure yarns, it is helpful to understand the number of total connections per yarn distance. The total of both connections originated from a particular yarn and the connections received by that particular yarn are also described herein as connection "ends" or connecting points. In one embodiment, such as for example in a knitted fabric, the yarns that form the upper blister layer or the upper blister layer in the blister zone of the fabric incorporating the present invention, have a minimum of at least about 1.1 total connections (or connection ends) per yarn-inch securing the yarn, and a maximum of about 1 ,650 total connections per yarn-inch. In one preferred embodiment, the yarns that form the lower blister layer or the upper blister layer of the blister zone of the fabric incorporating the present invention, have from about 1.4 total connections per yarn- inch to about 4.2 total connections per yarn-inch, and more preferably about 2.8 total connections per yarn-inch.

Because the fibers of the yarn are the source of the connections, different yarns will have different availability of fibers for the connection, and different needs for the amount of connections based on the fiber content of the yarn. A measurement of filament distance is length of a yarn having filament(s) multiplied by the number of filaments in that yarn bundle. Therefore, it is helpful to understand the number of total connections (the total of both connections originated from a particular yarn and the connections received by that particular yarn) per filament distance of the yams for the portion of the fabric incorporating the present invention.

In the examples provided below, the fabric was needle punched from both sides, but other embodiments of the invention may use methods of construction that needle punch from only one side of the fabric.

Referring again to Figure 2, a knitted fabric is shown in which the base zone 200 is a unitary construction with a lower base layer portion 210, an upper base layer portion 220, and trapped yarns 230 passing between the upper base layer portion

210 and the upper base layer portion 220. In the embodiment illustrated, the lower base layer portion 210 and the upper base layer portion 220 are formed by the base yarns 11 , and the blister yarns 12 form the trapped yarns 230 between the two layers. As illustrated, base layer connections 240 are formed between the lower base layer portion 210 and the upper base layer portion 220. Also, trapped yarn connections 250 are formed between the lower base layer 210 and the trapped yarn

230 and the upper base layer portion 220 and the trapped yarn portion 230.

Referring still to Figure 2, similar to the blister zone connections 230, the base layer connections 240 are formed between the lower base layer 210 and the upper base layer 220 by portions of the fibers from the yarns in one layer of the base zone 200 passing from those yarns into the other layer of the base zone 200. Lower base layer connections 241 are formed by fibers that originate from a yarn in the lower base layer 210 and then project into, and/or between, the yarns of the upper base layer 220. The fibers from the lower base layer 210 forming the lower base layer connections 241 are secured by the fibers or filaments in the main body of the yarns in the upper base layer 220. A portion of the fibers forming the lower base layer connections 241 are secured between fibers within the main body of the yarns in the upper base layer 220, the main body being the group of fibers which are oriented in about the same direction as the yarn itself. Another portion of the fibers forming the lower base layer connections 241 are secured between yarns of the upper base layer 220 by the fibers in the main body of those yarns. Upper base layer connections 242 are formed by fibers that originate from a yarn in the upper base layer 220 and then project into the lower base layer 210. The fibers from the upper base layer 220 forming the upper base layer connections 242 are secured by the fibers or filaments in the main body of the yarns in the lower base layer 210. A portion of the fibers forming the upper base layer connections 242 are secured between fibers within the main body of the yarns in the lower base layer 210, the main body being the group of fibers which are oriented in about the same direction as the yarn itself. Another portion of the fibers forming the upper base layer connections 242 are secured between yarns of the lower base layer 210 by the fibers in the main body of those yarns. The lower base layer connections 241 and the upper base layer connections 242 provide a securing tie between the lower base layer 210 and the upper base layer 220.

As with the lower blister layer connections 131 and the upper blister layer connections 132, many of the lower base layer connections 241 and the upper base layer connections 242 are loops of the fibers in the respective source yarns that insert into the corresponding receiving layer. In some instances, the lower base layer connections 241 and/or the upper blister layer connections 242 can be formed by sections of the fibers that are attached at only one end to the respective source yarns. In some further instances, a fiber attached at only one end and forming a lower base layer connection 241 or, an upper base layer connection 242 can be hooked, bent, or looped at the free end to further secure with the fibers of the corresponding receiving layer to which the connection engages. The base layer connections 240 provide a securing tie between the lower base layer 210 and the upper base layer 220, thereby giving the base zone 200 a more stabilized and abrasion resistant fabric.

In one embodiment, the base zone of a fabric incorporating the present invention has a total of at least about 57 total connections (the total of both the . connections originating from a particular layer and the connections received by that particular layer) per square inch securing the lower base layer to the upper base layer, and a maximum of about 109,110 total connections per square inch, and more preferably about 150 total connections per square inch, depending on the stability needed and the construction of the fabric. In one embodiment, the yarns that form the lower base layer of the upper base area of the base zone of the fabric incorporating the present invention, have a minimum of at least about 0.6 total connections per yarn-inch securing the yarn, and a maximum of about 11.61 total connections per inch, and more preferably about 1.6 total connections per yarn-inch. In one embodiment, the yarns forming the connections have from about 28.8 connections per filament-inch to about 557 connections per filament-inch.

Still referring to Figure 2, the trapped yarn connections 250 are formed between the trapped yarns 230 and the lower base layer 210 and the upper base layer 220, by portions of the fibers from the trapped yarn 230 passing into, and/or between, the main body of the yarns in the lower base layer 210 or the upper base layer 220, and/or fibers from yarns in the lower base layer 210 or the upper base layer 200 passing into the trapped yarn 230. Lower base trapped yarn connections 251 are formed between the trapped yarns 230 and the lower base layer 210 by portions of the fibers from the yarns in the lower base layer 210 passing from those yarns into the main body of the trapped yarns 230, and by fibers from the trapped yarns passing from the trapped yarns 230 into, and/or between the main body of the yarns of the lower base layer 210. Upper base trapped yarn connections 252 are formed between the trapped yarns 230 and the upper base layer 220 by portions of the fibers from the yarns in the upper base layer 220 passing from those yarns into the main body of the trapped yarns 230, and by fibers from the trapped yarns 230 passing from the trapped yarns 230 into, and/or between, the main body of the yarns of the upper base layer 220.

As with the lower base layer connections 241 and the upper base layer connections 242, many of the lower base trapped yarn connections 251 and the upper base trapped yarn connections 252 are loops of the fibers in the respective source yarns that insert into the corresponding receiving yarns or layer. In some instances, the lower base trapped yarn connections 251 and/or the upper base trapped yarn connections 252 can be formed by sections of the fibers that are attached at only one end to the respective source yarns. In some further instances, a fiber attached at only one end and forming an lower base trapped yarn connection 251 or an upper base trapped yarn connection 252 can be hooked, bent, or looped at the free end to further secure with the fibers of the corresponding receiving yarn or layer to which the connection engages.

The trapped yarn connections 250 provide a securing tie between the trapped yarn 230 and the lower base layer 210, and the trapped yarn 230 and the upper base layer 220, thereby giving the base zone 200 a more stabilized and abrasion resistant fabric. In one embodiment, the yarns that form the trapped yarns of the base zone of the fabric incorporating the present invention, have a minimum of at least about 0.6 total connections per yarn-inch securing the yarn, a maximum of about 11.61 total connections per yarn-inch, and more preferably about 1.6 total connections per yarn-inch. In one embodiment, the trapped yarns have from about 28.8 connections per filament-inch to about 557 connections per filament-inch.

In one embodiment, the needled blister fabric 10 also includes a back coating disposed on the back side of the lower blister layer 110 and the lower base layer 210. It has been found that a backcoating further improves the abrasion resistance of the opposite side of the needled blister fabric 10. The back coating can be any polymeric material, such as latex, polyvinylacetate, or the like. The back coating can be applied to knitted, woven, or other substrate, and may be applied at a level of from about 0.25 oz/yd² to about 5 oz/yd². In general, backcoating may be employed upon knitted fabrics, woven fabrics, or any other fabric type employed in the practice of the invention.

Referring now to Figure 3, there is shown an enlarged cross section of a fabric composite 20 illustrating another embodiment of the present invention. The fabric composite 20 is a multiple layered cloth, such as a double cloth, a triple cloth, etc. The fabric comprises at least a first layer 21 and a second layer 22. At least one of the first layer 21 and the second layer is a knitted fabric. In the embodiment illustrated in Figure 3, the first layer 21 is formed from first layer yarns 23, and the second layer 22 is formed from second layer yarns 24. In one embodiment, the first layer yarns 23 and/or the second layer yarns 24 have a yarn size of up to about 600 denier. In another embodiment, the first layer yarns 23 and/or the second layer yarns 24 have a yarn size of at least about 15 denier. In one preferred embodiment, both the first layer yarns 23 and the second layer yarns 24 comprise filaments. In another embodiment, the first layer yarns 23 are filament yarns and the second layer yarns 24 are spun yarns. In yet another embodiment, both the first layer yarns 23 and the second layer yarns 24 are spun yarns. Additionally, it is contemplated that first layer yarns 23 and/or the second layer yarns 24 can include yarns formed of the combination of filaments and staple fibers.

Connections 25 are formed between the first layer 21 and the second layer 22 by filaments of the yarns in the two layers. First layer connections 26 are formed by portions of the fibers in the first layer 21 that project into the second layer 22. The first layer connections 25 are secured by the fibers of the main body of the second layer yarns 24. Second layer connections 27 are formed by portions of the fibers in the second layer 22 that project into the first layer 21. The second layer connections 27 are secured by fibers of the main body of the first layer yarns 23. It is contemplated that the connections 25 of the present invention can be formed across the entire composite fabric 20, or in discrete zones. Many of the first layer connections 26 and the second layer connections 27 are loops of the fibers from the respective source layers that insert into the corresponding receiving layers. The loops of fibers create two connections, each of the connections being one half of the loop that originates in the same yarn and then project into the same receiving layer. In some instances, the first layer connections

26 and/or the second layer connections 27 can be formed by sections of the fibers that are attached at only one end to the respective source yarns. In some further instances, a fiber attached at only one end and forming a first layer connection 26 or a second layer connection 27 can be hooked, bent, or looped at the free end to further secure with the fibers of the corresponding layer to which the connection engages.

In one embodiment, the composite fabric, or zone of the composite fabric incorporating the present invention, has a total of at least about 275 total connections (the total of both the connections originating from a particular layer and the connections received by that particular layer) per square inch securing the first layer to the second layer, and a maximum of about 520,000 total connections per square inch, depending on the stability needed and the construction of the fabric. In one preferred embodiment, there is a total of from about 350 total connections per square inch to about 1 ,050 total connections per square inch, and more preferably about 750 total connections per square inch.

In yet another embodiment, the yarns that form the first layer or the second layer of the composite fabric incorporating the present invention, have a minimum of at least about 1.1 total connections per yarn-inch securing the yarn, and a maximum of about 1 ,650 total connections per yarn-inch. In one embodiment which employs knitted fabric, these yarns have from about 1.4 total connections per yarn-inch to about 4.2 total connections per yarn-inch, and more preferably about 2.8 total connections per yarn-inch.

In one embodiment, the yarns that form the first layer or the second layer of the composite fabric incorporating the present invention, have at least about 0.02 total connections per filament-inch, and a maximum of about 6.4 total connections per filament-inch. In one preferred embodiment, these yarns have from about 0.022 total connections per filament-inch to about 0.07 total connections per filament-inch, and more preferably about 0.04 total connections per filament-inch. Knitted Fabrics

In one embodiment of the invention, which is a knitted fabric, the yams that form the lower blister layer (or the lower blister layer in the blister zone), have at least about 0.02 total connections per filament-inch, and a maximum of about 6.4 total connections per filament-inch. In yet another embodiment, the yarns that form the upper blister layer or the lower blister layer of the blister zone have from about

0.022 total connections per filament-inch to about 0.07 total connections per filament-inch, and in other instances about 0.04 total connections per filament-inch.

Woven Fabrics

In yet another embodiment of the invention, which is a woven fabric, the yarns that form the entire (total) two layered fabric, in the blister zone, have at least about 9,000 total connections (connecting ends) and up to about 65,000 connecting ends per square inch of woven fabric. In yet another embodiment, the woven fabric includes about 4 X 10⁴ first and second connecting fiber ends per square inch of fabric. Other embodiments include about 24,000 first and second connecting fiber ends per square inch of woven fabric.

Other applications result in a woven fabric with a two-part blister layer, in which the overall two-part blister layer as a whole provides greater than about 100 connecting fiber ends per yarn inch. In other appliations, the number of connecting fiber ends per yarn inch in said fabric is at least about 4 X10². In some embodiments, the number of connecting fiber ends per filament inch is at least about 0.3.

Further Detailed Description

In one method of making the present invention, the fabric to be further processed is formed and then subjected to a needling process. In one embodiment, the fabric can be a blister fabric which is formed by standard knitting or weaving techniques of filament yarns. The blister fabric includes areas with two separated layers of knitted material, and areas of a double layer jersey knit with yarns from one of the two separated layers sandwiched between the layers of the double layer jersey knit. In another embodiment, the fabric two be processed is two layers that are to be joined in the subsequent processing. At least one of the layers in a multilayer fabric to be processed is a knitted fabric, and both layers could be a knitted fabric. In a preferred embodiment, the yarns forming the fabric to be processed are filament yarns. However, it is contemplated that the yarns could include shorter fibers or could be spun fiber yarns with, or without, filaments. The formed fabric to be processed is fed into a needling machine that needles the fabric by the insertion of a bed of needles into the fabric. Typically, the needling machine inserts the needles into the fabric, and withdraws the needles, at a direction generally perpendicular to the surface of the fabric. Backing plates (not shown) provide support to the fabric on the opposite side of the needle bed, and have openings to allow the needles to pass completely through the fabric. The needles can be inserted and withdrawn from either side of the fabric, or both sides of the fabric. By inserting the needles from only one side, connections will only be generated by the side of the fabric to be processed that the needles are inserted. If more needle insertions per square area are required than can be provided by a single insertion of the bed of needles, then the bed of needles can be inserted more than once in a particular area of the fabric, or multiple beds of needles can be used to be inserted into the same area.

In one embodiment, the needling machine inserts the needles into the fabric in a manner that produces little to no relative motion between the beds of needles and the fabric in the linear direction (the machine direction) as the fabric moves into, through, and exits the machine. The lack of relative linear motion between the needle beds and the fabric can be accomplished by moving the needle beds with the direction of travel of the fabric as the needles are inserted into the fabric and removed from the fabric. After the fabric is needled, a backcoating can be applied to the fabric by various known methods, such as knife coating, foam coating, lamination, spray coating, or other similar methods.

Referring now to Figure 4, there is shown an enlarged partial view of one embodiment of one of the needles 400 used in the present invention. The needle 400 has a pointed end 410 and notches 420 along the length of the needle 400. The pointed end 410 of the needle 400 facilitates the passage of the needle 400 through the yarns and the fabric layers. The notches 420 of the needle 400 pick up or "hook" fibers of the yarns as the needle 400 passes through the yarns and fabric layers. As the needle 400 continues to pass through adjacent yarns and/or fabric layers, the fibers previously hooked by the notches 420 of the needle 400 are moved into the main body of the adjacent yarns and/or fabric layers. The movement of the fibers by the needle 400 will stretch or pull the fibers from the originating yarns. For fibers with free ends near the needle 400, the fiber will follow the notch 420 of the needle 400 until the free end of the fiber passes through the notch 420 or the needle 400 reaches the end of its travel, and fiber is deposited into the adjacent yarn and/or fabric layer. For other fibers, the fiber will pass into the adjacent yarn and/or layer until the needle 400 reaches the end of its travel, or the tension in the fiber causes the fiber to come free from the notch 420, or the fiber breaks. The portion of the fiber that follows the needle and becomes free from the needle, or breaks, will deposit that portion of the fiber into the adjacent yarn and/or layer.

With regard to needle punching the fabric, other applications of the invention could employ needles that are different than that shown in Figure 4. For example, needles could be employed which include a cross section that is non-triangular, such as for example cross-sections which are "tear-drop shaped", or "pinch-blade" shaped, or other shapes, in cross-section Many cross-sectional shapes are known and used in the application of needles to fabric, and could be employed in certain applications of the invention. Furthermore, the notches 420 as seen in Figure 4 could be of a different configuration in which the notches (or barbs) are provided with all of the notches or barbs along one edge of the triangular needle or in any other combination of notches/edge that should prove workable for a given substrate fabric. Thus, the number and configuration of the notches (barbs) on the needle may be varied to fit a particular application. The invention is not limited to the employment of any particular needle or needling procedure. Referring now to Figure 6, a top plan view of a woven fabric 701 is shown.

The woven fabric 701 includes a warp direction 725 (also known as the machine direction) and a perpendicularly positioned fill direction 730, also known as the cross direction. The woven fabric 701 includes a plurality of interconnected based zones, which are seen for example in Figure 6 as base zones 702, 703, and 704. In Figure 6, these base zones 702-704 extend from the bottom of Figure 6 to the top of Figure 6, and form a relatively narrow band between blister zones 710,711. In the particular embodiment shown in Figure 6, the blister zones 710, 711 have a length as shown along the bottom edge of Figure 6, and a width as shown as indicated by "W" on the left lower portion of Figure 6. Thus, Figure 6 contains about 4 blister zones from top to bottom, and a total of about 3 blister zones from left to right as shown in Figure 6. Furthermore, these blister zones as shown in Figure 6 include within them a grid of interconnected base zones. Therefore, the blister zones 710 , 711 are positioned within an interconnected grid. In Figure 6, the warp direction 725 is oriented generally perpendicular to the weft direction (or fill direction) 730, and the base zones 702, 703, and 704 extend along the warp and weft directions, with the base zones being connected within a grid to each other, and blister zones 710, 711 being positioned within the grid. The particular woven fabric 701 shown in Figure 6 is a fabric having two plies or layers. These two plies or layers may be seen in Figure 7. Figure 7 illustrates a cross sectional view of a portion of the woven fabric 701 as indicated by section 7-7 shown in Figure 6. In Figure 7, woven fabric 701 is shown in an expanded view wherein the blister zone 711 is shown in the center of the Figure. This particular embodiment includes two layers, a lower base layer 715 and an upper blister layer 716 which make up or comprise the blister zone 711. The upper blister layer 716 is comprised of yarn 718, and the lower base layer 715 is comprised of yarn 717. Furthermore, a relatively large number of connecting fibers 720 are seen extending from the lower base layer 715 to the upper blister layer 716. In this particular embodiment, the woven fabric 701 was needled from both sides, and therefore connecting fibers 720 were displaced from the upper blister layer 716 to extend down into the lower base layer 715; furthermore, other connecting fibers were displaced from the lower base layer 715 to extend upward and into the upper blister layer 716. Other embodiments of the invention may include a needle punching from only one side of the woven fabric 701.

Figure 8 shows still further expanded view of the woven fabric 701 showing inset 740 which is shown on the left side of Figure 7. This inset 740 shows an expanded view of the woven fabric 701 in cross section, and reveals a detailed view of the base zone 704 which lies adjacent to the blister zone 711. Furthermore, the cut end of a warp yarn 722 is seen in the center of Figure 8. The cut end of a warp yarn 721 within the blister zone 711 is seen in Figure 8. Furthermore, interconnected fibers 741 are shown in Figure 8, each of which includes a first end 742 and a second end of 743. In Figure 8, the first end 742 is deposited or positioned within the lower base layer 715, while the second end 743 is positioned within the upper blister layer 716.

Near the left side of Figure 8 another fiber 746 is shown which includes connecting ends 745a, b as shown in the Figure. In general, the employment of interconnected fibers 741 , 746 serve to strengthen the overall woven fabric 701 such that the fabric is strengthened against abrasion, and may be much more likely to pass the stringent standards needed for the use of such textiles in various applications, including for example automotive seating applications.

In applications of the invention for which the substrate fabric is woven, or when employing a so called "pocket" woven or blister fabric, it is possible to use several different types of weaving machines. For example, Example 2 employs a

Jacquard type of loom in forming the two plies together into a pocket woven or blister fabric material. In other applications of the invention it would be possible to use other types of looms, for example a Dobby-type loom, or any other loom which is capable of achieving a pocket weave, blister type woven fabric. The invention is not limited to any particular loom type, or weaving procedure.

With regard to the types of yarn that may be employed in the invention, it would be possible to use a packaged dyed filament yarn as shown in Example 2, while in other applications it would be feasible to use a spun yarn. Example 1 below employs a package dyed yarn. In some applications it would be possible to use a piece dyed yarn, in which the yarn is dyed after the fabric is woven. In the package dye yarn example, the yarn is pre-dyed prior to weaving. Furthermore, it would be possible to employ a solution dyed yarn, in which the yarn is dyed prior to weaving.

With regard to the chemical composition of the yarn employed, it would be possible to use polyester, rayon, cotton, wool, or any other composition or substrate in the yarn that is employed for the manufacture of yarn in the industry.

In some applications of the invention, it may be feasible to use other means for forming interconnections (or connections) between adjacent layers. Essentially any mechanical or hydraulic means of moving fibers from one layer to deposit them into an adjacent layer could be employed.

The result achieved by needle punching the multi-layered fabric of the present invention typically includes a positive movement or displacement of a portion of the fibers or filaments of certain yarns from one layer directly into the main body of the adjacent yarns or adjacent fabric layers, whereby such fibers or filaments may thereafter create an anchor directly within the main body of the adjacent yarns or fabric layers. The fiber or filament displaced within the adjacent yarn forms the connection between the fabric layers or the yarns of a fabric layer.

Count Procedure

The following interconnection or connection count estimation procedure was used to estimate the number of fiber connecting ends formed by needling the fabric according to the practice of the invention. First, one may note that it is impractical, and maybe even impossible, using currently known techniques, to provide an actual count of the number of interconnections in a given square portion of fabric. However, it has proved convenient to measure the desired effect from the needling of the fabric by employing the following estimation method, which provides an estimation of the actual number of such interconnections (or connecting ends) which occupy a given space.

A fabric which has been prepared and needle punched according to the invention may be cut in the weft direction, for example. After cutting, the woven needled punched fabric is examined under a scanning electron microscope (SEM) having suitable magnification, which in some cases has been found between about 20X and 40X. Then, an actual count is made of connections (fiber ends which have been displaced into a subsequent layer) along one linear edge of the fabric along the cut. In some cases, it has been found convenient to count such fiber connections resulting from displacement from a first layer to a second layer along a linear length of about 20-25 mm. In general, the formula that may be used in the estimation method to determine the number of interconnections in a square unit and area is as follows:

Number of interconnections = (actual counted connections^')² (magnification of SEM)² unit area (linear distance in which the counts are made)² Example 1

Knitted Fabric

The present invention can be better understood with reference to the following

Example. The fabric is a blister fabric formed of two 1/200/48 yarns of different color for the base yarns and 2/150/50 yarns for the yarns employed in the blister area of the fabric. The fabric having blisters is formed on a two bed circular knitting machine with the knitting pattern as shown in Figures 5A and 5B. On the back of the fabric, the two base yarns are used to make two different colors knitted in alternate courses, each yam having about 18 courses per inch each (combined making about 36 courses per inch) and about 13 wales per inch (combined making about 26 wales per inch). The blister yarn does not become knitted in the back of the fabric. On the face of the fabric in the blister zone, the blister yarn forms a jersey knit with about 32 courses per inch and about 28 wales per inch. Also on the face, but in the base area, the two base yarns are knitted in alternate courses, each yarn having about 18.25 courses per inch each (combined making about 36.5 courses per inch) and about 14 wales per inch (combined making about 28 wales per inch).

The blister fabric was then subjected to a needling process to form the connections in the fabric. A Dilo Hyperpunch Double Needle Loom (Dilo Manufacturing Co.) was used to needle the fabric with a needling motion that had little to no relative motion in the machine direction between the fabric and the needle bed. The needle bed contained Groz-Beckert F222 needles, which are a triangular needle with six notches (2 per corner edge of the needle). The needle bed was inserted into the fabric sufficient times that about 900 needle insertions were made per square centimeter of the fabric. It was found that this needling process resulting in about 350 connections per square inch of the fabric in the blister zone, which was about 1.4 connections per yarn inch and about 0.022 connections per filament inch. The needled fabric was then backcoated with about 3 oz/yd² of latex.

The face of the fabric was subjected to the Taber snag testing according to SAE J948, using H-18 wheels with 1000 grams weight for 200 cycles for samples that were not needled, and samples that were needled. For fabric that was not needled, the face of the fabric received a rating of 3.0. For fabric that was needled, the face of the fabric obtained a rating of 3.5. Example 2

Woven Fabric This further example can be understood with reference to the following description. In this example, the fabric is woven, not knitted. The fabric is a blister fabric formed of both warp and fill yarns, a 2/300/136. In this example, the warp and the fill yarns are identical, but other examples could be provided in which the yarns are not identical. In general, the invention is not limited to any particular configuration or identity of yarns. In this particular example, both the warp and the fill yarns consist of two plies, having a 300 denier per ply. There were 136 filaments provided in each ply. A filament yarn was used which was a packaged dyed yarn, meaning that the yarn was dyed prior to weaving. The fabric was woven on a Jacquard-type weaving machine.

In the fabric, there were about 38 picks per inch and about 60 ends per inch. In the area of the blister for the fabric, the two layers remained essentially separate after weaving (in the pocket area). In the base zone or perimeter area (also known as the "tied down" area) the two layers were tightly woven together.

The "pocket weave" fabric was subjected to a needling process in which needles were pushed into the blister zones to form interconnections in part by displacing fibers, moving such fibers into positions in which they extend between or span two layers of the woven fabric. A Dilo Hyper Punch double needle loom (Dilo Manufacturing Company) was used to needle the woven fabric with a needle motion that included little or no relative motion in the machine direction between the fabric and the needle bed.

In this particular type of needling method, the needle moves in an elliptical motion, so that the needle travels along with the fabric for a period of time while the needle is engaged into the fabric. This allows for faster run speeds in manufacturing the fabric.

The needle bed contained F222 needles made and distributed by the Groz- Beckert Company, which included a triangular needle having about 6 notches (2 per corner edge of the needle). The needle bed was inserted into the woven fabric sufficient times that about 300 insertions were made per square centimeter of the fabric for this particular example. Using the counting procedure detailed in this specification, it was found in this example (under a SEM magnification of about 40X) that the needling process resulted about 40,854 connections/in² in the woven fabric within the blister zone

(also known as pocket weave zone). Under magnification of only about 22X, the count resulted in an estimate of about 27,530 connections per square inch. This number is somewhat less than the count achieved at higher magnification, and thus is believed to be less due to the lesser ability to observe the actual interconnected fibers under low magnification. Therefore, the count obtained under higher magnification is believed to me more accurate. Clearly, it may been seen that in this example using a pocket woven fabric the needling process produces a significant amount more connections per square unit, and in this example produced more than 100 times (or more) connections per square unit then a knitted fabric as seen for example in Example 1.

In this example an estimate of yarns was made to estimate the number of connections (connecting ends) formed in the fabric per yarn inch within the fabric, and also the number of connections (connecting ends) formed in the fabric per filament inch. In this particular example, it may be noted that there were about 60 warp ends per inch in the woven fabric, and about 38 picks per inch, resulting in total of about 98 yam ends per one square inch of finished fabric. Therefore, in this particular example, 272 filaments for each single yarn strand were employed, which resulted in an estimated total amount of about 26,656 filament connecting ends/ in² of fabric.

The number of connections per filament inch, then, was estimated to be about 1.53 in this particular example. Further, there were about 417 connections per yarn inch in the finished fabric.

The face of the finished fabric was subjected to the Taber snag testing according to SAE J948 testing procedure, using H-18 wheels with about 1000 grams of weight and 1000 cycles for samples that were not needled and for samples that were needled. For fabric that was not needled, the face of the fabric received a rating of only about 3.0. For fabric that was needled according the example and the process of this invention, the face of the fabric abtained a rating of about 6.0. The higher score is believed to be due at least in part to the formation of fiber ends within adjacent layers which serve to stabilize and strengthen the overall fabric against abrasive forces.

Claims

1. A fabric comprising:

(a) a plurality of interconnected base zones, said base zones having a single layer, and (b) a plurality of blister zones positioned among said base zones, said blister zones comprising at least the following: i) a lower base layer comprised of yarn, said yarn being comprised of a plurality of bundled fibers; and, ii) an upper blister layer comprised of yarn, said yarn being comprised of a plurality of bundled fibers; and

(c) connecting fibers extending between said lower base layer and said upper blister layer.

2. The fabric of claim 1 wherein said fabric further comprises a warp direction and a weft direction, said warp direction being oriented generally perpendicular to said weft direction, wherein said base zones extend lengthwise along said warp and said weft directions, said base zones being connected in a grid, said blister zones being positioned within said grid.

3. A woven fabric comprising:

(a) at least two interconnected base zones, said base zones having a single woven layer; and

(b) a plurality of blister zones positioned among said base zones, said blister zones further comprising: (i) a lower base layer comprised of woven yarn, said woven yarn being comprised of a first plurality of fibers; and,

(ii) an upper blister layer comprised of woven yarn, said woven yarn being comprised of a second plurality of fibers; and

(c) connecting fibers extending between said lower base layer and said upper blister layer, said connecting fibers having a first end and an opposite second end, said first end being positioned within said lower base layer and said second end being positioned within said upper blister layer.

4. The woven fabric of claim 3 wherein said woven fabric consists essentially of a two ply fabric, said two plies comprising said lower base layer said upper blister layer, wherein said woven fabric provides between about 9,000 and about 65,000 first and second connecting fiber ends per square inch of woven fabric.

5. The woven fabric of claim 4 wherein said woven fabric provides greater than about 24,000 first and second connecting fiber ends per square inch of woven fabric.

6. The woven fabric of claim 5 wherein said fabric provides about 4 X 10⁴ first and second connecting fiber ends per square inch of fabric.

7. The fabric of claim 4 wherein said woven fabric is capable of achieving a Taber snag testing rating according to SAE J 948 of greater than 3.

8. The fabric of claim 3 wherein the number of connecting fiber ends per yarn inch is greater than about 100.

9. The fabric of claim 8 wherein the number of connecting fiber ends per yarn inch in said fabric is at least about 4 X 10².

10. The fabric of claim 3 wherein the number of connecting fiber ends per filament inch in said fabric is at least about 0.3.

11. A method of manufacturing a needled, woven fabric comprising:

(a) providing a plurality of interconnected base zones, said base zones having a single woven layer; and

(b) providing a plurality of blister zones positioned among said base zones, said blister zones further comprising: (i) a lower base layer comprised of a first woven yarn, said first woven yarn having a first plurality of fibers; and (ii) an upper blister layer comprised of a second woven yarn, said second woven yarn having of a second plurality of fibers; (c) pushing needles into said blister zone of said woven fabric; and

(d) displacing fibers from one of said layers to another of said layers.

12. A method of making a multi-layered fabric wherein the fabric provides blister zones upon the fabric, said method comprising:

(a) providing a plurality of base zones, said base zones being at least partially interconnected and wherein said base zones have a single layer, and

(b) providing at least one blister zone positioned among said base zones, said blister zone comprising: i) a lower base layer comprised of a first yarn, said first yarn being comprised of a plurality of bundled fibers; and, ii) an upper blister layer comprised of a second yarn, said second yarn being comprised of a plurality of bundled fibers; and

(c) applying needles to said blister zone, (d) displacing fibers from one of said lower base layer or upper blister layer to the other of said layers, said displaced fibers being defined as connecting fibers having a first end and a second end, and

(e) forming a fabric comprising in part said connecting fibers, said connecting fibers being held at said first end within said lower base layer and at said second end within said upper blister layer.

13. The method of claim 12 in which said fabric is moved in a machine direction during manufacture of the fabric, further wherein during the applying step (c), said needles are moved in said machine direction, such that relative motion of said needle to said fabric is minimized while the needle engages the fabric.