WO2017064728A1

WO2017064728A1 - Method of making banners and flags like american flag having three dimensional effect by weaving.

Info

Publication number: WO2017064728A1
Application number: PCT/IN2016/000247
Authority: WO
Inventors: Shailesh Kantilal Shah
Original assignee: Shailesh Kantilal Shah
Priority date: 2015-10-13
Filing date: 2016-10-13
Publication date: 2017-04-20

Abstract

The present invention relates to a method of making banners and flags like American flag, having three dimensional effect, by weaving. This method uses dyed yarn which have been exposed to high temperature, to provide the different colors required to make the banner or flag due to which the color of the fabric doesn't fade on continuous exposure to heat and sunlight. The complete product is made by jacquard weaving making it a single piece fabric without any seams or patches due to which it doesn't tear from the seams or stitches. Three dimensional effect is provided to the final product by using the various processes of weaving and finishing. The banners and flags made by this method are long-lasting and highly tolerant to normal as well as harsh weather conditions.

Description

TITLE OF THE INVENTION:

Method of making banners and flags like American flag having three dimensional effect by weaving. FIELD OF THE INVENTION:

The present invention relates to the textile industry and involves the weaving of cloth by jacquard weaving to make flags like the American flag and banners having three dimensional effect. BACKGROUND OF THE INVENTION:

Weaving is a method of textile production in which two distinct sets of yams or threads are interlaced at right angles to form a fabric or cloth. Knitting, felting, braiding, plaiting are other such methods to form a fabric. In weaving, the longitudinal threads are called the warp and the lateral threads are called the weft. One waip thread is called an end and one weft thread is called a pick. The method of interweaving these threads affects the characteristics of the cloth. This weaving of cloth is usually done on a loom which holds the warp threads in place while filling threads are woven through them. The way the warp and the filling threads interlace with each other is called the weave. This weaving can be done to make plain cloth or to make cloth with decorative or artistic designs.

A flag is a piece of fabric mostly rectangular or quadrilateral, with a distinctive design that is used as a symbol, as a signaling device or as decorative material. National flags are potent patriotic symbols with varied interpretations, often including strong military associations due to their original and ongoing military uses. Similarly, a banner is a flag or other piece of cloth bearing a symbol, logo, slogan or other message. Different methods for making flags and banners are available in the prior art.

US Patent 5348056 describes a three-dimensional woven fabric with varied thread orientations which is woven on a rotor-carrier type 3D fabric weaving machine, and provides a reinforcing three-dimensional fabric for composite material, which is imparted with unevenly functioning characteristics by arbitrarily changing the thread orientation angle in part of the fabric structure. In the weaving process of the three-dimensional fabric, a large number of threads, which are oriented with an angle of inclination relative to the longitudinal direction of the fabric, are folded back at the surface of the fabric as they are continuously interwoven in the longitudinal direction thereof, and varied orientation angle portions are formed in part of the sectional area of the fabric by partially changing the angle of inclination of thread portions which continuously extend between adjacent weave portions of the fabric. The three-dimensional fabric can be woven on a rotor-carrier type 3D fabric weaving machine having a large number of rotors arranged in a matrix of multiple rows and arrays alternately with a large number of thread carriers, dividing the rotors into two groups each consisting of rotors in non-confronting positions, repeating a cycle of regular weaving operations where firstly rotors of a first group are turned through 90 DEG or 180 DEG in one direction and then rotors of the second group are turned through 90 DEG or 180 DEG in the reverse direction.

US Patent 5353844 discusses a method and weaving machine for weaving a thick reinforcing fabric comprising multiple noncleaving layers with a 2.5 D or 3 D type structure. The warp yarns successively move into a yarn joining comb, a calibrating comb and then into a dobby weaving unit, where the warp yarns on n superimposed laps are separated upstream of the calibrating comb, n being equal to (N- 1/2 ) and N being the number of layers of said reinforcement so as to have (N- 1/2 ) warp yarns moving into each tooth of the calibrating comb. Two adjacent yarns of a given tooth of the calibrating comb are threaded into the eyes of two heddles of the same row of two heddle frames of the dobby, so that the displacement planes of two adjacent yarns during formation of the shed form between them a sufficient angle so as to prevent the yarns from catching on one another.

US Patent 6315007 discloses a method and machine for high speed formation of a three- dimensional woven fiber structure having at least two warp yarn systems having approximately zero crimp and at least three filling yarns having approximately zero crimp, wherein the warp and filling yarns are non-interlacing with each other, and are secured as an integral fabric via at least one vertical or Z yarn system and the warp yarn systems provided to be positioned via harness frames. The 3-D woven fabric of the present invention is fabricated on a 3-D weaving machine having rapier filling insertion that provides filling yarn insertions in unique shed openings in series to produce a complete filling insertion cycle for every movement of Z- direction yam harnesses.

WO 2015032426 provides a novel add-on weaving method, a device based on this method, 3D fabric items producible by this method and device, and composite materials reinforced with such 3D fabric items are disclosed. The 3D fabric items are produced directly by the add-on weaving process using a complementary fabric (CF), warp yams (P) and weft yams (G). The interacting woven fabric produced by interlacing the warp (P) and weft (G) yams is simultaneously integrated with the complementary fabric (CF) used. The complementary fabric (CF) and interacting woven fabric integrate in mutual through-thickness directions at their intersecting planes and create directly 3D fabric items which are useful for manufacturing delamination resistant and high-performance composite materials. JP 10060781 discloses a cloth for printing on both sides, used for a long narrow vertical flag, a banner, etc., and capable of carrying out the clear printing without light transmitting properties at a lower production cost. This cloth comprises five-layer structure composed of a plain weave cloth 1, a white coating material layer (a coating material containing an adhesive mixed therein) 2 having adhesion and flexibility after drying and a light nontransmitting coating material layer (a urethane coating material containing an adhesive and an aluminum powder mixed therein) 3, a white coating material layer 2' and the plain weave cloth . The white coating material layers 2 and 2' function so as not to express a color of the light nontransmitting coating material layer 3 on the surfaces of the plain weave cloths 1 and 1 ' or the surface of an oil- based ink 5 without visualizing a print on one surface from the other side through the resultant cloth by the light blocking function of the light nontransmitting coating material layer 3. The respective coating material layers 2, 3 and 2' can readily be formed at a low cost and the production cost is more remarkably reduced than that using a silver color-coated resin film as in a conventional method and the production efficiency is high.

JP 2000259107 details the requirement to create freshness in the shape of the flag cloth of a banner and to obtain the banner which prevents the unraveling of fibers, is smooth in the actuation of a jumping-up preventive mechanism and facilitates the detention of the flag cloth by forming a fabric which is subjected to bonding between fibers by a heat treatment of the surface of the fabric formed by weaving and knitting of synthetic fibers to a longitudinally long isosceles triangle shape. The flag cloth 1 formed to the longitudinally long isosceles triangle shape around a supporting pole 2 with respect to a flag rod 9 is mounted symmetrically to the central line. The flag cloth 1 is the fabric constituted by weaving and knitting the chemical fibers and the fibers thereof are bonded to each other by heating the surface of the flag cloth fabric, by which the unraveling thereof is prevented and the fibers are reinforced to each other. Further, the external shape is cut by hot cutting, by which the unraveling of the fibers at the selvages of the flag cloth fabric may be prevented. The freshness is created by forming the flag cloth to the longitudinally long isosceles triangle shape. The jumping-up preventive mechanism 10 ensures the smooth execution of the vertical movement by a sliding ring 12 consisting of a cylinder and is capable of relieving the impact on the flag by a wind pressure.

JP 2005140899 discloses new flags which flutter well and trail by wind gracefully, that is, even if good wind blows, poor fluttering due to clinging to a pole is less frequent in comparison with a conventional flags, and which maintain beauty and vividness of a color over a long term, even if they are used outdoors for a long period of time. The flags are made of flat woven fabric in which polyester real twist yarn made by applying additional twist having the number of twist of 100 to 800 T/m to polyester multifilament false twist yarn is used for warp and weft.

TW 201514353 relates to a fabric forming method comprises the following steps: providing at least one setting yar and at least one base yarn; weaving the setting yam and the base yarn to form a prototype fabric ^" structure; sleeving the prototype fabric structure on a forming mold; heating the prototype fabric structure with high temperature to hot-melt the setting yarn in the prototype fabric structure into a setting film covering the base yarn; solidifying the setting film covered on the base yarn with low temperature to set the prototype fabric structure into a set fabric structure; and removing the set fabric structure from the forming mold such that the thennoplasticity of the setting yam can be used to sleeve the planar fabric into the 3D structure required and formed by the forming mold, thereby simplifying the process of 3D objects and saving costs substantially. CN 101294327 relates to a novel 3D loom capable of producing 3D textile composite material skeleton. The novel 3D loom comprises a frame and a transmission portion, and is characterized in that the loom also includes a 3D woven fabric winding mechanism arranged on the front end of the frame, a multilayer warp let-off mechanism arranged on the tail end of the frame, and a Y- direction opening, a Z-direction weft inserting mechanism, a Z-direction opening and a Y- direction weft inserting mechanism, which are sequentially arranged between the winding mechanism and the let-off mechanism. The 3D loom has the advantages that (1) the loom can weave completely and has good stability, the woven fabrics have various structures, and the produced textile composite material has excellent performance; (2) four different fabrics can be woven; (3) the integrity of the fabric can be ensured; (4) the pitch between yams can be better controlled to combine with the looseness of the 3D woven fabrics, and the loom obviates the need of a beating up mechanism; and (5) the loom has simple structure and operation and convenient maintenance by fully utilizing electromechanical integration technology.

CN 103099573 provides a strip weaving type multi-material towel and a manufacture method thereof. The manufacture method includes the steps: strip-shaped towel fabrics made of at least two materials are woven into a towel through mixed weaving of warps and yarns. The peripheries of overlapped positions of the strip-shaped towel fabrics are sewn to form finished towel products. The strip weaving type multi -material towel breaks through a manufacture method and embodying pattern of a traditional towel, and is simple in manufacture type. Compared with the traditional towel, the strip weaving type multi-material towel is novel and plentiful in appearance form, greatly strengthens three dimension feeling and layering feeling, moreover, due to variety of the materials, functions of the strip weaving type multi-material towel are strengthened to a certain extent (integrated with performance advantages of various material fabrics), can meet aesthetic demands of people, and simultaneously brings economic benefit to related industries.

CN 1934295 gives a filament yarn that has low wicking, i.e., less than or equal to about 6 mm; has a contact angle of greater than or equal to about 65 DEG but less than about 90 DEG according to the straw method; and a static voltage of +/- 400 volts (between -400 to +400 volts). Such yams are traditionally employed in weaving signs, banners, awning, tents and other products where moisture resistant yam is important. -The yams can be made into fabrics that possess the same features as the yarn, namely low wicking, and water and oil repellency.

CN 201456488 provides an advertisement banner cloth, which consists of a weaving layer, an adhesive layer and a coloring material layer. The adhesive layer is arranged between the weaving layer and the coloring material layer. The advertisement banner cloth provided by the utility model adopts a three-layer structure form of the weaving layer, the adhesive layer and the coloring material layer, and theweaving layer and the color material layer are adhered to each other by the adhesive layer, thus, matching with a common carving machine, a nicking tool can carve the color material layer without scratching the weaving layer by utilizing computer typesetting to control the carving machine, the nicking tool can carve characters or patterns on the advertisement banner cloth, and the printing work of the banner is completed by tearing off the color material layer except for the characters and the patterns, so that under the condition of not using a dedicated banner printing apparatus, the working efficiency is greatly improved and the printing cost is reduced.

Although a number of weaving methods are available in the prior art, flags and banners which have to remain in all kinds of weather for longer time durations tend to get torn and faded due to unfavorable weather conditions like heavy rains, storms etc. Most of these flags, like the American flag, are stitched together and coloured. Due to strong winds blowing, the seams at the stitches in the flag open up due to which they appear torn. Their colour too fades as they are exposed to high temperatures. So a method for making banners and flags which provides three dimensional effect to the product, with the help of weaving, such that it doesn't get torn or damaged easily, and can tolerate harsh weather conditions, is the need of the day.

OBJECT OF THE INVENTION:

The main object of the invention is to provide for a method of making banners and flags like American flag having three dimensional effect by weaving which involves the use of dyed yarn to provide the different colours required in the product so that the colours don't fade away when exposed to high temperatures.

Another object of the invention is to provide for a method of making banners and flags like American flag having three dimensional effect by weaving which produces the entire product selectively by jacquard weaving without the involvement of stitches so that the product doesn't get torn from the seams due to the excessive winds.

Still another object of the invention is to provide for a method of making banners and flags like American flag having three dimensional effect by weaving which provides three dimensional effect to the final product by using processes of weaving and finishing which isn't possible in printed products.

Yet another object of the invention is to provide for a method of making banners and flags like American flag having three dimensional effect by weaving which doesn't involve the commonly used methods of stitching, patching or printing but use special techniques of weaving and finishing to manufacture the final product thereby making long-lasting banners and flags. SUMMARY OF THE INVENTION:

The present invention is a method of making banners and flags like American flag having three dimensional effect by weaving which doesn't involve traditionally used methods like stitching, patching or printing. The yarn used in the product is dyed yarn which has been heated upto 300°C so that the colors of the manufactured product don't fade away due to excessive temperatures. The warp used is white in color in the complete weaving process while the weft involves the use of different colors in accordance to the requirement in the flag or banner to be made. The weaving is done by jacquard weaving such that it provides a three dimensional effect to the product as well as gives it a long life such that the banners and flags made using this method do not get torn easily when exposed to harsh weather conditions.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 gives the diagram of the plain weave used in the fabric.

Fig. 2 gives the diagram of the base weave used in different colors.

Fig. 3 gives the diagram of the weaving of the star in an American flag.

Fig. 4 gives the cross section view of weaving in an American flag.

Fig. 5 gives the picture of the ground fabric weft.

Fig. 6 gives the picture of the white colored weft.

Fig. 7 gives the picture of the red colored weft.

Fig. 8 gives the picture of the blue colored weft.

Fig. 9 gives the picture of the American flag with all the weaves involved in its making.

DETAILED DESCRIPTION: The nature of the invention and the manner in which it is performed is clearly described in the specification. The invention has various components and they are clearly described in the following pages of the complete specification.

Throughout the world, flags and banners are fluttered and displayed at various places. Banners are displayed either for advertisements or for promotional campaigns while flags are fluttered at various important places, historical places, national monuments etc. These flags and banners have to remain in open for long times during which they have to face high temperatures, harsh weather conditions, heavy rains, storms, winds etc. due to which their colour starts fading and they slowly get torn from their seams as the stitches open up due to strong winds. A torn or faded banner becomes useless while a torn or faded flag is a shame for the country. A flag should be a single piece cloth as it represents the integrity of the country and is the pride for the nation. So patched up pieces of cloth shouldn't be used to represent a national flag. A flag represents a living country and so it should be considered a living thing and treated in such manner. According to mles, the national flag should not be displayed on days when the weather is inclement. On such days, an all weather flag should be displayed which is strong and can bear harsh weather.

The present invention is a method of making banners and flags like American flag having three dimensional effect by weaving. These banners and flags are made by special jacquard weaving and finishing techniques such that it provides a three dimensional effect to the product. The yarn used to weave the cloth is dyed yarn which has been heated at 300°C during the manufacturing of the dyed yarn and so doesn't fade even in excessive heat. As the different colors required in the banner or flag are provided from the dyed yarn, no stitching or patching up of the product is required, making it a seamless fabric. As it is a seamless fabric, it doesn't get torn from the stitches or joints. Thus the product produced using the method of the present invention is highly tolerant to harsh weather conditions like, rains, winds, thunderstorms etc. and its colours don't fade even in excessive heat. The flag produced using this method is an all weather flag which can be displayed in accordance with Government rules on all days, even when the weather is inclement.

In the present invention, mono polyester yarn is used in the warp while dyed yarn of the required colours, are used in the weft. Wherever a three dimensional effect is needed in the flag or banner, extra weft is used in the front and back side as per the requirement. The additional yarn is shredded by passing the fabric through a shredding machine to give a clear effect of the three dimensional object on the fabric produced. This fabric is also passed through calendar machine or finishing machine for textiles to provide the desired finishing. Thus single piece, multi-coloured flags and banners, having three dimensional effect can be produced by the method of the present invention.

The present invention can be explained in detail using the following example:

EXAMPLE: The making an American flag of 60" height and 36" width, using the method of the present invention, involves 4600 hooks, 92 reeds and 164 picks. However, the denier of the yarn is changeable as per requirement of weight, fabric structure and design. The warp partem is single while the weft pattern is variable. The warp pattern uses 20 mono polyester yam of white color throughout the weaving of the flag. The weft involves the use of three different colored yams, white, red and blue as the American flag is made of these three colors. These colors can be changed according to the requirement of design and jacquard weaving. Plain weave, as shown in Fig. 1, has been used to make the proper base of the fabric. The base weave sateen (8 end sateen), for all colors has been shown in Fig. 2. There are 4 different weft patterns: (1) The ground fabric weft, as shown in Fig. 5, involves plain weave for ground color weft and uses 20 mono polyester yarn of white color with 48 picks.

(2) The white color weft, as shown in Fig. 6, involves 8 sateen weave for white color weft and uses 150 BRT polyester yarn of white color with 48 picks. The white color weft for star involves only binding weave.

(3) The red color weft, as shown in Fig. 7, involves 8 sateen weave for white color weft and uses 150 BRT polyester yarn of red color with 48 picks.

(4) The blue color weft, as shown in Fig. 8, involves 8 sateen weave for white color weft and uses 150 BRT polyester yarn of blue color with 20 picks.

Fig. 3 shows the weaving of the star in the American flag which is white in color with navy blue background. Only centre binding is given to the white weft used in the star, thereby increasing its robustness. Fig. 4 gives the cross section view of weaving in the American flag to give the complete understanding of the weaving pattern.

The fabric used is same on both the sides. So the same weaves which are used on front side, are used at the back side but in reverse pattern. Fig. 9 gives the picture of the American flag with all the weaves involved in its making.

Although the preferred embodiment as well as the construction and use have been specifically described, it should be understood that variations in the preferred embodiment could be achieved by a person skilled in the art without departing from the spirit of the invention. The invention has been described with reference to specific embodiment which is merely illustrative and not intended to limit the scope of the invention as defined in the claims.

Claims

Method of making banners and flags like American flag having three dimensional effect by weaving comprises jacquard weaving using dyed yarn, heated at 300°C, to produce the seamless fabric which doesn't fade and tear due to harsh weather conditions.

The method of making banners and flags like American flag having three dimensional effect by weaving as claimed in claim 1 wherein mono polyester yarn is used in the warp while dyed yarn of required colors are used in the weft.

The method of making banners and flags like American flag having three dimensional effect by weaving as claimed in claim 1 wherein extra weft is used in the front and the back side in accordance with the requirement to produce the three dimensional effect. The method of making banners and flags like American flag having three dimensional effect by weaving as claimed in claim 3 wherein after producing the three dimensional effect, the additional yarn is shredded by passing the fabric through a shredding machine to give a clear effect of the three dimensional object on the fabric produced.

The method of making banners and flags like American flag having three dimensional effect by weaving as claimed in claim 4 wherein the fabric is finally passed through one among calendar machine or finishing machine for textiles to provide the desired finishing to the single piece, multi colored fabric having three dimensional effect.

The method of making banners and flags like American flag having three dimensional effect by weaving as claimed in claim 1 wherein the denier of the yarn is changeable in accordance with the weight, fabric structure and design.

7. The method of making banners and flags like American flag having three dimensional effect by weaving as claimed in claim 1 wherein making an American flag of 60" height and 36" width, involves 4600 hooks, 92 reeds and 164 picks.

8. The method of making banners and flags like American flag having three dimensional effect by weaving as claimed in claim 7 wherein to make the American flag, the warp pattern is single and uses 20 mono polyester yarn of white color throughout the weaving of the flag while the weft pattern involves three different colored yarns, white, red and blue which are the three colors of the American flag.

9. The method of making banners and flags like American flag having three dimensional effect by weaving as claimed in claim 8 wherein to make the American flag, the ground fabric weft involves plain weave for ground color weft and uses 20 mono polyester yarn of white color with 48 picks while the white color, red color and blue colored wefts involve 8 sateen weave for white color weft and uses 150 BRT polyester yam of white color with 48 picks, 48 picks and 20 picks respectively.

10. The method of making banners and flags like American flag having three dimensional effect by weaving as claimed in claim 9 wherein to make the American flag, the same fabric is used on both the sides with same weaves on the back side as are on the front, but in reverse pattern.

1 1. The method of making banners and flags like American flag having three dimensional effect by weaving substantially herein described with reference to the foregoing description and drawings.