US20040097152A1 - Composite fabrics with internal connecting elements - Google Patents
Composite fabrics with internal connecting elements Download PDFInfo
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- US20040097152A1 US20040097152A1 US10/298,475 US29847502A US2004097152A1 US 20040097152 A1 US20040097152 A1 US 20040097152A1 US 29847502 A US29847502 A US 29847502A US 2004097152 A1 US2004097152 A1 US 2004097152A1
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- layer
- yarns
- connections
- fabric
- blister
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
- D03D13/004—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft with weave pattern being non-standard or providing special effects
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D1/00—Woven fabrics designed to make specified articles
- D03D1/0035—Protective fabrics
- D03D1/0041—Cut or abrasion resistant
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D11/00—Double or multi-ply fabrics not otherwise provided for
- D03D11/02—Fabrics formed with pockets, tubes, loops, folds, tucks or flaps
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/242—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads inorganic, e.g. basalt
- D03D15/247—Mineral
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B1/02—Pile fabrics or articles having similar surface features
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/02—Pile fabrics or articles having similar surface features
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
- D10B2201/01—Natural vegetable fibres
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2211/00—Protein-based fibres, e.g. animal fibres
- D10B2211/01—Natural animal fibres, e.g. keratin fibres
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/40—Knit fabric [i.e., knit strand or strip material]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/40—Knit fabric [i.e., knit strand or strip material]
- Y10T442/488—Including an additional knit fabric layer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/40—Knit fabric [i.e., knit strand or strip material]
- Y10T442/494—Including a nonwoven fabric layer other than paper
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Knitting Of Fabric (AREA)
Abstract
A composite fabric formed of a double cloth of jersey knit material which is needled to produce internal connections of filaments and/or fibers from yarns extending into, and/or between, the yarns of an adjacent layer.
Description
- The present invention relates to fabrics having internal connecting elements to help stabilize the fabric construction.
- Many methods have been used to stabilize the construction of a knit or woven fabric. Coatings have been applied to prevent the yarns from moving. However, coatings alone may not give 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 can sometimes affect the aesthetic characteristics of the fabric due to the large number of free fibers needed to create entanglements by the fluid jets. Therefore, there is a need for fabrics that have been stabilized by other methods, and the particular methods for stabilizing the fabrics.
- FIG. 1 is a top view of a blister fabric illustrating one embodiment of the present invention;
- FIG. 2 is an enlarged cross sectional view of the blister fabric from FIG. 1, taken about the section lines2-2.
- FIG. 3 is an enlarged cross sectional view of another embodiment of the present invention, using a composite of two separate layers of fabric.
- FIG. 4 is an enlarged partial view of a needle used in the present invention.
- FIGS. 5A and 5B are diagrams illustrating stitches used in one example of the present invention.
- Referring now to the figures, and in particular FIGS.1-2, there is shown a
blister fabric 10 illustrating one embodiment of the present invention. Theblister fabric 10 has alternating zones ofblister zones 100 andbase zones 200. Theblister zones 100 have alower blister layer 110 of a first material independent of anupper blister layer 120 of a second material. Thebase zones 200 are a unified layer of material. - As illustrated, the
blister fabric 10 is formed ofbase yarns 11 andblister yarns 12. In one embodiment, theblister fabric 10 is formed from yarns having a size of up to about 600 denier. In another embodiment, theblister fabric 10 is formed from yarns having a size of at least about 15 denier. In one preferred embodiment, the fibers forming thebase yarns 11 and theblister yarns 12 can both comprise filament yarns. As used herein, filament yarns includes multifilament yarns. In another embodiment, thebase yarns 11 and theblister yarns 12 can both comprise spun yarns. In yet another embodiment, thebase yarns 11 can comprise filament yarns and theblister yarns 12 can comprise spun yarns. In yet another embodiment, thebase yarns 11 can comprise spun yarns and theblister 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 thebase yarns 11 and/or theblister 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 FIGS.1-2, as illustrated, the
lower blister layer 110 of theblister fabric 10 is a jersey knit of thebase yarns 11, and theupper blister layer 120 of theblister fabric 10 is a jersey knit of theblister yarns 12. Also as illustrated, thebase yarns 11 form a unified double layer jersey knit in thebase zones 200, and theblister yarns 12 are sandwiched between the unified double layer jersey knit of thebase yarns 11 in thebase zones 200. Although theblister 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 unifiedbase 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 FIG. 2, there is shown an enlarged cross sectional area of the
blister fabric 10. As illustrated, blister zone connections 130 are formed between thelower blister layer 110 and theupper blister layer 120 by portions of the fibers from the yarns in one layer of theblister zone 100 passing from those yarns into, and/or between, the yarns of the other layer of theblister zone 110. Lowerblister layer connections 131 are formed between thelower blister layer 110 and theupper blister layer 120 by portions of the fibers from the yarns in thelower blister layer 110 passing from those yarns into, and/or between, the yarns of theupper blister layer 120. Upperblister layer connections 132 are formed between theupper blister layer 120 and thelower blister layer 110 by portions of fibers from the yarns in theupper blister layer 120 passing from those yarns into, and/or between, the yarns or of thelower blister layer 100. The lowerblister layer connections 131 and the upperblister layer connections 132 provide a securing tie between thelower blister layer 110 and theupper blister layer 120. - Still referring to FIG. 2, a fiber forming one of the lower
blister layer connections 131 originates from a yarn in thelower blister layer 110 and then projects into theupper blister layer 120. The fibers from thelower blister layer 110 forming the lowerblister layer connections 131 are secured by the fibers or filaments in the main body of the yarns in theupper blister layer 120. A portion of the fibers forming the lowerblister layer connections 131 are secured between fibers within the main body of the yarns in theupper 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 lowerblister layer connections 131 are secured between yarns of theupper blister layer 120 by the fibers in the main body of those yarns. A fiber forming one of the upperblister layer connections 132 originates from a yarn in theupper blister layer 120 and then projects into thelower blister layer 110. The fibers from theupper blister layer 120 forming theupper layer connections 132 are secured by the fibers or filaments in the main body of the yarns in thelower blister layer 110. A portion of the fibers forming the upperblister layer connections 132 are secured between fibers within the main body of the yarns in thelower 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 upperblister layer connections 132 are secured between yarns of thelower 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 upperblister 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 upperblister layer connections 131 and/or the lowerblister 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 upperblister layer connection 131 or a lowerblister 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 (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 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 preferred 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 more preferably about 750 total connections per square inch.
- Because the source of the connections comes from within yarns, and the connections also secure yarns, 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 yarn distance. In one embodiment, 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 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 yarns for the portion of the fabric incorporating the present invention. In one embodiment, the yarns 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 one preferred 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 more preferably about 0.04 total connections per filament-inch.
- Referring again to FIG. 2, the
base zone 200 is a unitary construction with a lowerbase layer portion 210, an upperbase layer portion 220, and trappedyarns 230 passing between the upperbase layer portion 210 and the upperbase layer portion 220. In the embodiment illustrated, the lowerbase layer portion 210 and the upperbase layer portion 220 are formed by thebase yarns 11, and theblister yarns 12 form the trappedyarns 230 between the two layers. As illustrated,base layer connections 240 are formed between the lowerbase layer portion 210 and the upperbase layer portion 220. Also, trappedyarn connections 250 are formed between thelower base layer 210 and the trappedyarn 230 and the upperbase layer portion 220 and the trappedyarn portion 230. - Referring still to FIG. 2, similar to the
blister zone connections 230, thebase layer connections 240 are formed between thelower base layer 210 and theupper base layer 220 by portions of the fibers from the yarns in one layer of thebase zone 200 passing from those yarns into the other layer of thebase zone 200. Lowerbase layer connections 241 are formed by fibers that originate from a yarn in thelower base layer 210 and then project into. and/or between, the yarns of theupper base layer 220. The fibers from thelower base layer 210 forming the lowerbase layer connections 241 are secured by the fibers or filaments in the main body of the yarns in theupper base layer 220. A portion of the fibers forming the lowerbase layer connections 241 are secured between fibers within the main body of the yarns in theupper 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 lowerbase layer connections 241 are secured between yarns of theupper base layer 220 by the fibers in the main body of those yarns. Upperbase layer connections 242 are formed by fibers that originate from a yarn in theupper base layer 220 and then project into thelower base layer 210. The fibers from theupper base layer 220 forming the upperbase layer connections 242 are secured by the fibers or filaments in the main body of the yarns in thelower base layer 210. A portion of the fibers forming the upperbase layer connections 242 are secured between fibers within the main body of the yarns in thelower 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 upperbase layer connections 242 are secured between yarns of thelower base layer 210 by the fibers in the main body of those yarns. The lowerbase layer connections 241 and the upperbase layer connections 242 provide a securing tie between thelower base layer 210 and theupper base layer 220. - As with the lower
blister layer connections 131 and the upperblister layer connections 132, many of the lowerbase layer connections 241 and the upperbase layer connections 242 are loops of the fibers in the respective source yarns that insert into the corresponding receiving layer. In some instances, the lowerbase layer connections 241 and/or the upperblister 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 lowerbase layer connection 241 or an upperbase 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. Thebase layer connections 240 provide a securing tie between thelower base layer 210 and theupper 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 FIG. 2, the trapped
yarn connections 250 are formed between the trappedyarns 230 and thelower base layer 210 and theupper base layer 220, by portions of the fibers from the trappedyarn 230 passing into, and/or between, the main body of the yarns in thelower base layer 210 or theupper base layer 220, and/or fibers from yarns in thelower base layer 210 or theupper base layer 200 passing into the trappedyarn 230. Lower base trappedyarn connections 251 are formed between the trappedyarns 230 and thelower base layer 210 by portions of the fibers from the yarns in thelower base layer 210 passing from those yarns into the main body of the trappedyarns 230, and by fibers from the trapped yarns passing from the trappedyarns 230 into, and/or between the main body of the yarns of thelower base layer 210. Upper base trappedyarn connections 252 are formed between the trappedyarns 230 and theupper base layer 220 by portions of the fibers from the yarns in theupper base layer 220 passing from those yarns into the main body of the trappedyarns 230, and by fibers from the trappedyarns 230 passing from the trappedyarns 230 into, and/or between, the main body of the yarns of theupper base layer 220. - As with the lower
base layer connections 241 and the upperbase layer connections 242, many of the lower base trappedyarn connections 251 and the upper base trappedyarn 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 trappedyarn connections 251 and/or the upper base trappedyarn 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 trappedyarn connection 251 or an upper base trappedyarn 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 trappedyarn 230 and thelower base layer 210, and the trappedyarn 230 and theupper 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 thelower blister layer 110 and thelower base layer 210. It has been found that a backcoating further improves the abrasion resistance of the opposite side of the needledblister fabric 10. The back coating can be any polymeric material, such as latex, polyvinylacetate, or the like. The back coating can be applied at a level of from about 0.25 oz/yd2 to about 5 oz/yd2. - Referring now to FIG. 3, there is shown an enlarged cross section of a
fabric composite 20 illustrating another embodiment of the present invention. Thefabric composite 20 is a multiple layered cloth, such as a double cloth, a triple cloth, etc. The fabric comprises at least afirst layer 21 and asecond layer 22. At least one of thefirst layer 21 and the second layer is a knitted fabric. In the embodiment illustrated in FIG. 3, thefirst layer 21 is formed from first layer yarns 23, and thesecond layer 22 is formed fromsecond layer yarns 24. In one embodiment, the first layer yarns 23 and/or thesecond layer yarns 24 have a yarn size of up to about 600 denier. In another embodiment, the first layer yarns 23 and/or thesecond layer yarns 24 have a yarn size of at least about 15 denier. In one preferred embodiment, both the first layer yarns 23 and thesecond layer yarns 24 comprise filaments. In another embodiment, the first layer yarns 23 are filament yarns and thesecond layer yarns 24 are spun yarns. In yet another embodiment, both the first layer yarns 23 and thesecond layer yarns 24 are spun yarns. Additionally, it is contemplated that first layer yarns 23 and/or thesecond layer yarns 24 can include yarns formed of the combination of filaments and staple fibers. -
Connections 25 are formed between thefirst layer 21 and thesecond layer 22 by filaments of the yarns in the two layers.First layer connections 26 are formed by portions of the fibers in thefirst layer 21 that project into thesecond layer 22. Thefirst layer connections 25 are secured by the fibers of the main body of thesecond layer yarns 24.Second layer connections 27 are formed by portions of the fibers in thesecond layer 22 that project into thefirst layer 21. Thesecond layer connections 27 are secured by fibers of the main body of the first layer yarns 23. It is contemplated that theconnections 25 of the present invention can be formed across the entirecomposite fabric 20, or in discrete zones. - Many of the
first layer connections 26 and thesecond 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, thefirst layer connections 26 and/or thesecond 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 afirst layer connection 26 or asecond 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 one 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 preferred embodiment, 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.
- 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 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 needling machine. The 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 FIG. 4, there is shown an enlarged partial view of one embodiment of one of the
needles 400 used in the present invention. Theneedle 400 has apointed end 410 andnotches 420 along the length of theneedle 400. Thepointed end 410 of theneedle 400 facilitates the passage of theneedle 400 through the yarns and the fabric layers. Thenotches 420 of theneedle 400 pick up or “hook” fibers of the yarns as theneedle 400 passes through the yarns and fabric layers. As theneedle 400 continues to pass through adjacent yarns and/or fabric layers, the fibers previously hooked by thenotches 420 of theneedle 400 are moved into the main body of the adjacent yarns and/or fabric layers. The movement of the fibers by theneedle 400 will stretch or pull the fibers from the originating yarns. For fibers with free ends near theneedle 400, the fiber will follow thenotch 420 of theneedle 400 until the free end of the fiber passes through thenotch 420 or theneedle 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 theneedle 400 reaches the end of its travel, or the tension in the fiber causes the fiber to come free from thenotch 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. - The result is a positive movement of a portion of the fibers and/or filaments of the yarn directly into the main body of the adjacent yarns and/or fabric layers where those fibers and/or filaments create an anchor directly within the main body of the adjacent yarns and/or fabric layers. The fiber and/or filament left in the adjacent yarn forms the connection between the fabric layers or the yarns of a fabric layer. In contrast, methods such as hydroentanglement force fibers external to the main body of a yarn to entangle with fibers external to another yarn, providing a less direct connection between the two components. Additionally, hydroentanglement has a limited ability to provide stability to a filament yarn fabric because there are no or few free ends of the filaments that can be broken free from the main body of the yarn and/or fabric layer to entangle with the free ends of filaments from other yarns and/or layers.
- 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 blister yarns. The blister fabric is formed on a two bed circular knitting machine with the knitting pattern as shown in FIGS. 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 yarn 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 get 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.
Claims (3)
1. A composite fabric comprising:
a first fabric layer being a knitted fabric and having first yarn with first yarn fibers; and,
a second layer having blister yarn with second yarn fibers;
wherein the first layer and the second layer are independent layers; and,
further including:
first layer connections between the first layer and the second layer formed by a portion of the first yarn fibers from the first layer; and,
second layer connections between the second layer and the first layer by a portion of the second yarn fibers from the second layer.
2. A composite fabric comprising:
a first fabric layer being a knitted fabric having first yarn with first yarn fibers; and,
a second layer having blister yarn with second yarn fibers;
wherein the first layer and the second layer are independent layers; and,
further including first layer connections between the first layer and the second layer formed by a portion of the first yarn fibers from the first layer.
3. A composite fabric comprising:
a first fabric layer being a knitted fabric and having first yarn with first yarn fibers; and,
a second layer having blister yarn with second yarn fibers;
wherein the first layer and the second layer are independent layers; and,
further including second layer connections between the second layer and the first layer by a portion of the second yarn fibers from the second layer.
Priority Applications (29)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/298,475 US20040097152A1 (en) | 2002-11-15 | 2002-11-15 | Composite fabrics with internal connecting elements |
CA002505369A CA2505369A1 (en) | 2002-11-15 | 2003-09-16 | Blister fabrics with internal connecting elements |
MXPA05005074A MXPA05005074A (en) | 2002-11-15 | 2003-09-16 | Blister fabrics with internal connecting elements. |
PCT/US2003/028955 WO2004046435A2 (en) | 2002-11-15 | 2003-09-16 | Blister fabrics with internal connecting elements |
CN038251507A CN1694983B (en) | 2002-11-15 | 2003-09-16 | Blister fabrics with internal connecting elements |
BR0315626-5A BR0315626A (en) | 2002-11-15 | 2003-09-16 | Bubble fabrics with internal connecting elements |
KR1020057008498A KR101012909B1 (en) | 2002-11-15 | 2003-09-16 | Blister fabrics with internal connecting elements |
AU2003267214A AU2003267214A1 (en) | 2002-11-15 | 2003-09-16 | Blister fabrics with internal connecting elements |
JP2004553425A JP2006506550A (en) | 2002-11-15 | 2003-09-16 | Blister cloth with internal connection elements |
CA002505391A CA2505391A1 (en) | 2002-11-15 | 2003-10-24 | Fabric with floating yarn having internal connecting elements |
AU2003287211A AU2003287211A1 (en) | 2002-11-15 | 2003-10-24 | Fabric with floating yarn having internal connecting elements |
MXPA05005075A MXPA05005075A (en) | 2002-11-15 | 2003-10-24 | Fabric with floating yarn having internal connecting elements. |
PCT/US2003/033844 WO2004046446A2 (en) | 2002-11-15 | 2003-10-24 | Fabric with floating yarn having internal connecting elements |
PCT/US2003/033846 WO2004046437A1 (en) | 2002-11-15 | 2003-10-24 | Blister fabrics with internal connecting elements |
CA002505388A CA2505388A1 (en) | 2002-11-15 | 2003-10-24 | Blister fabrics with internal connecting elements |
BR0316356-3A BR0316356A (en) | 2002-11-15 | 2003-10-24 | Floating woven fabric that has internal connecting elements |
BR0316354-7A BR0316354A (en) | 2002-11-15 | 2003-10-24 | Knitted fabric with internal connecting elements |
KR1020057008489A KR100752857B1 (en) | 2002-11-15 | 2003-10-24 | Blister fabrics with internal connecting elements |
JP2004570364A JP4919600B2 (en) | 2002-11-15 | 2003-10-24 | Blister cloth with internal connection elements |
JP2004570363A JP4599589B2 (en) | 2002-11-15 | 2003-10-24 | Cloth with floats with internal connection elements |
EP03781391A EP1581680A4 (en) | 2002-11-15 | 2003-10-24 | Fabric with floating yarn having internal connecting elements |
EP03779253A EP1583856B1 (en) | 2002-11-15 | 2003-10-24 | Blister fabrics with internal connecting elements |
CN2003801033712A CN1711379B (en) | 2002-11-15 | 2003-10-24 | Blister fabrics with internal connecting elements |
MXPA05005077A MXPA05005077A (en) | 2002-11-15 | 2003-10-24 | Blister fabrics with internal connecting elements. |
KR1020057008475A KR20050086561A (en) | 2002-11-15 | 2003-10-24 | Fabric with floating yarn having internal connecting elements |
DE60335297T DE60335297D1 (en) | 2002-11-15 | 2003-10-24 | CLOQUE WITH INTERNAL CONNECTING ELEMENTS |
AU2003284934A AU2003284934A1 (en) | 2002-11-15 | 2003-10-24 | Blister fabrics with internal connecting elements |
CNB2003801032014A CN1296198C (en) | 2002-11-15 | 2003-10-24 | Blister fabrics with internal connecting elements |
HK06106173A HK1086229A1 (en) | 2002-11-15 | 2006-05-27 | Fabric with floating yarn having internal connecting elements |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/298,475 US20040097152A1 (en) | 2002-11-15 | 2002-11-15 | Composite fabrics with internal connecting elements |
Publications (1)
Publication Number | Publication Date |
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US20040097152A1 true US20040097152A1 (en) | 2004-05-20 |
Family
ID=32297465
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/298,475 Abandoned US20040097152A1 (en) | 2002-11-15 | 2002-11-15 | Composite fabrics with internal connecting elements |
Country Status (1)
Country | Link |
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US (1) | US20040097152A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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US20210062374A1 (en) * | 2019-09-04 | 2021-03-04 | Korea Institute Of Civil Engineering And Building Technology | Apparatus for manufacturing textile grid with increased adhesion and method thereof |
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