Note: Descriptions are shown in the official language in which they were submitted.
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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;
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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 fibersof
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
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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 ail 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 blisfier 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
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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 fihe 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
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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
5 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 filaments)
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 the examples provided below, the fabric was needle punched from both
sides, but other embodimenfis 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
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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
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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
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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
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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
aboufi 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 firsfi 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.
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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
5 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
furfiher
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
10 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 embodimenfi, 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 fiotal connections per
filament-inch,
and more preferably about 0.04 total connections per filament-inch.
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Knitted Fabrics
In one embodiment of the invention, which is a knitted fabric, 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 yet another embodiment, the yarns that
form
the upper blister layer or the tower 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 (east one of the layers in a
multilayer
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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 fio 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 complefiely 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 fihe 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
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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 botches 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
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14
"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 709 .
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
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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
5 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
10 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
15 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
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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 acfiual 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) (magnification of
SEMI
unit area (linear distance in which the counts are made)2
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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 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 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 3Ø For fabric that was
needled,
the face of the fabric obtained a rating of 3.5.
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Example 2
Woven Fabric
This further example can be understood with reference to the following
description. (n 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 fihe 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
(D(lo
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.
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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
infierconnected
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 yarn 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 parfiicular 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 3Ø For fabric that was needled according the example
and the
process of this invention, the face of the fabric abtained a rating of about
6Ø The
higher score is believed to be due at least in part to the formation of fiber
ends within
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adjacent layers which serve to stabilize and strengthen the overall fabric
againsfi
abrasive forces.
