CA1150071A

CA1150071A - Filling effect designs on a stitch-through fabric

Info

Publication number: CA1150071A
Application number: CA000359946A
Authority: CA
Inventors: Stanley S. Rosner
Original assignee: Polylok Corp
Current assignee: Polylok Corp
Priority date: 1979-10-02
Filing date: 1980-09-09
Publication date: 1983-07-19
Also published as: BR8006261A; IL61050A; BE885485A; DE3037308A1; GB2059467B; IE50356B1; ES495532A0; IT8068515A0; ES496991A0; FR2472624B1; GB2059467A; IE802044L; ES8200933A1; NL8005414A; JPS56101955A; IT1130519B; ES8106774A1; FR2472624A1; ES496992A0; ES8201653A1

Abstract

ABSTRACT Filling Effect Designs On A Stitch-Through Fabric A novel concept in stitch-bonded fabrics made on a stitch-through type machine such as a Malimo machine is disclosed which involves in one embodiment, the creation of a block pattern design using a textile pattern design element (e.g., a single yarn end) disposed along non-rectilinear pathways, with segments of the design element extending essentially perpendicular to the longitudinal direction of the fabric. A single system of longitudinal knitting thread wales, each wale comprising a multiplicity of looped stitch courses which engage the design element with loops of knitting thread on the rear surface of the fabric and laps of the knitting thread courses on the front surface, binds and secures the design element into an integrated unitary textile structure. In one embodi-ment, a block pattern design is formed from a single tex-tile element having segments of substantial length dis-posed in parallel configuration perpendicular to the longitudinal direction of the fabric. The creation of the present fabric is made possible by the method and apparatus of the invention, which, in one embodiment, comprises a novel yarn feeding mechanism for guiding a textile pattern design element through a tube, the exit end of which delivers the element at a point in proximity to the fabric-forming work zone of the stitch-through machine, whereupon a circular rotating brush flanking the tube engages the element and places or pushes it into the work zone and holds it down therein whereupon the segment of the design element thus placed is stitched into the fabric construction while disposed essentially parallel to the elongated work zone during a stitching cycle of the stitch-through machine. In this way the stitched-in segment becomes a horizontal decorative yarn portion integral with the fabric. The tube and circular brush cooperate as a unitary design element feed mechanism adapted to reciprocate along the work zone by a pre-programmed computer-controlled stepping motor which propels the design element feed mechanism by means, e.g,, of a flexible drive belt. The aggregate effect of this operation is a pre-determined design pattern on the fabric derived from a single textile element.

Description

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FILLING EFFECT DESIGNS
ON A STITCH--THROUGH FABRIC

DESCRIPTIO~I

Technical Field This invention relates to fabrics which are produced on stitch-through type machines such as a Malimo machine. More particularly, it relates to a novel im-proved Malimo-type fabric and to an apparatus and method used in making it wherein the improvement resides in the capability of forming heretofore unattainable pattern designs from a single textile element.

Background Art Malimo fabrics typically comprise a layer o substantially parallel warp yarn elements or ends on a ~lexible substrate such as a layer o~ substantially parallel selvage-to-selvage textile filling yarn elements, the two components being ~oined together into an inte-grated structur'e by means of relatively fine knitting threads. Where desired a more or less open mesh abric can be obtained by controlling the spacing between the individual yarn elements. This and other "stitch-through"
type non-woven ~abric construction can be obtained on machines of the "Malimo" type, using methods and equip-ment described in U.S. Pat. Nos. 3,890,57g; 3,030,786;
30 3,253,426; 3,274,806; 3~279J221; 3,309,900; 3,389,583;
3,392,078; 3,440,840; 3,452,561; 3,457,73~; 3,460,599;
3,540,238; 3,541,812; 3,567,565; 3,592,025; 3,672,187;
3,677,034; 4,144,727; and U.S. Re. Pat. No. 25,749.

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The ability to readily mass produce a basic fabric in a variety of patterns is extremely important to the commercial success of the fabric. While non-woven fabrics can be produced on "Malimo"-type machines at relatively high speeds compared to the production of woven fabrics using looms, much attention has been given to augmenting this desirable feature with design flexibility, not only with respect to the density, gage, and color combinations of the textile components, the spacing between them, and the purposeful omission of one or more of such components, but also with respect to the spatial configuration of the textile components in the fabric.
In particular, there is a need for Malimo fabrics of still grea-ter design flexibility, particularly with respect to the creation of unusual visual or decorative effects. The present invention makes possible for the first time an enhanced variety of designs in which a single textile element or end can be used to form pat-terns, including filling effect designs, heretofore unattainable on stitch-through machines. For example, the present invention permits the creation of figure patterns of any desired shape, including but not limited to block patterns, from a single yarn end, whereas here-tofore, there has been no means or method by which such an effect could be achieved on Malimo machines at commercial production speeds.

Accordingly, it is an object of the present invention to provide fabrics such as are produced on stitch-through type machines having enhanced design flexibility stemming from a single textile pattern design element, or from a plurality of such elements.

A further object is to provide an apparatus for producing fabrics on stitch-through type machines ~s~o~-having enhanced design capabilities stemming from a single textile pattern design element, or from a plurality of such elements.

~et another object is to provide a method for producing fabrics on stitch-through type machines having enhanced design capabilities stemming from the use of a single textile pattern design element, or from a plurality of such elements.

These and other objects of the invention as well as a fuller understanding of the advantages thereof can be had by reference to the following detailed de-scription, drawings and claims.

Disclosure of Invention The foregoing objects are achieved according to the present invention by a novel stitch-bonded type fabric and an apparatus and method for making same on a stitch-through type machine such as a Malimo machine wherein the fabric comprises one more more textile pattern design elements disposed along non-rectilinear pathways, said one or more elements having segments extending essentially perpendicular to the longitudinal direction of the ~abric. A single system of longitudinal knitting thread wales, each wale comprising a multiplicity of looped stitch courses, engages the design element(s) with loops of knitting thread on the rear surface of the fabric and laps of the knitting thread courses on the front surface to bind and secure said design elements into an integrated unitary textile structure. The system of knitting thread wales can comprise a half-tricot stitch configuration by alternating two threads in a loop series, and/or a chain stitch configuration.

7~g In the stitch-bonded fabric of the present invention employing knitting thread to bind the aforesaid design element(s) and other optional textile yarn components into an integrated structurer the knitting thread pierces and/or laps the individual elements at a substantial number of random points to further secure such elements against relative displacement.

It is a feature of the present fabric that a pattern design having any desired shape can be formed from a single textile element having segments extending essentially perpendicular to the longitudinal direction of the fabric. In general, such pattern design can have any configuration which, by analogy, coulcl be produced by a recording pen on a moving graph paper strip chart.
Exemplary of such pattern designs are "solid" block pat-terns (wherein the "blocks", ~Yhen produced sequentially~
can be disposed along an axis parallel to the lengthwise direction of the fabric or in a step-wise or side-step direction oblique to the lengthwise direction of the fabric) of any desired shape such as squares, rectanglesr trianglesr diamondsr circles, and the li~e; and linear or semi-soli~ patterns from which there could be formed numerals, lettersr alphanumeric symbols and/or words.
Also, by using a plurality of textile design elementsr it becomes possible according to the invention to produce arrays of pattern design sequences, such as a "checker-board" pattern, wherein each sequence is produced inde-pendently of the others and is derived from a single textile design element. It is even possible to control the density of the textile elemenc "lay-down" to achieve a degree of coverage corresponding to a "solid fabric"
having one or more solid stripes extending either part way or entirely across t}- width of the fabric r each stripe capable of being derived from a single textile design ~L~5~

element having segments perpendicular to the longitude of the fabric and extending across the width of the stripe.
In these respects the invention is a departure from the teachings of commonly assigned U.S. Pat. No. 3,672,187 wherein yarn design elements can be made to follow non-rectilinear pathways, but never in a direction per-pendicular to the lonqitude of the fabric. This inherent limitation in the prior '187 patent permits only the formation of "outline" patterns from two or more yarn ends and precludes the creation of the aforementioned pattern designs made possible for the first time in stitch-through type machines by the method and apparatus of the present invention.

As used herein, the term "segments" oE a textile pattern design element is understood to mean portion of such elements perpendicular to the longitude of the fabric and having a length corresponding, as a minimum, to the distance between two knitting thread wales. A segment extending across a plurality o~ wales so as to create the appearance of a horizontal portion of the element is referred to herein as a "portion oE substantial length".

A more detailed description of the fillin~
effect designs which can be produced on stitch-through fabrics accordin~ to the apparatus and method of the invention is provided in the following sections.

_rief Description of the Drawings Further details of the present in~ention and it preferred embodiments can be had by reference to the accompanying drawings, wherein corresponding ~lements are denoted by the same reference numeral:
3~

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FIGS. l and 2 are a photographic plan view and an enlaryed portion, respectively, oE the front surface of a fabric embodiment of the present invention;

FIG. 3 is a photographic plan view of the front surface of a selvage-to-selvage portion of another fabric em~odiment of the invention;

FIG. 4 is an enlarged photographic view of the front surface of a fabric of the type shown in FIG. 3;
FIG. 5 is a photogrpahic plan view of the front surface of a portion of another fabric accordiny to the invention;

FIG. 6 is a photo~raphic plan view of the front surface of a laryer portion of the fabric shown in FIG. 5;

FIG. 7 is a plan vie~Y of the front surface of a portion of another fabric according to the invention;
FIG. 8 i5 a photographic plan view of the front surface o~E a portion oE a Eabric embodiment like that shown in FIG. 7 but with the incorporation of an integral self-liner constitùtiny the rear surface of the fabric;

FIGS. ~, lO and ll are a photographic plan view, an enlarged front portion, and a rear plan view, respec-tively, of another fabric embodiment according to the30 invention;

FIGS. 12 and 13 are a photographic plan view and an enlarged Eront portion, respectively, of the front surEace of another fahric accordiny to the invention;

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FIG. 14 ~s a photographic plan view of the frontsurface of a portion of another fabric embodiment of the invention;

FIGS.15, 16 and 17 are a photographic front plan view, an enlarged front portion, and a rear plan view, respectively, of another fabric embodiment according to the invention; and FIG. 18 is a partially schematic view of an em-bodiment of the pattern design element delivery mechanism of the apparatus according to the present invention.

Best Mode For Carrying Out The Invention Referring to FIGS. 1 and 2, fabric 1 is composed of single pattern design yarn element 3 and warp yarn element 4 which are disposed on top of a filling layer in the form of a plurality of textile yarn elements 5 which in turn is disposedon longitudinal strip 7 of nonwoven spun fibrous batting self-liner ~e.g., Reemay or Sontara) constituting the rear surfaces of the fabric. Fabric components 3, 4, 5 and 7 are secured against relative displacement and are bound together to form the integrated unitary textile structure of fabric 1 by means of knitting thread network 9 having a half-tricot stitch configuration.
As can be seen in FIG. 1 and particularly in FIG. 2, substantial portions 11 of pattern design element 3 extend essentially perpendicular to the longitudinal direction of fabric 1, in this case for a distance corresponding to roughly 14 adjacent knitting thread wales.

Referring to FIG. 3, fabric 13 is composed of a plurality of pattern design elements disposed on layer 14 of filling yarn elements and each having consecutive ~-~ ..

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portions of substantial length extending essentially horizontally or perpendicular to the longitudinal direc-tion with proximate horizontal portions of adjacent elements being disposed in parallel configuration to one another. In this way there is created a simulated fill-ing yarn effect having the appearance of a decorative continuous selvage-to-selvage zig-zag pattern design 15, even though, as shown in FIG. 4, the fine structure of each pattern design element 17, 18 and 19 involves a step-wise pattern of horizontal portions (i.e., portions essentially perpendicular to the longitudinal direction) alternating with verticalportions. Fabric 13 additionally contains several optional conventional warp yarn elements 20 disposed near the edge for added strength along the selvage and also to create an attractive border effect.

Referring to FIG. 5, fabric 21 comprises textile element filling layer 2'~ upon which is disposed ; a single pattern design element 25 from which there is created a longitudinal sequence of alternating square and diamond-shaped solid block figures which is made possible by the abilit~ of the present m~3thod and apparatus to lay down a sin~le yarn end substantial predetermined portions of which are disposed essential:Ly perpendicular to the longitudinal direction of the fabric. FIG. 6 is a more distant view of the fabric 21 o~ FIG. 5 in which two adjacent longitudinal sequences of alternating square and diamond-shaped solid block figures are created from just two pattern design yarn elements 25a and 25b.

Referring to FIG. 7, fahric 27 is composed of three pattern design yarn elements 29, 31, and 33 which are disposed on top of a filling layer in the form of a plurality of textile yarn elements 35. Fabric components _, 31, 33 and 35 are secured against relative displace-_ _ ~' ment and bound together to form an integrated unitary textile structure of fabric 27 by means of a network of knitting threads 37 applied in a half-tricot stitch configuration. Of particular importance to understanding the concept of the present invention is the fact that pattern design yarn elements 29, 31 and 33 are simul-taneously delivered to the fabric forming work zone of the machine by a single yarn feeding mechanism according to the invention wherein each design element 29, 31, and 33 is fed by a separate tube, each tube being flanked on either side by a circular brush (four brushes in all).
In this way there is created a longitudinal sequence of solid block figures 39, 41 and 43, each figure being characterized by interdigitation of substantial horizontal parallel portions of the three elements 29, 31 and 33 to create an attractive overlapping effect as shown.

Referring to FIG. 8, fabric 45 is essentially the same as that depicted in FIG. 7 with the additional feature of longitudinal strip 4,7 of nonwoven spun fibrous batting constituting an integra:l portion of the rear surface of the fabric for the creation of an added relief effect.

eferring to FIG~. 9, 10 and 11, there is depicted a fabric 49 which is similar in general respects to the construction of the fabric of FIG. 8 except that there is created a less dense or more "open" filling effect in the block figure as a result of increased vertical spacing between the horizontal portions of interdigitated pattern design yarn elements 51, 53 and 55. With partic-ular reference to FIG. 10 there is clearly shown how astitching thread pierces a pattern design element, e.g., at 57, 59, and 61 and how at other points the pattern design elements are lapped by knitting thread courses to 7~ ~

achieve securement of these elements and the filling to form an integral unitary textile fabric construction.
FIG. 11 illustrates the appearance of fabric 49 when viewed from the rear and shows the visual barrier effect created by the longitudinal strip 63 of nonwoven spun fibrous batting.

Referring to FIGS. 12 and 13, fabric 65 is similar in general respects to the construction of the fabric of FIG. 8 except that there is created a somewhat different effect by virtue of the fact that the longi-tudinal sequence of block pattern designs formed by design elements 67, 69 and 71 only partially overlaps one side of integral strip of self-liner 73.

Referring to FIG. 14, fabric 75 is composed of three pattern design yarn elements 77, 79 and 81 each of which is fed through a separate tube of the yarn feeding mechanism of the present apparat.us to form a longitudinal sequence of overlapping laterall.y adjacent block pattern designs, each block of which is characterized by densely packed interdigitation of the horizontal portions of adjacent elements, and as such dramatically demonstrates the high degree of coverage (textile element density) which is possible according to the present invention.
Such coverage is enhanced still further in fabric 75 by the incorporation of integral self-liner 83 which con-stitutes the rear surface of the fabric.

With respect to FIGS. 15, 16 and 17, fabric 85 is composed of three pattern design yarn ends 87, 89 and 91 disposed on top of a filling layer consisting of a plurality of textile yarn elements 93 which in turn is symmetrically disposed on a longitudinal strip 95 of nonwoven spun fibrous batting integral self-liner, the latter constituting the rear surface of the fabric as can be seen in FIG. 17. Fabric components 87, 89, 91, 93 and 95 are secured against relative displacement and bound together to form the integrated unitary textile structure of fabric 85 by means of a network o~ knitting threads 97 in a half-tricot stitch configuration. Each of the three pattern design yarn ends 87, 89, and 91 is fed to the fabric-forming work zone of the stitch-through machine through a separate delivery tube of the yarn feeding mechanism of the apparatus of the invention, the latter being driven by the drive belt of a computer-governed stepping motor in such a way that a continuous longi-tudinally-extending block pattern design of constant width is obtained which is characterized by interdigitation of the substantial horizontal patterns of adjacent pattern design elements as can be more c]early seen in FIG. 16.

Referring to FIG. 18, ~:here is depicted a partially schematic repre~sentation oE an apparatus and its use according to the invention. Pattern design element feed mechanism 101 comprises a frame 102 upon which are disposed yarn conduit tube 105 and circular rotatable bristle brushes lO9a and lO9b flank;ng the exit end of the tube. In the general case, n conduit ,tubes for n design elements could be coupled alter-natingly with n + 1 circular brushes. The mechanism 101 is disposed on the stitch-through type machine e.g., a Malimo machine, such that brushes lO9a and 109b can extend into the elongated fabric-formation work zone 103, the bristles 111 of the brushes being sufficiently pliable to permit the stitching needles 104 in the work zone to pass through them during the textile design yarn element insertion operation thereby facilitating yarn lay-down hout disrupting the operation of the stitching elements or damaging either the brushes or the needles. The bristles 111 can be fabricated of any material meeting the aforementioned criteria, e.g., synthetic fibers such as nylon, polyester or polyolefin; animal fibers such as horsehair; and fine metal wire.

During the stitch-through fabric-forming process textile pattern design element 107 is fed throu~h tube 105 from which it exits at a point 106 in proximity to wor~
zone 103. ~eanwhile, mechanism 101 is caused to traverse back and forth in the direction indicated by arrows a and b through the action of a stepping motor 113 coupled to the mechanism by means of a drive belt (e.g., of a flexible material such as rubber for the sake of economy of space and ease of replacement) indicated by 114, said stepping motor being governed in its function by means of digital computer 115 which has been pre-programmed by means of an appropriate "chip" to cause the formation of a desired design pattern from textile element 107. In this connection,~the steppin~ motor 113 governs the travel of

2~ mechanism 101 digitally so that the velocity of the latter across the work zone of the machine is at least as great as, and prefera~ly greater than, the speed with which the stitching elements o~ the work zone complete a full stitching cycle. In this way, the speed of the feed mechanism stepping motor~computer ensemhle is conjoint with but generally independent of the speed of the stitch-through machine. If desired, one or more stepping motors can be in conjunction with multiple design elements.

As machanism 101 travels in the direction of arrow _, yarn element 107 exiting from the delivery tube 105 is taken under or "run over" by the bristles 111 of rotating brush l~a and are thereby laid into the work zone and held down therein until it is secured by knitting thread (not shown) into the fabric structure whereby a ~LS~1~7~

"segment" of the pattern design element becomes disposed in a direction essentially perpendicular to the longitude ol the resulting fabric. When mechanism 101 completes its traverse in the direction of arrow a, the stepping motor 113 pursuant to instruction from computer 115, and via drive belt 114 causes the mechanism to reverse direction at a pre-determined point in time and proceed back along the direction indicated by arrow b, whereupon the function of wheel lO9a is assumed by wheel 109b. In this way feeding mechanism 101 lays in single design elemen~ 107 horizontally to build up a block pattern design of pre-determined shape. A feature of this operation resides in the timing of the stepping motor so that the lay-down motion begins as soon as the tips of the stitching needles penetrate the plane of the filling. The effect of such timing is to force the pattern yarn to pull on the needles rather than against the thread, and provide a maximum amount of time in which to complete the lay-down motion.

The foregoing examples are presented for the purpose of illustrating the invention and its advantages without intending to limit the same in any way to specific features or embodiments. It is understood that change and variations can be made in the fabric, apparatus and method without departing from the scope of the invention which is defined in the following claims.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:-l. A fabric made in a stitch-through type machine, comprising:
(a) one or more textile pattern design elements dis-posed along non-rectilinear pathways, with a majority of segments of said design elements between adjacent turns thereof extending essentially perpendicular to the longi-tudinal direction of the fabric and in sufficiently close proximity to one another to give a viewer the impression that said design elements comprise areas whose boundaries are substantially filled with design element material; and (b) a single system of longitudinal knitting thread wales, each wale comprising a multiplicity of looped stitch courses which engage the design elements with loops of knitting thread on the rear surface of the fabric and laps of the knitting thread courses on the front surface to bind and secure said design elements into an integrated unitary textile structure.
2. A fabric according to claim 1 wherein the system of knitting thread wales comprises a half-tricot stitch configuration by alternating two threads in a loop series.
3. A fabric according to claim l wherein the system of knitting thread wales comprises a chain stitch configu-ration.
4. A fabric according to claim 1, 2 or 3 wherein a block pattern design is formed from a single textile ele-ment having segments of substantial length disposed in parallel configuration perpendicular to the longitudinal direction.
5. A fabric made on a stitch-through machine, com-prising:

(a) a layer of filling;
(b) one or more textile pattern design elements dis-posed upon the filling along non-rectilinear pathways, with a majority of segments of said design elements between ad-jacent turns thereof extending essentially perpendicular to the longitudinal direction of the fabric and in suffi-ciently close proximity to one another to give a viewer the impression that said design elements comprise areas whose boundaries are substantially filled with design ele-ment material; and (c) a single system of longitudinal knitting thread wales, each wale comprising a multiplicity of looped stitch courses which engage and hold together the filling and the design elements with loops of knitting thread on the rear surface of the fabric and laps of the knitting thread courses on the front surface to bind and secure said filling and design elements into an integrated unitary textile structure.
6. A fabric according to claim 5 wherein the layer of filling comprises a plurality of textile yarn elements.
7. A fabric according to claim 6 wherein the system of knitting thread wales comprises a half-tricot stitch configuration by alternating two threads in a loop series.
8. A fabric according to claim 6 wherein the system of knitting thread wales comprises a chain stitch confi-guration.
9. A fabric according to claim 5, 7 or 8 wherein a block pattern design is formed from a single textile ele-ment having segments of substantial length disposed in parallel configuration perpendicular to the longitudinal direction.
10. An integrally self-lined fabric made on a stitch-through type machine, said fabric having a front surface and a rear surface and comprising:
(a) a backing material constituting the rear surface of the fabric;
(b) a layer of filling disposed upon the backing material;
(c) one or more textile pattern design elements dis-posed upon the filling along non-rectilinear pathways, with a majority of segments of said design elements between adjacent turns thereof extending essentially perpendicular to the longitudinal direction of the fabric and in suffi-ciently close proximity to one another to give a viewer the impression that said design elements comprise areas whose boundaries are substantially filled with design ele-ment material; and (d) a single system of longitudinal knitting thread wales, each wale comprising a multiplicity of warpwise looped stitch courses which engage and hold together the backing material, filling and the design elements with loops of knitting thread on the rear surface of the fabric and laps of the knitting thread courses on the front sur-face to bind together into an integrated unitary textile structure the backing material, filling, and design ele-ment.
11. A fabric according to claim 10 wherein:
the backing material is composed of spun-bonded con-tinuous filament;
the layer of filling comprises a plurality of textile yarn elements; and the system of knitting thread wales comprises a chain stitch configuration of a half-tricot stitch configuration by alternating two threads in a loop series.
12. A fabric according to claim 10 wherein:
the backing material is composed of spun-laced staple filament;
the layer of filling comprises a plurality of textile yarn elements; and the system of knitting thread wales comprises a chain stitch configuration or a half-tricot stitch configuration by alternating two threads in a loop series.
13. A fabric according to claim 10, 11 or 12 wherein a block pattern design is formed from a single textile ele-ment having segments of substantial length disposed in parallel configuration perpendicular to the longitudinal direction.
14. A method for forming a stitch-bonded type fabric on a stitch-through type machine having a comb-like sinker bar, a comb-like retainer pin bar, the sinker bar and the retainer pin bar defining an elongated fabric-forming work zone for fabric formation between them, a row of pronged sharp-pointed needles parallel to and reciprocatingly movable through said zone and a row of knitting thread guides co-acting with the needles for forming a multipli-city of longitudinal knitting thread loop chains, compris-ng:
(a) guiding one or more textile pattern design ele-ments to and delivering said elements at a point in proxi-mation to the fabric-forming work zone;
(b) placing the design element delivered in step (a) into the work zone whereby a segment of the design element is disposed in a position essentially parallel to the stitching elements during a stitching cycle of -the stitch-through machine; and (c) forming a single system of longitudinal knitting thread wales at the work zone of the stitch-through machine, each wale comprising a multiplicity of looped stitch courses which engage the design elements by loops of knitting thread on the rear surface of the fabric and by laps of the knit-ting thread courses on the front surface to bind and se-cure said design elements into an integrated unitary tex-tile structure.
15. A method according to claim 14 wherein the system of knitting thread wales comprises a half-tricot stitch configuration by alternating two threads in a loop series.
16. A method according to claim 14 wherein the system of knitting thread wales comprises a chain stitch confi-guration.
17. A method according to claim 14, 15 or 16 wherein a block pattern design is formed from a single design ele-ment having segments of substantial length disposed in parallel configuration perpendicular to the longitudinal direction of the fabric.