US3034541A - Reinforced pile fabric - Google Patents

Description

y 1962 H. F. NOWICKI ETAL 3,034,541

REINFORCED PILE FABRIC Filed Jan. 22, 1959 2 Sheets-Sheet 1 FIG. I PK; 4

' INVENTORSZ HENRY E NOWICKI HARRY J. SMILEY ATTY y 1962 H. F. NOWICKI ETAL I 3,034,541

REINFORCED PILE FABRIC Filed Jan. 22, 1959 2 Sheets-Sheet 2 FIGII. FIGIZ INVENTORS: HENRY F NOWICKI HARRY J. SMILEY ATTY.

United States Patent Office 3,@34,541 Patented May 15, 1952 This invention relates to woven pile fabrics in which the weft shots are inserted by means of a needle as distinguished from a shuttle. It is the particular feature of the present invention to provide a fabric having a relatively heavy or stiff backing structure which not only improves the desirability of the fabric, but also enhances tuft-bind and dimensional stability.

The production of pile fabrics using a needle instead of a shuttle for the insertion of the weft shots or picks is, of course, well known. Experience with this type of fabric has indicated the necessity for some strengthening feature in order to produce satisfactory and saleable merchandise. Heavy back-sizing and the lamination of a second woven fabric have all been tried with varying degrees of success. The present invention overcomes the necessity for subsequent operations after the initial weaving in that it produces a firm, heavy backing for any type of velvet, Wilton, Brussels, or tapestry fabric.

A primary object of the invention, therefore, is to provide in a needle inserted double weft woven fabric a relatively heavy woven backing.

A further object of the invention is to provide in a fabric of the type described a series of specially woven extra warps which enhance the pile binding properties of the fabric.

A further object is to provide in a single shot needle insertion fabric means for insuring dimensional stability and tuft-bind.

A further object of the invention is to provide in a two shot needle insertion fabric a stuifer warp carried between simultaneously inserted top and bottom double weft shots.

A further object of the invention is to provide in a two shot needle insertion fabric a stuffer warp interwoven with simultaneously inserted top and bottom double weft shots.

A further object of the invention is to disclose the various combinations of pile effects that are desirably achieved in a fabric that is constructed in accordance with the pres ent invention.

Further objects will be apparent from the specification and drawings in which:

FIGURE 1 is a schematic top view of a pile fabric constructed in accordance with the present invention,

FIGURE 2 is an enlarged warp-wise section showing the fabric of FIGURE 1 in both loop and cut pile,

FIGURE 3 is a weft-wise sectional detail as seen at 33 of FIGURE 2,

FIGURE 4 is an enlarged schematic top view showing a variation of the fabric of FIGURE 1,

FIGURE 5 is a warpwise section having both cut and uncut pile of the fabric of FIGURE 4,

FIGURE 6 is an enlarged sectional detail of the fabric of FIGURE 5 as seen at 6-6,

FIGURE 7 is an enlarged warpwise section of a single shot fabric having both cut and uncut pile and additionally a variation in the backing weave,

FIGURE 8 is an enlarged sectional detail as seen at 88 of FIGURE 7,

FIGURE 9 is an enlarged warpwise section of a single shot Wilton weave embodying the present invention,

FIGURE 10 is an enlarged sectional detail as seen at 10-10 of FIGURE 9,

FIGURE 11 is an enlarged warpwise section of a velvet pile fabric having both out and uncut pile showing the invention as applied to a two shot fabric with stuifer p,

FIGURE 12 is an enlarged sectional detail as seen at 12-12 of FIGURE 11,

FIGURE 13 is an enlarged warpwise section of a velvet fabric constructed in accordance with the invention having modified arrangement of stuffer warps,

FIGURE 14 is an enlarged sectional detail as seen at 1414 of FIGURE 13,

FIGURE 15 is an enlarged warpwise section of a velvet fabric having both out and uncut pile using a different reinforcing ground fabric construction,

FIGURE 16 is an enlarged sectional detail as seen at 1616 of FIGURE 15,

FIGURE 17 is an enlarged warpwise section of a two shot Wilton constructed in accordance with the invention, and

FIGURE 18 is an enlarged sectional detail as seen at 18-18 of FIGURE 17.

The invention comprises essentially the provision of a reinforcing means for the ground or base fabric in a non- Axminster pile weave but produced with double wefts on a loom having a needle motion as distinguished from a shuttle motion. The one shot fabric utilizes certain interwoven extra warps to achieve dimensional stability and to provide a stronger base fabric. The double needle fabric utilizes a weave having simultaneously inserted upper and lower double filling wefts.

Referring now more particularly to the drawings, the velvet pile fabric shown in FIGS. 1-3 comprises a plurality of double filling wefts 20, 20 which are positioned in substantially the same horizontal plane. The pile wires 21 over which the pile warps 22 and 23 are woven are inserted with each one of the double filling wefts 2% In the fabric shown in FIGURE 1 there is only one end of pile yarn in each dent which may be defined by the space between double chain warps 25 and stutfer warps 26. As seen in FIGURE 1, the double chain warps 25 and 25a weave opposite to each other which means that they are controlled by separate harness frames and they weave alternately over and under successive filling wefts 29. The pile end 23 weaves over and under successive wefts 29 whereas the pile end 22 weaves over and under intermediate wefts 20, 20. This provides the weftwise staggered weave shown clearly in FIGS. 1 and 2. Ordinarily a one shot or single plane pile fabric requires an additionally adhered material such as scrim, a foam rubber backing, or relatively stiff backsizing to achieve the desired dimensional stability. We propose, however, to increase the stability of the fabric and to reinforce the fabric backing by using the double chain warps 25 and 25a together with additional stuffer warps 26 and 27. These stuffer warps are double and weave under and over successive pairs of filling wefts 20, 26 but at least one of the stufier warps 26 or 27 is separated from the pile yarn 23 by means of an oppositely weaving binder 25. Likewise stuflfer 26 is separated from pile warp 22 by binder warp 25a. The tendency of the double weaving of stutter warp 26 to twist successive filling wefts 29 and thereby hold them in a substantially straight plane is well pronounced. This is an important feature of the invention. It will also be apparent that between every row of pile yarns 22 and 23 there is woven at least two double warps one of which weaves over and under each succeeding filling weft and the other of which weaves over and under successive pairs of double filling wefts.

In FIGURE 4 the reinforcing of the base or ground fabric is accomplished by the addition of a single relatively heavier stutter '30 which weaves under and over pairs of filling wefts 20. On either side of the stuffer 30 we provide chain or hinder warps 31 and 32 which weaves over and under successive filling wefts 20, but which are spaced apart from each other. The above weaving of the warps in each dent is identical, but it will be noted that the innermost binder warps 33 and 31 work together so that they are simultaneously over and under the same filling shot. Again it is to be noted that the adjacent double and single weaving of the ground warps in a dent is a very important factor in providing greater dimensional stability. In this form it is desirable to use double pile ends working together over and under successive wefts. FIGURE 4 also illustrates a variation in the pile projections which are formed from double warps 22 and 23.

Where even further reinforcing of the ground fabric is indicated, it is possible to achieve this result by using two cotton binder warps 35, 35 workin together and opposite to a pair of warps 36 (FIG. 8). This construction is also repeated between successive pairs 37 and 38 of the pile loop projections. This fabric lends itself to both velvet and Wilton construction (as seen in both FIGURES 7 and 9, the former being velvet) since the weave is one in which there is no selection of the pile ends working over the wires except as may be achieved by means of conventional harness frames. In FIGURE 9 there is shown'a one shot Wilton weave having pile wires 21 inserted on each double filling weft 20 but in which some of the pile yarns, for example pile yarn 40, run dead on the back of the fabric as shown at float 41. The pile yarn 42 is likewise controlled by a jacquard, not shown, so that either or both of the yarns may be selected to weave over any one of the set of pile wires 21. In the Wilton weave there are single opposed binder warps 43 and 44 which run in each dent and which are separated from the pile yarns and 42 by means of a relatively heavier stufier warp 45. The stufier warp 45 may weave over and under successive filling wefts 20 or it may be carried over two or more successive filling wefts as shown in the velvet weave of FIGURE 5 By judicious selection of the place and length of the back floats 41, added reinforcing and stiffening for the ground fabric is achieved. The weaving of two pile warp ends per dent contributes to the general stability of the fabric. In FIGS. 2, 5, and 7, the cut pile is illustrated at C and the uncut or loop pile is shown at L. It will be understood that any particular fabric may be all cut, all uncut, or partly cut and partly uncut.

A further manner in which a needle or double weft pile fabric may be reinforced involves the provision of simultaneously inserted top and bottom double filling wefts and 51. These wefts are inserted between reversals of the harness frames so that the opposed single binder warps 52 and 53 compress the top and bottom wefts 50 and 51 against the stulfer warps 54. FIGURE 12 shows a four ply stuifer warp 54, but it will be understood that the stutfer warp may be single or any number of separate yarn ends. The weaves shown in FIGS. 11 and 12 illustrate cut and uncut pile areas in a velvet weave having two oppositely working pile yarns per dent. In FIGURES 13 and 14, the single heavy stufier 55 weaves over and under successive upper double wefts 50 and a second oppositely working single heavy stuifer 56 also weaves over and under the top wefts 50, but the stuffers 55 and 56 split the pile yarns in each dent. V

An alternative manner in which the backing of the pile fabric may be reinforced is shown in FIGS. 15 and 16 which utilize in addition to the binder warps 52 and 53, one or more heavy reinforcing or stuifer warps 60, 61, 62, and 63. These reinforcing warps may work side by side and weave together over pairs of double filling wefts or they may split the pile warps 64 and 65 as shown, clearly in PEG. 16. The fabric of FIGS. 15 and 16 is what might be called a hybrid fabric since the upper and lower filling wefts 50 are not separated by a staffer, but the so-called stutfer warps 6l63 weave over and under double pairs of the filling wefts to provide what is in effect an extra heavy single plane fabric. It will also be noted that the pile warps 64 and 65 weave through to the back as is the case with the ordinarily single plane or one shot fabric.

FIGURES 11l6 illustrate various forms of a reinforced velvet pile fabric whereas FIGURES 17 and 18 show a two shot Wilton fabric with double needle, double weft insertion. Here again the upper wefts 50 and the lower wefts 51 are inserted simultaneously and are separated by the four ply stuifer as well as the pile warps 71 and 72. The single opposed binder warps 73 and 74 weave over and under, a single upper and lower filling weft 50 and 51. The pilewarps 71 and 72 are shown in the form of high floats 75 and running dead in the fabric at 76.

It will thus be understood that we have provided an improved reinforcing for needle inserted double weft woven fabric which achieves adequate dimensional stability for utilizing an extraneous backing material or backsize.

Having thus described our invention, we claim:

1. A single plane one shot woven pile fabric comprising a plurality of double filling wefts in spaced co-planar relation to each other, rows of parallel pile yarns interwoven with said filling wefts and forming pile projections on only one side of said co-planar wefts, pairs of binder warp being interwoven with said filling. wefts, at least one reinforcing ground warp of greater diameter than.

the pairs of binder warps running with the binder warps and being interwoven with said filling wefts, said pairs of binder warps and said reinforcing warp being spaced weftwise of the fabric between at least every second row of pile yarn.

2. A fabric in accordance with. claim 1 in which the reinforcing ground warp interweaves with pairs of double filling wefts.

3. A fabric in accordance with claim 2 in which the binder warps interweave with every double filling weft.

4. A fabric in accordance with claim 1 having pair of opposed adjacent binder warps interweaving with every double filling weft.

References Cited in the file of this patent UNITED STATES PATENTS 111,325 Crompton Ian. 31, 1871 1,341,417 Davis May 25, 1920 2,578,173 Clark Dec. 11, 1951 2,647,546 Ryan Aug. 4, 1953 2,715,918 Eisler et al Aug. 23, 1955 2,760,528 McKnight et a1 Aug. 28, 1956 2,860,669 Moberg Nov. 18, 1958

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