US2252433A - Pile fabric and method for producing the same - Google Patents

Description

F. KocH Y 2,252,433 PILE FABRlQ AND METHOD OR vPRODUCING THE' SAME Aug-12, 1941.A

Filed March 14, 1940 s sheets-sheet 1 m V m F. KOCH Aug. 12, 1941. i

' PILE FABRIC AND METHOD FOR nonucms THE SAME Filed March 14, 1940 3 Sheets-Sheet 2 IN VENT OR Aug l2, 1.941- F. KOCH 4 PILE FABRIC AND METHOD FOR PRODUCINQ THE SAME Filed March 14,1940 3 Sheets-Sheet 3 VPatented Aug. 12, 1941 pier-ENT 'c1-msg y' A 7: PILE rAmcANpMErnon'Foit R'onUoiNo`1l =f .'rnnsAME Fritz Koch, Derby, Conn., miglior. to Sidney Blumenthal& Co. Inc., New York,.N. Y., a corporaf tion of New .York

` Application March 14,1940, serial'Naszassi v15 claims. -(ci.139397) vthe ,finished fabric against pushing or pulling out or dislodgment when the fabric is in use as,

for instance, when' it is serving as motor vehicle upholstery.

l Another object is to ,provide for the manufacn ture of such a fabric in `which the pile Vlsare held in position in Athe ground without the .use of extra threads suchas stuifer or .cover warps, and without the use of any cementitious binding material. 2 y

Another object is to provide for the manufacture of such a fabric in` which ground Warp threads are woven so as to overlie the bights of the pile Vs and thereby secure the latter against dislodgrnent in-use, as already indicated.

Another object is to provide for the manufacture of such a fabric in which ground warp threads are Woven so as to overlie-not only the bights of the pile Vs but also other ground Warp threads, and are looped under certain weft threads in order rmly to bind the pile V.s into the ground and prevent their dislodgment from correct position when the fabric is in use.

Another object `is to provide for the manufacture of such a` fabric inl which ground warp threads are Woven in a zig-zag line so as to have f portions which lie substantially in a weft-Wise direction and overlie bightsofthe pile Vs.

Another object is to provide for the manufacture of such a fabric in which ground Warp` threads are Woven as just described and also underlie weft threads located intermediate the pile Vs; l

Another'objectis to provide for `the'manufacture of such a fabric in which ground warps are interwoven with relation to wefts, other ground warps and pile Vs :so as greatly to 'strengthen the fabric without reducing its iiexibility.

Another object is to provide for the manufacture. of such a fabric by a method involving a n'ovel adaptation' of the principle of leno Weav. `ing. l

Another object is to providefor the manufactureof such a fabric through the provision of novel, apparatus fitted to Iacconplish the above Y 'named objects'in a loom operatingonthe double shuttle principle.

- A further object 'consists .in providing :certain improvements in the form, construction, material and --arrangement of the fabric and apparatus elements, and in the steps `followed in the method of" production, y whereby the above named and Vother objects may effectively be attained. A practical embodiment of means for produc-` ing this fabric and embodiments of two such' fab# ric weaves arel represented in the accompanying drawings. in which t Fig. 1 represents a detail, largely diagram-` matical, view of certain parts o f weaving" apparatus and yarn in position for accomplishingone w step of the method or procedure of manufacture; Fig. 2 represents a similar view Withtheparts oi' the fabric Weave accomplished by the opera ations represented in Figs. 1 to 4 inclusive;

, Fig. 6 represents a section taken in the planeof the line VI--VI of Fig. 5, looking in the direction of the arrows:

Fig. 7 represents a section taken in the plane 4.of the line VII-VII of Fig. 5, looking in the direction of the arrows;

Fig. 8 represents a view similar to Fig.;5 but showing amodied form of weave; and l s Fig. 9 represents a. section taken in the plane of the line IX-IX of Fig. 8, looking in the direction of the arrows.4

AIt is well recognized in this art that cut Vpile fabrics have important characteristic advantages that reside chiefly in the excellent pile coverage; in economy of pile material, which is frequently expensive; andin simplicityi of weave. On the other hand there is an equally well recognized I disadvantage in this typeof fabric as compared,

for instance, with cut W-pile fabric, consisting inthe fact that, especially when submitted to `frictionalwear as in the caseof vehicle or furniture upholstery,y the pile Vs become disturbed in position. dislodged, and often entirely pushed or'pulledout of the` fabric ground. To over- 'come vthis disadvantage, the art long ago vresorty ed to the inclusion in the fabric of extra ground warps whichwere called by various names such as stuffer war-ps or cover warps, and which served `th` Dllrpo'se of binding-and crowding the pile Vsl *soas .to` cause them to retain their position in 'the lfabric-ground. This expedient, of course,

involved large addedexpense in material, labonl ground, lbythe application to the back of the fabric of a cementitious binding material, such, for instance, as rubber or pyroxylin; as set forth in United States Patent to Leonard L. Crabtree No. 2,007,078, dated July 2,1935. This last named procedure has been eminently successful but it has, of course, involved a certain expensefor material and labor relating to the application of the cementitious material.

According to my present invention. both the above named procedures for improving the cut V-pile fabric are eliminated, and the pile Vs are firmly secured in position` in the ground without the use of any extra threads or any cementitious binding agent, By the expedient of interweaving certain of the normal ground warps in a novel relationship to the other threads, I am able to accomplish this important function as Well as to increase the general strength of the fabric and the resistance of its other warp and weft threads to displacement.

In the accompanying drawings which include representations of apparatus suitable for carrying out my invention there are shown, for the sake of clarity, only those parts to which reference need particularly be made, because the other associated parts are well understood by those versed in this branch of theart as to form, construction, arrangement and operation.

Referring to Figs. 1 to 4 inclusive, al pile yarn' is denoted by I and is threaded through a heddle 2 which latter is connected to any suitable operating mechanism for the purpose of floating the pile back and forth-between the upper and lower fabrics beingwoven on a double shuttle loom,

' and shedding the said pile yarn so that it will lie around alternate wefts or picks as the upper and lower shuttles are shot through the loom. It will be understood, of course, that a large number of such pile yarns are arranged across the loom to be operated in the same manner and that only a single one is here shown in order to avoid encumbering the drawings.

Upper and lower ground warps 3, 4 are threaded through heddles', 3, which latter are also connected with suitable actuating mechanism as is common practice in this art, to be shedded and interwoven with the weft threads in the usual manner for the formation of the grounds of the upper and lower fabrics being woven. As in the case`of the pile yarn I. it'will here also he understood that these ground warps 3 and 4 are duplicated in large number across the loom for the formation of the fabric webs.

Two more ground warps 1, 3 are threaded through ilxed heddles 8, Ill. These ground warps 1, 8 are, however. also threaded through doup needles I I, I2 that may have the usual spring. rod and shaft, or other suitable connection for moving them in directions opposite to the motions imparted to them by their heddles I3, I4. The needles I I. I2 are preferably of the standard form commonly used in lenb weaving and their arms I6, I3, I1, I8 lie between the members I8,

28, 2L 22 of the heddles I3, I4, which members -are interlaced as is usual. through slots 23, 24,

antenas The general mechanical construction of the parts to which reference has just been made is set forth in United States patent to Jacob Kaufmann No. 1,037,151, dated August 27, 1912, but my apparatus embodies a new form of heddle for the doup needles residing particularly in the fact that each heddle I3, I4 is designed andv shaped for operative interconnection with both the upper and lower doup needles Il, I2, so as to intermittently actuate the needles against their connecting springs or other mechanism for the purpose of imparting the desired movements to the ground warps 1,` 8 in the upper and lower fabrics and with respect to the pile yarn I that is being interwoven, as above indicated, with both grounds and oated therebetween. l

In addition to the novelty in the form of the heddles I3, I4, they are also positioned in a novel arrangement with respect to the needles il, I`2, notably in that one needle has its head or eye through which the yarn passes extending downwardly, while the other needle has its head or eye extending upwardly, with the result that the heddles I3, I4 serve to pull one needle downwardly and the other needle upwardly at intervals to accomplish the desired weaving motions in both the upper and lower fabrics. So far as I know, no apparatus has previously been devised for performing leno movements or any variations or adaptations thereof in the upper and lower fabrics being woven in a double shuttle loom.

From the foregoing description, it will be clear that the ground warps 3 and 1 are intended to be shedded and interwoven in the upper fabric,

and the ground warps 4 and 8 to be shedded and 4 interwoven in the lower fabric, while the pile yarn I is shedded and interwoven with both upper and lower fabrics as is customary in double shuttie looms weaving pile materials. It should also be noted that, as will be observed, the pile yarn I is shown in the drawings so as to have a somewhat diiferent appearance from the ground warps, and the ground warps 3, 4 have a some' what different appearance from the ground warps 1, 8. This has-been done to facilitate reading of the drawings wherein the yarnstake different positions in the first four figures, and is not intended as an indication of any particular characteristic with respect to the material, or composition, or twist of the different yarns.

The movements of the parts to perform the weaving operation will now be described; and it will, at the outset, be seen that, in the positions represented by Fig. 1, the ground warps 3 and 1 are shedded in the upper fabric so that weft or pick 21 may be shot through by its shuttle in the usual way. Likewise, ground warps 4 and 8 and pile yarn I are shedded so as to permit the insertion of weft or pick 28 below warp 4 and above warp 8 and pile vI in the lower fabric. Ground warp 3 lies in front of ground warp 1 and pile warp l lies in front of ground warp 8. All the threads or yarns pass between the doup needle heddles, being behind heddle I3 and in front of heddle I4.

Turning now to Fig. 2 which illustrates the next step in operation, it will be observed that heddle I4 has moved upwardlythus permitting doup needle II to be raised by its controlling mechanism and carry warp 1 into the top position in the upper shed in which it is bound more completely around pick 21. Heddle i has moved downwardly so as to carry warp 3 into the bot- Heddle 2 hasbeen elevated so as to bring the pile I from the bottom position in the lower shed tothe top position in the upper shed which -causes it to forma V-bight around pick 23 and also to be shedded for the insertion of an additional pick 29 in the upper fabric between the pile and the`warp 3,. Along with the movements just describedthe heddle has been depressed to carry warp 4 into the bottom 'position in the lower shed, while heddle I3 has been elevated and moved doup needle I2 with warp l upwardly i'n front of warp 4 so as to form a lower shed for the insertion of a further pick 30. -This last named movement of doup needle .I2 not 'only brings warp from a position in back of warp 4 to a-positionin front of the latter, b ut it also forms a covering bend over the pile bight lying underneath pick 28, as hereinabove mentioned, thus binding the said pile bight firmly in positionagainst the said pick.

Fig. 3 illustrates the next step in the weaving tothe other of the pile land the warps 3 and 4 respectively. v'I'ljiese movements produce an interweaving bearing some resemblance to a leno effect because the picks are shot through sheds formed betweenthe warps and the pile, as alneedles II, |-2.

operation, from which it will be seen that heddle `2 has moved downwardly so as to bring the pile to the bottom `position of the lowershed and cause it to form a bight around the top of pick 29; while heddle 6 has moved upwardly to carry with the movements just described, heddle l has Y carried warp 4 into the top position of the lower lshed and doup-needle II has carried warp 3 into the lower position, whereupon another pick` 32 is shot through above the pile and warpV 8V and below warp 4,

In the next step represented in Fig. 4, the heddle E has moved downwardly so as to bring warp 3 into 'the bottom position ofthe upper shed and causeg-it to bend around the top of pick 3|, while heddle 2 has raised the pile into the top position of the top shed and heddle I3 has permitted doup needle to be raised by its actuating mechanism and carry warp 1 upwardly in front of the pile; in which position a further pick 33 is shot through the shed above warp 3 and below the pile and warp 1. The last named lby heddle I4 which carries the needle upwardly in back of warp 4 as thelatter is depressed by 'I'he movements hereinabove described and villustrated in Figs.' 1 -to 4 inclusive, represent the completion of onerepeat ofthe weave, and it will be understood that, while I have described the operations as though all of the picks named were inserted consecutively, the actual operation will LAwhich cuts the pile floats intermediate the upper and lower grounds, the construction, arrangement and operationof the knife being well understood in this industry and requiring no illus-1 tration or description." Although the pile in each of the severed fabrics now has the form of Vs each of whichis looped around only a single weft or pick, the said vVs are firmly sec'ured in position and against dislodgment or pushing or pulling out of the fabric grounds by the bends of the warps 1, 8 which have been manipulated by the doup needles and heddles as above set forth.

the downward movement of heddle 5, thus forming a shed for the insertion of an'additional pick 34 between the warps 4 and 8.

As clearly appears'from the drawings, and as already. mentioned, the heddle I3 is ini front of all the yarns or threads while `the heddle I4 is in back of them. Hence, when the doup needle v I| is moved downwardly or the doup needle I2 moved upwardly by the heddle I3, the-said neea zigzag weaving or positioning ofthe warps 1` and 8 since they-pass rst to one side and then The arrangement of the threads in plan view is well shown in Fig. 5 which represents the top or back of the-upper fabric as well as the bot'tom or back of the lower fabric, because both are alike. Assuming this view'to show the top or back of the upper fabric, the numerals I, 3 and 1` denote the pile and the upper shed ground warps to which reference has heretofore Abeen made. The wefts or picks woven in one repeat of this fabric Vare given their previous numbers 21, 2li,` 3| land 33.` Examination of this- View will show that the pile I is looped around alternate picks 29, 33 etc.; that the ground warp 3 is interwoven with the picks, going over and under thern in alternation as is usual; and tha-t the ground warp 1, which has been manipulated by the doup needle II and the heddles I3, I4, passes under pick 21 in a warp-wise direction, then-,over pick 29' and the bight of pile I in substantially a weft-fwise direction, although at an angle thereto; then under pick 3| in a warp-wise direction; then over pick 33 and the bight of 'pile I in an angular weft-wise direction which is similar but opposite to the angularity of the warp 1 when passing over pick 29 and bight of pile I just mentioned. This angular zigzag course of the warp`1 continues throughout the length of 'the fabric; and the just described arrangement -the pilefloats are severed is-shown in section in Fig. 6 looking in a warp-wise direction, and in section in Fig. '7 looking in a weft-wise direction;

from which figures, in addition to those previously descr d. the interweaving or interlacing and tyingeffect of the threads or yarns As thewin be evident, and from which it be seen that the ground warps 1 and 8 not only overlie the pile bights so as to hold the Vs in position after the floats have been severed, 'but also act to hold the other ground warps. wefts and the with the use of extra threads or anchoring or cementitious material, while improving the characteristics of the fabric in several respects. On

' the other hand, it should be emphasized that pile in correct relative contiguity as originally woven, thereby preventing undesirable displacement of any of the threads by movements in the plane of the fabric, which displacement, if it occurred, would tend to militate against the uniformity of the fabric.

As previously indicated, Figs. 1 to 4 inclusive of the drawings show only two ground warps, with the appropriate picks,v for each fabric, upper and lower, and one pile which is interwoven with the two fabrics and floated therebetween.

As also previously indicated, the fabric resulting from the interweaving of the said threads, with their necessary duplication in the other dents of the loom, is illustrated in Figs. 5, 6 and 7.

While such a fabric is practical. I feel that! it will be desirable in most cases to include an additional ground warp for each dent of each fabric, upper and lower, inv order to improve the .balance and general construction of the fabric.

This modification is illustrated in Figs. 8 and 9, in which an additional ground warp Il is interwoven in the same way as 'the ground warp 3 in the upper fabric; and an additionalfground warp 36 is interwoven in the Same way as the ground warp A in the lower fabric. This provides a ground warpv on each side of the pile running ina straight warp-wise direction, and

this invention in its broad aspect is applicable not only tothe weave constructions shown in the drawings,`but also to various other forms of pile fabrics, the significant feature being that ground warp threads are interwoven so as to overlie pile bights and hold the bights in position, regardless of the particular arrangement of the bights or the number and form of intert weaving of the other warp and weft threads.

It will be understood that various changes may be resorted to in the form, construction, ar-

, threads, ground weft threads and pile tufts, certain of the warp threads being interwoven so as to extend angularly in a combined weft-wise and Warp-wise direction over the bights of the pile the zigzag warps 1 and 8 which are actuated by the doup needles, and their heddles so as to bind in the pile bights, span in their weft-wise extent the pile bights and the warps on each side thereof which, as just noted, are numbered l and in the upper fabric, and 4 and 36 in the lower fabric.l

The arrangement of heddles and other loom mechanism for interweaving these ground warps 35 and 36 is so well understood in the art that ther is` no call for illustrating or describing the same further than has been illustrated and. described in connection with the operating mechanism for warps 3 and l, it being sufilcient to note that the warps $5 and 35 are interwoven like the warps 3 and I, respectively, although they may, of course, be arranged so as to pass around each pick on opposite sidesthereof, 'instead of on the same side as shown in Figs. 8 and 9, by mere adjustment of the shedding mechanism, which is well understood and commonv practice in this art. It should be addedthat these warps 35 and 3l, if used. are not to be considered as extra or additional threads in the sense that the stuffer'or cover warps hereinabove referred to were extra or additional threads: because this form of fabric illustrated in Figs. 8

Vand 9 contains no more warp threads than have customarily been used in V-pile fabrics that were not provided with stui'fer or cover warps or the like. These warps I5' and are merely for the' purpose of improving the general construction or balance of the fabric in a way analogous to the interweaving of ground warps in known fabrics.

.In both forms of fabric the securing of the pile Vs in position is obtained, not by the employment of additional threads or of any anchoring or cementing application but. on the other of the pile tufts, other warp threads and certain` and interweaving certain warp threads so as to hand, by the novel interweaving of one `of the tufts on the back of the fabric and to underlie weft threads intermediate the pile tufts.

2. A pile fabric comprising, ground Warp threads, ground weft threads and pile tufts, certain of the warp threads being interwoven in a zigzag warp-wise course so as to overlie bights of the pile tufts and other warp threads on the back of the fabric and to underlie weft threads.

3. A pile fabric comprising, ground Warp threads, ground weft threads and pile tufts, cerf tain of the warp threads being interwoven in a zigzag warp-wise course so as to overlie bights weft threads on the back of the .fabric and to underlie other weft threads.

4. A method of weaving pile fabric including; interweaving warp and weft threads to form a ground, interweaving pile threads in said ground,

cause them to pass to and fro weft-wise across and over the bights of certain pile threads.

5. A method of weaving pile fabric including; interweaving warp and weft threads to form a ground, interweaving pile threads in said ground, and interweaving certain warp threads so as to cause them to passvto and fro weft-wise across and over .the bights of certain pile threads and across certain other warp threads.

6. A method of weaving pile fabric including; interweaving warp and weft threads to form a ground, interweaving pile threads in said ground, and interweaving certain warp threads so as to cause them to pass to and fro weft-wise across and over the bightsk of certain pile threads and across certain other warp threads and underneath certain weft threads at points \on both sides of .the pile threads.

'7. 'A method of weaving pile fabric including; interweaving warp and weft threads to form a ground, interweaving pile threads in said ground, and interweaving certain warp threads so as to cause them to pass to and fro weft-wise across and over the bights of certain pile threads and across certain other warp threads and underneath certain weft threads at points on both fle (liuAJA sides of the pile threads and said other warp weft-wise and warp-wise' direction over the pilev form upper' and lower grounds, interweaving.

pile threads in both grounds and floating them between the grounds. and interweaving certain warp threads so as tocause them to pass to and fro weft-wise across certain pile threads.

10. A method of weaving double pile fabric including; interweaving' warp and weft threads to \i'orm upper andlower grounds, interweaving pile threads in both vgrounds vand`fioating them between the grounds, and interweaving certain.

warp threads so as'to cause them to pass to and fro weft-wise across certain pile threads and certain other warp threads.

11. A method of weaving double pile fabric inciuding: intel-weaving warp and weft threads to form upper and lower grounds, interweaving pile threads in both grounds andoating them between the grounds, 'and interweaving certain warp threads so as to cause .them to pass to and fro weft-wise across certain pile threads and undemeath certain weft threads at points on both sides of the Pile threads.

12. A method of weaving double pile fabric including; interweavlng warp and wett'threads to form upper and'lower groundainterweaving Dilethreads in both grounds and floating-them between the grounds. and interweaving certain ascuas weaving certain warp threads with other warp threads in the ground. whereby said .cross-woven warp threads overlielthe bights of warpthreadssoastocause themtopasstoand fro weit-wise acres certain pile threads and certain other warp threadsy and underneath certain weit threads at points on both sides of the pile threads and said other warp threads.

13. A method of weaving pile fabric including; 4shedding ground warps and inserting picks to the pile threads in the ground in a combined weft-wiseand warp-wise direction. I

14. A method of weaving double pile fabricv including; shedding ground warps and inserting picks to form upper and lower grounds, oating a pile thread from one 'ground' to the other, intermittently shedding said pile thread with' one of the warp threads in each ground and cross- Weaving` a warp thread with respect to another warp thread in each ground, whereby said crosswoven warp threads `overlie the bights of the' pile thread in each ground in a combined weft-wise and warp-wise direction.V v l 15. A method of weaving double pile fabric including; shedding ground warps and inserting picks to form upper and lower grounds, oating pile threads from one ground to the other, intermittently shedding said kpile threads with warp threads in each ground and cross-weaving certain warp threads with respect to other warp threads in each ground, whereby said crosswoven warp threads overlie the bights of the pile threads in each ground in a combined weftwise and warp-wise direction.

. 'FRITZKOCR

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