AU672016B2

AU672016B2 - Fabric, machine, and process for making same

Info

Publication number: AU672016B2
Application number: AU44878/93A
Authority: AU
Inventors: Tass Zorbas
Original assignee: Finmar Pty Ltd
Current assignee: Finmar Pty Ltd
Priority date: 1992-08-25
Filing date: 1993-08-25
Publication date: 1996-09-19
Anticipated expiration: 2013-08-25
Also published as: AU4487893A

Description

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AUSTRALIA

PATENTS ACT 1952 COMPLETE SPECIFICATION (Original) APPLICATION NUMBER:

LODGED:

COMPLETE SPECIFICATION LODGED:

ACCEPTED:

PUBLISHED:

RELATED ART: r rr r ~re r* NAME OF APPLICANT: ADDRESS OF APPLICANT: ACTUAL INVENTOR(S): ADDRESS FOR SERVICE: TASS ZORBAS Silverwood, Lot 51, Canns Road, Bedfordale, Western Australia, 6112, AUSTRALIA TASS ZORBAS rr KELVIN LORD AND COMPANY 4 Douro Place West Pertn WA 6005 c ~r r COMPLETE SPECIFICATION FOR THE INVENTION ENTITLED: "FABRIC, MACHINE, AND PROCESS FOR MAKING SAME" The following statement is a full description of this invention including the best method of performing it known to me/us:- _i s _L 1 2- 2 The present invention relates to a fabric, an apparatus for 3 producing the fabric and a process for producing the 4 fabric.

In accordance with a first aspect of the present invention 6 there is provided a fabric comprising warp yarns and weft 7 yarns, wherein each weft yarn extends between respective 8 first and second warp yarns in a zigzag manner.

9 In accordance with a second aspect of the present invention there is provided an apparatus for producing a fabric 11 comprising a crochet machine for crocheting yarns to make 12 said fabric and a creel for feeding yarns to said crochet 13 machine, said crochet machine having a plurality of needle S 14 means for crocheting said yarns to make said fabric and 15 said creel having yarn tensioning means provided at the 16 downstream part of said creel to provide substantially even S 17 tension to said yarns prior to being fed to said crochet 18 machine. A finishing machine may also be provided.

19 The finishing machine comprises (dyeing and) coating means, drying means, heat.ng means, tensioning means, and cooling 21 means for the fabric passing through the finishing 22 machine. The tension of the fabric can be controlled 23 throughout its passage through the finishing machine.

24 In accordance with a third aspect of the present invention there is provided a process for producing a fabric 26 comprising providing warp and weft yarns, crocheting said 27 yarns to make said fabric such that each weft yarn extends 28 between respective first and second warp yarns in a zigzag 29 manner. The fabric of the present invention may be crocheted such that there are other warp yarns intermediate 1 3 2 the respective first and second warp yarns. Alternatively, 3 the fabric may be crocheted such that there are no warp 4 yarns between the respective first and second warp yarns.

The present invention will now be described by way of 6 example, with reference to the accompanying drawings, in 7 which: 8 Figure 1 shows the pattern of warp and weft yarns of a 9 fabric in accordance with an embodiment of the present invention; 11 Figure 2 is an enlarged view of the pattern of warp and 12 weft yarns shown in Figure 1; 13 Figure 3(a) is a view of a conventional crochet needle; 14 Figure 3(b) is a view of an embodiment of a modified crochet needle used in producing fabric in accordance with 16 the present invention; 17 Figure 4 is a schematic elevation view of a machine and 18 creel for producing fabric in accordance with the present 19 i.nv nt2on: Figure 5 shows a needle (as shown in Figure with a 21 warp yarn threaded therethrough; and 22 Figure 6 is a schematic elevation view of a machine for 23 finishing the fabric of the present invention.

24 Figure 1 shows the crochet pattern of a fabric 10 in accordance with an embodiment of the present invention.

26 The fabric 10 comprises a plurality of warp yarns 12 and a 27 plurality of weft yarns 14. The warp yarns 12 extend in a 28 substantially parallel manner.

29 Each wett yarn 14 extends between respective first and second warp yarns 12 in a zigzag manner. Each weft yarn 14 1 4 2 extends laterally between the respective first and second 3 warp yarns 12.

4 Each weft yarn 14 may extend between a different pair of warp yarns 12.

6 A third warp yarn 12 is provided between each pair of 7 respective first and second warp yarns 12.

8 Figure 2 shows a portion of the fabric 10 shown in Figure 1 9 with the warp yarns 12 and weft yarns 14 shown in enlarged view.

11 In Figures 1 and 2 individual warp yarns 12 and weft yarns 12 14 are followed by a letter for easier identification and 13 description, whilst when referred to collectively no letter 14 is used.

S 15 With particular reference to Figure 2 a pair of first and 16 second warp yarns are shown at 12a and 12b, respectively.

17 A weft yarn 14a extends between the first and second warp 18 yarns 12a and 12b. The weft yarn 14a repeatedly extends 19 la.Let.ally between the fist and second warp yarns 12d and 12b in a zigzag manner. The weft yarn 14a turns at each 21 contact with a warp yarn 12a or 12b, as can be seen in I e S" 22 Figure 2.

23 A third warp yarn 12c is provided intermediate the first 24 and second warp yarns 12a and 12b.

Similarly, a second pair of first and second warp yarns 12b 26 and 12d have another weft yarn 14b repeatedly extending 27 laterally therebetween in a zigzag manner.

28 Another third warp yarn 12e is provided intermediate the 29 second pair of first and second warp yarns 12b and 12d.

The first and second and third warp yarns 12 a;:e not 1 5 2 distinct, e.g. the third warp yarns 12 also form respective 3 first and second warp yarns 12. By way of example, the 4 warp yarns 12c and 12e form first and second warp yarns between which a weft yarn 14c repeatedly extends in a 6 zigzag manner. The warp yarn 12b forms the third warp yarn 7 intermediate the warp yarns 12c and 12e.

8 Each weft yarn 14 is knotted, stitched or encapsulated, by 9 the respective first and second warp yarns 12 and the intermediate third warp yarn 12. This is best seen in 11 Figure 2. In this way, the warp yarns 12 and weft yarns 14 12 are interlocked to form the fabric 10 in a crocheted u, 13 manner.

14 Fabric in accordance with the present invention may be made with more than one intermediate warp yarn 12 between 16 respective first and second warp yarns 12. Such additional 17 intermediate warp yarns 12 are also knotted, stitched or 18 encapsulated, by the weft yarns 14. Alternatively, a 19 fhbri may be ltade wibhout any intermediate warp yarns 12 between the first and second warp yarns 12.

21 Each weft yarn 14 extends between respective first and 22 second warp yarns 12 and there may be none or, one or more 23 third warp yarns 12 intermediate the respective first and 24 second warp yarns 12. However, a single weft yarn 14 does not extend across the width of the fabric 10, i.e. more 26 than one weft yarn 14 is provided to span the width of the 27 fabric 10. This is best seen in Figure 1.

28 As best seen in Figure 2, each warp yarn 12 is formed as a 29 series of interlocking loops L. Each loop L is made up of a first outer portion A, a middle portion B and a second 1 6 2 outer portion C. The weft yarns 14 are knotted, stitched 3 or encapsulated, by the loops L of the warp yarns 12. This 4 is done by the weft yarns 14 passing over the first and second outer portions A and C, and under the middle portion 6 B of each loop L (of the warp yarns 12) by which they are 7 knotted, stitched or encapsulated, (as viewed in Figure 2).

8 The previously described pattern of warp yarns 12 and weft 9 yarns 14 is repeated throughout the fabric 10, as can be seen in Figures 1 and 2.

11 Thus, the weft yarns 14 are provided in a multi pass 12 pattern across the warp yarns 12 forming the main body of 13 the fabric 10, as can be seen in Figure 1.

14 The edges of the fabric 10 may be provided with dual warp 15 yarns 12, as can be seen in Figure 1. The weft yarns 14 16 have a single pass adjacent the dual warp yarns 12 at the 17 edges of the fabric 10. This can also be seen in Figure 18 1. The provision of the edges of the fabric 10 with the .9 crocheted warp and weft yarns 12 and 1.4 provides -Fini.shed edge which is resistant to fraying.

21 The fabric of the present invention may be used for 22 vertical blind slats. Vertical blind slats are made in 23 different widths. Two common widths are 90mm (3.5 inches) 24 and 127 mm (5 inches). Conveniently, fabric of the present invention has approximately 23 warp yarns 12 for a 26 slat and 32 warp yarns 12 for a 127mm slat.

27 The fabric of the present invention may be produced using 28 the apparatus shown in Figures 3 to 6. The fabric of the 29 present invention may be crocheted using a modified automatic crochet machine. This machine is designed tor S1 7 2 producing stretch fabric or elastic. This machine is 3 modified to enable it to crochet the fabric of the present 4 invention. In particular, the gaps of the needle hooks 16 of the crochet machine are reduced to prevent them from 6 picking up weft yarns when the machine is in operation.

7 The difference between the needle hooks 16 before and after 8 modification is shown in figures 3(a) and 3(b), 9 respectively. Additionally, the elastic feed is removed from the machine.

11 Figure 4 schematically shows a modified crochet machine S 12 and a creel 52 for feeding yarn to the machine 50. In 13 conventional manner, the creel 52 comprises rollers 54 14 carrying the yarns (12 and 14) that is to be fed to the 15 machine 50. However, in contrast to conventional creels, 16 the creel 52 has a tensioning mechanism comprising tension 17 springs and washers 56, through which the yarns (12 and 14) 18 is fed, provided at the downstream end 58 of the creel 52.

19 This is in contrast to convention creels which employ 20 tension springs adjacent the actual yarn rollers 54 at the 21 side of the creel.

22 The yarn tensioning mechanism of the creel 52 of the 23 present invention provides reduced tension in the yarns (12 24 and 14) along with an even tension in the warp yarns 12 as they are fed from the creel 52 to the machine 50, in 26 contrast to conventional creels.

27 The fabric 10 is then crocheted by the machine 50 in the 28 appropriate nattern, as exemplified in Figures 1 and 2.

29 Figure 5 shows a warp yarn 12 threaded through a needle 59 of the machine 50 making a chain stitch 59a.

*1 -8 2 Once the fabric 10 has been crocheted by the machine 50, it 3 is wound onto rollers knot shown). These rollers may be 4 then transferred to the feed end 62 of a finishing machine 60 which is shown in Figure 6.

6 The finishing machine 60 has a feed end 62 and a discharge 7 or collection end 64 for the fabric 10. Rollers 66, upon 8 which the fabric 10 is wound, are mount~ed on a support 68 9 at the feed end 62.

The fabric 10 is then fed to a dyeing and coating bath 11 The dyeing and coating bath 70 dyes the fabric 10 to the 12 desired colour and also coa~ts the fabric 10 with a suitable 13 coating. The coating is applied to provide a degree of 14 rigidity to the fabric 10. (However, if colour dyeing is not required, the dyeing facility may be omitted.) The 16 dyeing and coating bath 70 comprises a number of rollers 72 *17 which enable the fabric 10 to be double dipped in the 18 dyeing and coating bath 70. The double dipping consists of *19 the fabric 10 being dipped twice in the dyeing and coating bath 70 in a single passage/path. The rollers 72 are air 21 compressed and driven to enable the desired tension in the 22 fabric 10 to be maintained.

23 The fabric 10 then passes from the dyeing and coating bath 24 70 to a pre-drying heater 74. The pre-drying heater 74 dries the fabric 10 to a "touch-dry" condition.

26 After leaving the pre-drying heater 74, the fabric 27 passes to an oven 76. The fabric 10 passes through the 28 oven 76 in a vertical manner. This is effected by way of 29 rollers inside the oven 76. The oven 76 enables approximately 40 metres of fabric 10 to be heated therein 7, F T 17 1 9 2 at a given time. A tensioning arrangement is provided in 3 association with the oven 76. This tensioning arrangement 4 comprises a tension lever (not shown) inside the oven 76 and a counterweight (not shown) outside the oven 76. These 6 are used to control the tension of the fabric 10. The 7 rollers in the oven 76 vertically feed the fabric 10 and 8 are synchronised and driven rollers so that the tension in 9 the fabric 10 can be maintained as desired without undue stretching of the fabric 11 The fabric 10 leaves the oven 76 and passes around an 12 automatic electric tensioner in the form of a swivellable 13 bar 80. The bar 80 enables the speed of the fabric 14 travelling through the machine 60, to be controlled. The 15 bar 80 is able to swivel upwardly or downwardly as shown by 16 the double arrow D. If the bar 80 swivels upwardly, as 17 viewed in Figure 6, the speed of the fabric 10 will 18 increase. If the bar 20 swivels downwardly, the speed of 19 Lie 'abxi1 10 will decrease. Repositioning the bar 80 by swivelling it upwardly or downwardly can be used for 21 controlling the tension of the fabric 10 in its passage 0' 22 through the machine 23 The fabric 10 then passes around synchronised heating 24 rollers 82. These synchronised heating rollers 82 act as ironing or pressing rollers to iron or press the fabric 26 Next, the fabric 10 passes around synchronised cooling 27 rollers 84 to cool the fabric 28 Lastly, the fabric 10 passes onto tension roll-off rollers 29 84 at the discharge end 64.

An option is to incorporate a cutting station as shown at 1 10 2 90. The cutting station 90 is used to cut the fabric 3 However, the cutting station 90 need not be provided.

4 The finishing machine 60 enables the tension in the fabric 10 to be maintained throughout its passage through the 6 machine 60 from the feed end 62 to the discharge end 64.

7 By controlling the tension of the fabric 10 in the 8 finishing machine 60 it is possible to provide a flat and 9 even fabric The fabric of the present invention and the apparatus and 11 process for producing such fabric are, as indicated 12 previously, particu larly suited to making fabric for use as 13 vertical blind slats. Typically, these slats have a width *14 of 90mm. (3.5 inches), 100mm (4 inches) or 127 mm inches).

16 Conveniently, a 90mm slat has 23 warp yarns and a 127mm 17 slat has 32 warp yarns.

18 The warp yarn may be 100% polyester 150 Dennier (75 x 2) 19 nc'n-twist non-torgut- qernd di'i. JloM1. ir. The~ yarn may be a 100% polyester 300 Dennier (150 x 2) non-twist 21 non-torque semi dull look fibre.

22 The present invention provides a flat and even fabric made 23 by crocheting, but with the appearance of a stitch bonded, 24 non-woven fabric. The visual appearance of the final product is superior to conventional vertical blind slat 26 fabric. Further, the crocheted edges of blind slats made 27 in accordance with the present invention (incorporating the 28 dual warp yarns at the vertical edges) have an increased 29 strength and are resistant to fraying of the locked vertical edges in comparison with conventional vertical 11 blind slats.

Modifications and variations such as would be apparent to a skilled addressee are deemed within the scope of the present invention.

gi r: **BI ,tI I

Claims

2. An, apparatus according to claim 1, wherein said yarn tensioning means comprises tension springs and washers through which said yarns are fed.
3. An apparatus according to claim 1 or 2, wherein said needle means have hooks with reduced gaps.
4. An apparatus according to any one of claims 1 to 3, wherein a finishing machine 15 is provided through which said blind fabric is passed from a feed end to a discharge end, said finishing machine comprising coating means to coat said blind fabric, drying means to dry said blind fabric, heating means to heat said blind fabric, tensioning means to tension said blind fabric, and pressing means to press said blind fabric. An apparatus according to claim 4, wherein said tensioning means is provided 20 between said heating means and said pressing means.
6. An apparatus according to claim 4 or 5 wherein said tensioning means comprises a swivellable member around which said blind fabric passes such that the tension in said blind fabric is controllable by swivelling said swivellable member in a first or second direction.
7. An apparatus according to any one of claims 4 to 6, further comprising cooling means to cool said blind fabric after said blind fabric passes through said pressing means.
8. An apparatus according to any one of claims 4 to 7, wherein said pressing means comprises heating rollers which press or iron said blind fabric.
9. An apparatus according to any one of claims 4 to 8, further comprising dyeing means in association with said coating means to dye said blind fabric. An apparatus according to any one of claims 4 to 9, further comprising cutting o' \c'N" Y I a ~ea a LIIII a_ means to cut said blind fabric.
11. An apparatus according to any one of the preceding claims, wherein said blind fabric is a narrow woven blind.
12. A process for producing a blind fabric from an apparatus in accordance with any one of the preceding claims comprising providing warp and weft yams, crocheting said yams to make said blind fabric such that each said weft yam extends between respective first and second warp yams in a zigzag manner.
13. A process according to claim 12, further comprising knotting said weft yam at each contact with said first and second warp yams,
14. A process according to claim 12 or 13, wherei.: at least one other warp yam is provided between first and second warp yarn. A vertical blind slat made of blind fabric from a process as defined in any one of claims 12 to 14.
16. A vertical blind slat according to claim 15, wherein said blind fabric is provided 15 with dual warp yams at respective vertical edges to lock said weft yams that are adjacent said edges.
17. An apparatus for producing a blind fabric substantially as hereinbefore described with reference to Figures 3(a) to 6 of the accompanying drawings.
18. A fabric made from an apparatus according to any one of claims 1 to 11 or claim 20 17. DATED THIS 1ST DAY OF JULY 1996 i S TASS ZORBAS By his Patent Attorneys LORD COMPANY PERTH, WESTERN AUSTRALIA 1 2 ABSTRACT 3 A fabric (10) comprising warp yarns (12) and weft yarns 4 Each weft yarn (14) extends between respective first S and second warp yarns (12) in a zigzag manner. 6 An apparatus is provided for producing the fabric 7 This apparatus comprises a crochet machine (50) and a creel 8 The creel (52) feeds yarns (12, 14) to the c-rochet 9 machine The crochet machine (50) has a plurality of needles (59) for crocheting the yarns (12, 14). The creel 11 (52) has a yarn tensioning mechanism (56) at the downstream 12 part of the creel (52) to provide substantially even 13 tension to the yarns (12, 14) prior to being fed to the 14 crochet machine 15 The apparatus (50, 52) may also be provided with a 16 finishing machine (60) to provide finishing treatments to 17 the fabric o