WO2009059596A1 - Method for producing a woven fabric having at least two layers in some regions and woven fabric produced by said method - Google Patents

Abstract

The invention relates to a method, by which a woven fabric having at least two layers in some regions can be produced in a continuous weaving process. The invention further relates to a woven fabric having two layers at least in some regions produced by said method, and to uses of such a woven fabric.

Description

 A process for the preparation of at least two-ply tissue as well as tissue produced by this process

/ learn to produce a tissue at least partially two-ply fabric and fabricated by learning process tissue.

The invention relates to a method with which a partially at least two-ply fabric can be produced in a coherent weaving process. In addition, the invention also relates to an at least sectionally two-layered fabric formed by the method as well as uses of such a fabric.

As state of the art, it is known to produce multi-ply fabrics on jacquard weaving machines with two warp beams, it being possible in principle for regions not connected to one another, ie completely detached from one another, to be formed.

Moreover, it is known to produce fabrics from yarns that have a certain inherent elasticity. The total fabric produced is then determined in terms of its flexibility by the inherent elasticity of the yarns with which it is produced.

As a further state of the art highly elastic yarns are known which allow an elongation of several 100 percent, for example polyester / Lycra yarns, but which are usually classified as unsuitable for a weaving process.

The invention has for its object to provide a first method, with which a fabric can be produced, which is partially at least two layers, that is, two non-mutually bonded fabric layers, and in the partially single-layer, partially at least two-ply tissue regions can be formed, the are completely unyielding, teilnachgiebig or very compliant, so that such a fabric can be used for a variety of purposes. In particular, a fabric is to be produced which is particularly well suited for sitting or lying areas and forms pleasant sitting or reclining properties. The tissue should be highly resilient and be able to be adjusted in areas to a wide variety of requirements, for example weight loads, sinking depths and the like. This object is achieved by a method with the combination of the features of claim 1. Advantageous developments of the method will become apparent from the dependent claims 2 - 13. The claims 14 - 22 relate to a fabric produced by the method, the claims 23 - 31 different, particularly advantageous uses according to the method according to claims 1-13 fabric produced.

The process for the production of a fabric, at least two-ply fabric according to claim 1 proceeds in a coherent weaving process and is characterized by the following process steps:

• First, a jacquard weaving machine is provided with at least two warp beams, then one of the two warp beams is wound with a first yarn which is substantially inelastic. Inelastic yarns according to the invention essentially have an elongation of at most 35-40% and may for example be formed entirely from polyacrylic. But there are others

Yarns made of other materials in question.

The second warp beam is partially wound with a substantially inelastic yarn according to the above definition and partially stretchable with a yarn that has a significantly higher elasticity than the first yarn, in other words by at least 100% of its basic length is stretchable.

• Then two wefts are provided. Wherein a weft thread is substantially inelastic (as defined above "inelastic") and the other weft thread has a high elasticity with respect to the first weft thread, for example a thread as defined above as being substantially highly elastic.

• These weft threads are so injected into the looms formed by the warp threads running from the warp that the fabric layers at least partially abuts each other partially with its fabric layers, partially only partially connected to each other and partially not connected to each other and in at least one section of the fabric, a fabric layer of inelastic threads according to the above definition and an overlying or underlying fabric layer of highly elastic threads is formed, wherein the two non-interconnected fabric layers merge at the edge into interconnected fabric layers. Such a fabric is suitable, for example, to form an elastically yielding middle fabric layer in the flat-stretched state, which merges into less yielding or successively non-compliant fabric regions at the edge and under which a quasi-non-compliant "catchment fabric" is arranged is used for example as a seat element - a very advantageous Einsitzverhalten, that is, a user is resiliently intercepted by the elastic layer and sits at full load of the fabric supported by the inelastic fabric layer, which forms a "catching bag" at a short distance below the stretched elastic fabric layer ,

Such a progressive insertion behavior is normally only to be achieved by cushioning materials, in particular foams. In particular, when such foams must be transported or kept in stock, high volumes must be used, since in particular foamed oil products, but also other upholstery materials normally only in relaxed, i. voluminous state can be transported and stored. By means of the invention, it is now possible to transport and store flat fabrics which ensure a similar cushioning behavior as upholstery materials with greatly reduced space requirements.

The connection of the different fabric layers to each other can be more or less strong, i. for example, only every fifth or tenth warp thread may be incorporated into a weft of the underlying or overlying fabric plies, resulting in a relatively low hanger condition. A relatively rigid hitch condition is achieved by incorporating the warp yarns of one fabric ply into every other weft of the other fabric ply resulting in a very strong hanger. This can be done by pulling up only every other warp of a fabric layer into the other fabric layer, or by pulling up or pulling down the warp threads of both fabric layers into the other fabric layer, resulting in an extremely strong bond.

In a further development of the invention, it is provided that in at least one section of the fabric, a fabric layer exclusively of elastic threads and an overlying fabric layer is formed exclusively of inelastic threads, wherein the two fabric layers merge edge side into interconnected, formed from elastic and inelastic threads formed fabric layers , A fabric, which is produced by this method, thus consists in a preferably central region of a completely inelastic fabric layer, which in the case of using the fabric as a seat or The tension in the elastic fabric layer will cause the inelastic fabric layer located below or above it to become sagging Bends slightly from the elastic fabric layer and, for example, hangs under the elastic fabric layer like a "collection sack".

The claims 3, 4 and 5 provide in a particularly advantageous manner that graded tissue layers are provided with different connection, embrace the two separate fabric layers. Claims 6 - 9 relate to different combinations of elastic or inelastic chains and elastic or inelastic shots. This makes it possible to construct tissue layers and tissue areas in a very targeted manner, which can be adjusted by the designer of the fabric with regard to their elasticity with a wide range of variation. Fabrics produced in this way can be used in a wide variety of fields, for which reference is made to the following method claims.

The claims 10 - 12 relate to the structure of a fabric with at least three layers of fabric and the different connections of the fabric layers formed. Claims 14-22 relate to fabrics which can be produced by the process according to claims 1-13, claims 20-31 relate to particularly advantageous uses.

The uses include, in particular, areas of application that relate to seating and lying areas. In the field of use of sitting and lying arise with such multi-layered and structured in a special way fabrics completely new possibilities. For example, car seats or particularly light aircraft seats can be produced with a very good sitting comfort, whereby cushioning materials and springs arranged in the edge region of seating surfaces can be saved.

When using the fabric as seating surfaces, for example, elastic body zone areas can weave into the seats, so that a very pleasant progressive seating behavior is achieved. For the Auflagerung of sick or injured, the tissues also offer in a particularly advantageous manner. For example, sick beds can be made very flat and stored when not in use, so that, for example, in case of disaster, a variety of "padded" hospital beds (but without upholstery) can be transported from a storage location to a disaster site, and this with very low volume and Weight. Basically, too the possibility of filling the intermediate region between an inelastic and an elastic fabric layer with a so-called vacuum bag in which granular material is filled. For example, if a patient is placed on such a lying surface with a spinal injury, the contours of a body will be forced into the elastic region of the tissue. Subsequent evacuation of the vacuum bag, the granular bulk material conforms to the contour shape of the body and is fixed, so that between the two tissue layers as it were a solid storage shell for transporting a spinal injury occurs, which is covered by the elastically yielding fabric layer.

Particularly advantageously, the multilayer fabrics produced by the method can also be used as medical support corsets, as wall covering elements, as the outer skin of airbags, as transport sleeves and the like, whenever a further layer is to be present under a tensioned elastic surface or layer, which is to define a maximum indentation depth or bulge of the elastic layer.

In many areas, particularly in the field of sickness and injury storage, it may be advantageous to coat the fabric with a silver iodide-containing layer, i. This can be used wherever the tissue either comes into direct contact with the skin of a sick or injured person or is touched by many people.

The invention is explained in more detail with reference to advantageous embodiments in the drawing figures. These show:

Fig. 1 is a schematic representation of a Jacquard loom on which the inventive method can be performed.

Fig. 2 shows a longitudinal section, a two-ply fabric, wherein from top to bottom the two fabric layers a) are unconnected, b) have little attachment, c) have more attachment, d) are connected with fixed attachment, e) with very fixed attachment are connected;

3 is a longitudinal section through a three-ply fabric, wherein a) the three layers of fabric are unconnected, b) are connected with little attachment, c) are connected with fixed attachment;

Fig. 4 is a plan view of a portion of a fabric panel having zones of different hitch and elasticity;

5 is a plan view of a fabric web also with outwardly increasing connection;

Fig. 6 is a plan view of a fabric web of a third embodiment, in which elongated stiffening elements can be introduced.

First, reference is made to drawing Figure 1. The there only schematically illustrated jacquard weaving machine 1 has two warp beams 2, 3, from which warp threads 4, 5 enter the weft region 6 of the jacquard weaving machine and there are raised and lowered by the harness 7 to form sheds. In the looms weft yarns are entered, which are not visible in the representation of Figure 1.

The forming fabric 8 runs out after entry of the weft threads and compression on the left side of the jacquard loom 1 and is rolled up on a cloth beam 9. In Figure Ia, the two warp beams are shown, wherein the warp beam 3 is wound over its entire width exclusively with inelastic warp threads.

The upper warp beam 2 represented in FIG. 1b, which forms the warp I, is partially wound with inelastic warp threads 4 'and partially with elastic warp threads 4 ".

Hereinafter, reference is made to drawing Figure 2. There, a two-ply fabric is shown in different attachments. An upper fabric layer 20 and a lower fabric layer 21 are formed. The upper fabric layer 20 consists exclusively of elastic warp 4 "and elastic weft threads 10th

The lower fabric layer 21 consists exclusively of non-elastic warp threads 4 'and 5 and non-elastic weft threads 11. B ei the tissue with little attachment according to Figure 2b shows that z. B. after every eighth shot a warp thread 5 is pulled from the lower fabric layer 21 into the upper fabric layer 20 and is integrated there by the elastic weft. It is of course equally possible to pull an elastic warp thread 4 "or an inelastic warp thread 4 'or both down from the upper fabric layer 20 and to tie it into the lower inelastic weft.

In the two-ply fabric according to FIG. 2b, a reinforced attachment is achieved by attaching a lower warp thread 5 after every fourth shot. In the exemplary embodiment according to FIG. 2d, the warp thread 5 is attached to the weft 10 of the upper fabric layer 20 after every second Shot.

A very firm attachment according to Figure 2e is achieved in that alternately with each shot upper and lower warp threads are involved in each case in the other fabric layer.

In the three-ply fabric shown in FIG. 3, it is shown by way of example that all three fabric plies according to FIG. 3a can be present unconnected. The uppermost fabric layer 30 consists exclusively of elastic warp threads 4 ", the middle and lower fabric layers 31, 32 have exclusively inelastic warp threads 4 ', 5. In the upper and middle fabric layers 30 and 31, elastic weft threads 10 are inscribed into the lower fabric layer exclusively inelastic weft threads, thereby forming three fabric layers 30, 31, 32 with different elasticities.

In Figures 3b and c is now shown how, for example, the three fabric layers 30, 31, 32 can be attached to each other. In Figure 3b, only the fabric layers 30 and 31 are thereby attached to each other that a non-elastic warp thread 4 'in the elastic

Weft threads 10 of the uppermost fabric layer 30 is incorporated, the lower fabric layer 32 is detached from the two fabric layers 30 and 31. In the exemplary embodiment according to FIG. 3c, all three fabric layers 30, 31, 32 are connected in that a warp thread is inserted into each of the respective lower fabric layers in an overlying fabric layer

Weft threads is involved.

In the embodiment shown in Figure 4 is shown schematically how a fabric 40 can be formed with different zones with different elasticity. The fabric 40, which runs out of the weaving machine 1 in the direction of arrow 41, is divided, for example, into two juxtaposed regions 40a and 40b, the regions 40a and 40b being identical in the exemplary embodiment. It's just as good Of course it is possible to weave different structures of completely different elasticity and training on the two sides of the forming fabric web.

A centrally arranged region 42 is completely double-layered, i. in him, according to the sectional view in Fig. 4a, the fabric layers 20 and 21 (assuming a two-ply fabric) are separated, i. There is no connection of the two fabric layers 20, 21 in region 42. In region 43, which surrounds region 42, there is a zone with relatively little attachment according to FIG. 2b, in region 44, for example, a zone with more attachment according to FIG. 2c can be woven and in area 45 a fixed attachment zone according to FIG. 2d. The edge region 46 can be produced with a very strong attachment, for example according to FIG. 2e.

It is expressly pointed out that the zones of different connectivity and elasticity can of course also be arranged entirely differently within the fabric web. Not only can two adjacently located regions 40a and 40b be formed, just as well can only one tissue region or far more than two tissue regions be arranged in different juxtaposition. Just as well, it is also possible that the zones of different connectivity and elasticity are not lying one inside the other but next to each other, depending on the intended use of the fabric. The exemplary embodiment according to FIG. 4 can be provided, for example, for producing a seat surface, wherein the region 42 with separately present fabric webs is approximated to a seat region.

In the exemplary embodiment illustrated in FIG. 5, it is provided that the elasticity does not decrease in zones to the outside, but decreases continuously from a central region 52 through increasing binding, which is represented by the narrowing white lines in region 53, to an edge region 56 in which there is a very strong connection, for example, according to 2e.

FIG. 6 shows that a fabric can be produced which has continuously increasing outward binding in the weft direction 61, which is illustrated by the increasingly dense white lines, but in the warp direction 62 adjacent bonding zones can be formed, which are interrupted by pocket regions 63 in which there is no connection at all. If necessary, stiffening strips or the like can be inserted into the pocket regions 63. For example, the central areas 64 again exist without any connection. Which tissue area is now produced with which binding and elasticity, depends on the purpose for which the tissue is intended. As already noted above, it is possible to weave a wide variety of structures by the method according to the invention in a continuous weaving process, wherein zones of different elasticity and connection can be formed. Elastic weft and warp threads may consist of polyester or other fibers such as Lycra or elastane or of other elastic materials.

Vegetable fibers, animal fibers, mineral fibers and man-made fibers as well as mixtures thereof are suitable for the inelastic weft and warp threads. In particular, vegetable fibers may be cotton, kapok, linen, hemp, ramie, jute, manila, sisal or

Coconut, animal fibers may in particular be wool, mohair, cashmere, alpaca, llama,

Camel hair, angora and silk, mineral fibers are especially glass wool,

Rockwool and metal fibers are understood as fibers of viscose, rayon, modal, acetate, viscose rayon, polyester, polyacrylic, polyamide, polypropylene,

Trevira CS, Flamex, Kevlar and yarns with silver content. All said elastic and inelastic yarns made of corresponding materials or fibers can also be advantageously mixed with each other, i. it can make yarns out

Mixtures of vegetable and chemical fibers, vegetable and animal fibers, vegetable and mineral fibers, animal and man-made fibers and mineral and

Chemical fibers are formed.

Claims

1. A method for producing a partially at least two-ply fabric in a continuous weaving process, characterized by the following Steps: Providing a jacquard or shaft weaving machine (1) with at least two Warp beams (2, 3); Winding a warp beam (3) with a first yarn (5) that is substantially inelastic; Partially winding the second warp beam (2) with a first, substantially inelastic yarn (4) and partially with a yarn (4 ") which has a significantly higher elasticity than the first yarn (4); providing two weft yarns (10, 11 ), wherein one weft thread (11) is substantially inelastic and the other weft thread (10) is opposite to the first weft thread (11) has a comparatively high elasticity; Shooting the weft threads (10, 11) into the sheds formed by the warp threads running from the warp beams (2, 3) such that the forming, at least double-layered fabric (8) with its fabric layers (20, 21, 30, 31, 32 ) partially completely connected to each other, partially partially connected to each other and partially not connected to each other, as well as in at least a portion (42, 52, 64) of the fabric, a fabric layer of inelastic threads and an overlying fabric layer of elastic threads is formed, wherein the pass over the two fabric layers on the edge into interconnected fabric layers. 2. The method according to claim 1, characterized in that in at least one section (42, 52, 64) of the fabric (8) at least one fabric layer (20, 30) exclusively of elastic threads and an overlying fabric layer (21, 31) is formed exclusively of inelastic threads, wherein the two fabric layers at the edge in merging interconnected tissue layers formed of elastic and inelastic threads. 3. The method according to claim 2, characterized in that the area (42) of the at least two-ply fabric is surrounded by a first surrounding area (43) without mutual connection of the fabric layers, in which the fabric layers are only slightly attached to one another. 4. The method according to claim 3, characterized in that the first surrounding area (43) is surrounded by a second surrounding area (44) in which the at least two layers of fabric are compared with the first one Tissue area are more attached to each other. 5. The method according to any one of the preceding claims, characterized in that further surrounding regions (45, 46) are woven around the second surrounding region (44), in which the at least two fabric layers are substantially completely interwoven with each other. 6. The method according to any one of the preceding claims, characterized in that in fabric layers with elastic chain predominantly elastic weft thread are woven. 7. The method according to any one of the preceding claims, characterized in that in woven layers with non-elastic chain elastic weft threads are woven. 8. The method according to any one of the preceding claims, characterized in that in fabric layers with non-elastic chain not elastic weft thread and partially elastic weft thread are woven. 9. The method according to any one of the preceding claims, characterized in that the connection between a fabric layer with elastic chain and elastic weft thread as well as a fabric layer with non-elastic chain by non-elastic warp threads takes place from the fabric layer with non-elastic chain in the elastic Weft threads of the fabric layer of elastic chain and elastic weft are woven. 10. The method according to any one of the preceding claims, characterized in that a total of three-day fabric is produced, in which a fabric layer (30) has an elastic chain (4 ") and elastic weft (10), another fabric layer (31) has a non-elastic chain (4 ') and an elastic weft thread (10) and a third fabric layer (32) by a non-elastic chain (5) and a non-elastic Weft (11) is formed and the three fabric layers (30, 31 32) are connected in different tissue areas with different connection to each other, wherein at least one fabric area (42, 52, 64) is woven such that the fabric layer (30) with elastic chain and elastic weft thread without connection to the other two fabric layers (31, 32) is present. 11. The method according to any one of the preceding claims, characterized in that the two other fabric layers (31, 32) are connected to each other with non-elastic chain and the fabric layer (30) with elastic chain and elastic protective thread arranged without connection over it. 12. The method according to any one of the preceding claims, characterized in that the connection of the at least three fabric layers (30, 31, 32) is made such that a weave of a lowermost, formed from non-elastic chain and non-elastic protective thread fabric layer in the uppermost, formed of elastic chain and elastic weft fabric layer occurs. 13. The method according to any one of the preceding claims, characterized in that for introducing the elastic weft threads (10) the jacquard machine (1) has an elastic weft thread actively receiving gripper 14, in at least one edge region (46), the fabric layers (20, 21, 30, 31, 32) are connected to each other during the weaving process and in a defined tissue region (42 ) the fabric layers (20, 21, 30, 31, 32) are unbonded, and a fabric layer (20, 30) in the unbonded region (42) is formed substantially entirely of elastic warp (4 ") and weft yarns (10) and one or more underlying or overlying further fabric layer (21, 31, 32) is formed substantially entirely of inelastic threads (5, 11). 15. A fabric according to claim 14, characterized in that in the unbound tissue layers surrounding tissue regions (20, 21) the fabric layers (43, 44, 45, 46) are interwoven with different binding with each other. 16. A fabric according to any one of the preceding claims 14 or 15, characterized in that it is formed at least three layers and in the defined tissue region (42) a first fabric layer (30) is formed entirely of elastic weft (10) and warp threads (4 "), an underlying further fabric layer (31) formed from weft and warp is that compared to the weft and warp threads of the first fabric layer (32) have a reduced elasticity and a third underlying fabric layer is formed substantially completely of comparatively inelastic threads. 17. A fabric according to any one of the preceding claims 14-16, characterized in that the elastic weft (10) and warp threads (4 ") are made of polyester and Lycra. 18. A fabric according to any one of the preceding claims 14 - 17, characterized in that the inelastic weft (11) and warp threads (5) are made of polyacrylic. 19. A fabric according to any one of the preceding claims 14 - 18, characterized in that two or more juxtaposed elastic regions (42) are woven in a woven web of defined width. 20. A fabric according to any one of the preceding claims 14 - 19, characterized in that the extensibility of the elastic threads (10, 4 ") is in a range of 50 to 400%. 21. A fabric according to any one of the preceding claims 14 - 19, characterized in that the extensibility of the elastic threads (10, 4 ") is in a range of 150 to 300%. 22. Tissue according to one of the preceding claims 14 - 21, characterized in that an inner region (42) as a defined tissue region at least two non-interconnected fabric layers (20, 21), wherein a fabric layer (21) is formed from substantially inelastic weft and warp threads and the overlying or underlying further fabric layer (20) in essential only elastic Weft and warp threads is formed and the tissue area surrounding the defined inner fabric layer (43, 44, 45, 46) has an outwardly increasing bond of the at least two fabric layers to one another. 23. Tissue according to one of the preceding claims 14 - 22, characterized in that an outer edge region (46) of the fabric web is formed exclusively of inelastic warp threads (5). 24. Use of a fabric (8) according to any one of the preceding claims 14 - 23 as upholstered furniture cover. 25. Use of a fabric (8) according to any one of the preceding claims 14 - 23 as Sitting or lying surface clamped in a frame element. 26. Use of a fabric (8) according to any one of the preceding claims 14 - 23 as a disability element. 27. Use of a fabric (8) according to any one of the preceding claims 14 - 23 as a medical support corset (support stocking). 28. Use of a fabric (8) according to any one of the preceding claims 14 - 23 as a wall covering element in the vehicle or aircraft sector. 29. Use of a fabric (8) according to any one of the preceding claims 14 - 23 as the outer skin of an airbag. 30. Use of a fabric (8) according to any one of the preceding claims 14 - 23 as a transport cover, wherein between the non-interwoven fabric layers inflatable chambers or a foamable material is arranged. 31. Use of a fabric (8) according to any one of the preceding claims 14 - 23 as a sick storage, wherein between the non-interconnected fabric layers a in an evacuated shell a bed of granular material is arranged. 32. Use of elastic weft (10) or warp (4 ") with an elongation of more than 50% to form at least partially elastic fabric in a jacquard or shaft loom.