Paulato, Andrea (Via Monte Bò 32, Cene, I-24020, IT)
| 1. | A method for bestowing an appearance of an embossed type upon a fabric (1) by using elastic threads, characterized in that it comprises the following steps: stretching said fabric (1) in the warp direction (100); sewing for at least a part of the height (H) of said fabric (1) a first series of elastic threads (10) generally oriented in the warp direction (100), said first elastic threads (10) being in a state of tension; fixing to at least part of a side of said fabric (1) a second series of elastic threads (20) oriented in a state of tension in a generic weft direction (200), said fixing to said fabric (1) being performed in the region corresponding to said first elastic warp threads (10); and releasing said fabric (1) in such a way that said first series of elastic threads (10) and said second series of elastic threads (20) will recede from the state of tension to a state of nontension bestowing upon said fabric (1) said appearance of an embossed type. |
| 2. | The method according to Claim 1, characterized in that said first elastic threads of said first series (10) are sewn generally in the warp direction (100) throughout the height (H) of said fabric (1). |
| 3. | The method according to Claim 1, characterized in that said elastic threads of said second series (20) are fixed in the weft direction (200) throughout the height (H) and the extension (E) of the fabric (1). |
| 4. | The method according to Claim 2 or Claim 3, characterized in that said elastic threads of said first series (10) and of said second series (20) are, respectively, sewn and fixed throughout the height (H) and the extension (E) of the fabric (1). |
| 5. | The method according to Claim 1, characterized in that said first series of elastic threads (10) is sewn parallel to the warp direction (100). |
| 6. | The method according to Claim 1, characterized in that said second series of elastic threads (20) is fixed parallel to the weft direction (200). |
| 7. | The method according to one or more of Claims 1 to 6, characterized in that said first series of elastic threads (10) and said second series of elastic threads (20) are, respectively, sewn and fixed in the condition of maximum extension. |
| 8. | The method according to Claims 5 and 6, characterized in that said first series of elastic threads (10) and said second series of elastic threads (20) are, respectively, sewn and fixed to said fabric (1) so as to form a mesh comprising cells, the side of which, measured in the warp direction, has a length between 0.5 and 10 cm. |
| 9. | The method according to Claim 8, characterized in that said cells have a side the length of which is between 1 and 6 cm. |
| 10. | The method according to Claim 9, characterized in that said cells have a side the length of which is between 1.5 and 3 cm. |
| 11. | The method according to Claim 10, characterized in that said cells have a side measured in the warp direction of 2.5 cm. |
| 12. | The method according to one or more of Claims 1 to 11, characterized in that said elastic threads of said first series (10) and of said second series (20) are constituted by an elastomeric core coated on the outside with a spiral of nylon or polyethylene. |
| 13. | An apparatus (2) for bestowing an appearance of an embossed type upon a fabric (1), characterized in that it comprises: means for stretching (50) said fabric (1); means for translating (55) said fabric (1) in the warp direction (100); a plurality of needles (15) actuated for sewing a first series of elastic threads (10) generally in the warp direction (100), said needles (15) being arranged along at least a part of the height (H) of said fabric (1) at the front of a first side (A) thereof; first means (16) for feeding said first series of elastic threads (10) in a state of tension; an array of guides (30) for a second series of elastic threads (20) to be fixed to said fabric (1) in the location corresponding to said first series of threads (10) on a second side (B) opposite to that of said needles (15), said array (30) being generally moved in the weft direction (200) for carrying out a series of translations so as to fix to said fabric (1) each thread of said second series of threads (20) to one thread of said first series of threads; and second means (33) for feeding said second series of elastic threads (20) in a state of tension. |
| 14. | The apparatus (2) according to Claim 13, characterized in that said plurality of needles (15) is arranged on a needleholder bar (38) at the front of said first side (A) of said fabric (1), said needleholder bar (38) being operatively connected to first moving means (45), which impart thereon a reciprocating motion in the direction substantially orthogonal to said fabric (1). |
| 15. | The apparatus (2) according to Claim 13, characterized in that said array of guides (30) is actuated by moving means (40) for carrying out a first movement of translation, which determines fixing of each thread (20a, 20b) of said second series (20) to said fabric (1) in the location corresponding to one (10a, 10b) of said threads of said first series (10), and a second movement of translation, which determines fixing of each thread (20a, 20b) of said second series (20) to another thread (10b, 10c) of said first series (10). |
| 16. | The apparatus (2) according to Claim 13, characterized in that said array of guides (30) is actuated by moving means for carrying out a first movement of translation, which determines fixing of each thread (20a, 20b) of said second series (20) to said fabric (1) in the location corresponding to one (10a, 10b) of said threads of said first series (20), and a second movement of translation, which determines fixing of each thread (20a, 20b) of said second series (20) to another thread (10b, 10c) adjacent to said first series of threads (10). |
| 17. | The apparatus (2) according to one or more of Claims 13 to 16, characterized in that said array of guides (30) extends along a bar (35) operatively connected to said moving means (40) through a chaintransmission system. |
| 18. | The apparatus (2) according to one or more of Claims 13 to 17, characterized in that said guides (30) are tubular elements in each of which there slides a thread of said second series of elastic threads (20). |
| 19. | The apparatus (2) according to Claim 18, characterized in that said tubular elements are oriented according to an angle of aperture of 90° or less measured with respect to the plane of said fabric (1). |
| 20. | The apparatus (2) according to one or more of Claims 13 to 19, characterized in that said first feeding means (16) and/or said second feeding means (33) are constituted by reels and/or spools. |
| 21. | The apparatus (2) according to one or more of Claims 13 to 20, characterized in that said first feeding means (16) and/or said second feeding means (33) comprise at least one beam. |
| 22. | The apparatus (2) according to one or more of Claims 13 to 21, characterized in that said first feeding means (16) and/or said second feeding means (33) comprise a frictionclutch system (18) for stretching said elastic threads of said first series (10) and/or of said second series (20), respectively. |
| 23. | A fabric (1) with an appearance of an embossed type, characterized in that it comprises a mesh of elastic threads constituted by a first series of elastic threads (10) sewn in a state of tension in the warp direction (100) and by a second series of elastic threads (20) arranged in the weft direction (200) and fixed to said fabric (1) in the location corresponding to said threads arranged in the warp direction (100), the length (Ll) of a stretch of weft thread between its stitches for fixing to the fabric (1) in a condition of release of the tension being less than the length (L2) of the corresponding stretch of fabric (1). |
| 24. | The fabric (1) according to Claim 23, characterized in that said mesh is constituted by cells, the side of which measured in the warp direction has a length of between 0.5 and 10 cm. |
| 25. | The fabric (1) according to Claim 24, characterized in that said side measured in the warp direction has a length of between 1 and 6 cm. |
| 26. | The fabric (1) according to Claim 25, characterized in that said side measured in the warp direction has a length of between 1.5 and 3 cm. |
| 27. | The fabric (1) according to one or more of Claims 23 to 26, characterized in that the fixing stitches of each thread in the weft direction are made in two locations corresponding to two adjacent warp threads (10). |
| 28. | Use of the fabric of an embossed type according to Claims 23 to 27 for upholstery covering of armchairs, sofas and other similar articles of furniture. |
EMBOSSED TYPE UPON A FABRIC
DESCRIPTION
The present invention relates to a method and an apparatus to be used for bestowing an appearance of an embossed type upon a fabric in order to enable its use preferably in the field of the fabrication of covering elements for furnishing components such as, for example, upholstery covers for armchairs, sofas or other similar articles of furniture, hi the field of domestic furnishing, in the course of the last few years there has been a widespread use of fabrics having an embossed appearance, where by the term "embossed" is meant an effect of curling bestowed upon a fabric that is originally flat in order to bring about a series of reliefs and cavities on the surface of the fabric itself as illustrated, for example, in Figure 1. In the course of the description, also the expression "embossed fabric" will be used for convenience to indicate precisely this particular conformation. Likewise, the expression "embossing method" and "embossing apparatus" will be used to mean, respectively, a method and an apparatus for bestowing an embossed appearance upon a fabric. Currently known embossing methods are essentially based upon the use of heat-shrinkable elastomers which are inserted in the fabric during plane weaving of the same by means of traditional looms such as, for example, shuttle ones or air ones. The elastomers are usually arranged in the weft direction and warp direction so as to obtain squares throughout the height of the fabric, hi output from the loom the fabric presents a smooth and generally homogeneous conformation and is ready for the subsequent operation of cutting. To obtain the embossed appearance, once the fabric has been cut to size, it is subjected to a finishing treatment, generally using hot air, during which the elastomers undergo a contraction following upon the heating action. This contraction brings about the desired surface curling of the fabric, the final effect whereof, which may be more or less accentuated, depends not only upon the distribution of the elastomers within the fabric, but also upon the times and temperatures at which the finishing treatment has been carried out.
The method for producing embossed fabrics just described and other currently known methods, albeit relatively effective, presents, however, a considerable limit represented by the restricted range of use. In fact, this method is not very suited to being used in printed fabrics in so far as the operation of printing, as is known, involves the use of machines operation of which is accompanied by a heating action carried out at even beyond 12O 0 C. At such temperatures, there occurs a non-controllable alteration in the mechanical properties of the elastomers which are basically "ironed" at a high temperature, thus losing the capacity for i
elastic shrinkage that is responsible for the embossing effect. In fact, this decay in elastic properties is brought about already at temperatures above 30°-40°C.
There is hence felt the need of having available a new method and new equipment for bestowing an embossed appearance upon a fabric that will enable this major drawback typical of traditional methods to be overcome.
Consequently, the primary task of what forms the subject of the present invention is to provide a new method for bestowing an appearance of an embossed type upon a fabric.
In the context of this task, a purpose of the present invention is to provide a method for bestowing an appearance of an embossed type upon a fabric, which will be applicable to any type of fabric.
Another purpose of the present invention is to provide a method for bestowing an appearance of an embossed type upon a fabric that will be implementable through a reduced number of operations, which can be performed easily at competitive costs.
Another task of what forms the subject of the present invention is to provide an apparatus for embossing, as well as an embossed fabric that will be highly reliable and relatively easy to produce at competitive costs.
The above tasks and purposes are achieved through a method for bestowing an appearance of an embossed type upon a fabric by using elastic threads, characterized in that it comprises the following steps: stretching the fabric in the warp direction; sewing for at least a part of the height of the fabric a first series of elastic threads generally oriented in the warp direction, these elastic threads being in a state of tension; fixing to at least part of a side of the fabric a second series of elastic threads oriented, in a state of tension, in a generic weft direction, said fixing of the fabric being performed in the region corresponding to the warp threads; and releasing the fabric in such a way that the first and second series of threads will recede from the state of tension to a state of non-tension, thus bestowing upon the fabric the embossed appearance.
The embossing method according to the invention can advantageously be applied to any type of currently known fabric, as well as to the textile product known as "non-woven fabric". In fact, the application of the elastic threads, which are responsible for the embossing effect, is made on a fabric already formed, and this enables to cover a very extensive range of applications so as to satisfy a practically unlimited number of requirements. Further characteristics and advantages of the invention will emerge more clearly from the
description of preferred, but non-exclusive, embodiments of the method, of the apparatus, and of the fabric according to the invention, illustrated by way of example in the annexed drawings, in which:
Figure 1 is a view corresponding to an embossed fabric obtained with the method and apparatus according to the invention;
Figure Ia is a schematic view corresponding to a possible disposition of elastic threads during a possible implementation of an embossing method according to the invention;
Figures Ib and Ic are a first schematic view and a second schematic view of an embossed fabric produced, respectively, with a first embodiment and a second embodiment of the method according to the invention;
Figure 2, 2a and 2b are, respectively, a first schematic view, a second schematic view, and a third schematic view corresponding to a possible embodiment of an apparatus according to the invention;
Figures 2c, 2d, 2e and 2f are schematic illustrations that represent the working principle of an apparatus for embossing according to the invention;
Figure 4 and 4a are views of an embossed fabric according to the invention; and
Figures 4b and 4c are a first schematic view and a second schematic view of an embossed fabric according to the invention, respectively, in a state of tension and in a state of non-tension.
The embossing method according to the invention envisages the use of elastic threads and can be applied to any type of fabric normally produced in the textile sector. With reference to Figure Ia, the method comprises a first step in which a fabric 1 already formed is stretched in the warp direction (designated by reference number 100). The method subsequently envisages sewing on the fabric 1 a first series of elastic threads 10 subjected to a state of tension, hi particular, these first elastic threads 10 are sewn generally in the warp direction 100 on at least a part of the height H of the fabric 1.
The embossing method according to the invention envisages fixing to the fabric a second series of elastic threads 20, which are also subjected to a state of tension. Said second elastic threads 20 are oriented according to a generic weft direction 200 and are fixed to the fabric 1 in the region corresponding to the first elastic threads 10 oriented in the warp direction 100. hi the course of the description, for reasons of convenience, also the expressions "elastic warp threads" and "elastic weft threads" will be used to indicate, respectively, the threads of said first series 10 and of said second series 20 of elastic threads. The steps of sewing of the warp threads 10 and of fixing of the weft threads 20 just indicated
can advantageously be performed simultaneously, for example using an apparatus for embossing like the one described in what follows. In an alternative embodiment the two steps could, however, be performed also in succession.
After these two initial steps of sewing and fixing, the method envisages the release of the fabric 1 in such a way that said first series 10 and said second series 20 of elastic threads will recede from the state of tension to a state of non-tension for bestowing, with their action of shrinkage, the desired embossed appearance.
From what has been said so far, it emerges how the method indicated is altogether innovative in so far as it envisages the application of elastic threads on a fabric already formed and not during its formation, as is instead the case in traditional embossing methods. This means that the elastic threads can advantageously be applied on any type of currently known fabric, also including fabrics already comprising elastic filaments.
Figure Ib regards a first possible disposition of the elastic threads on the fabric 1. In particular, the first series 10 of elastic threads is sewn throughout the height of the fabric H and in particular parallel to the warp direction 100; the second series 20 of elastic threads is, instead, fixed to the fabric 1 parallel to the weft direction 200 throughout its extension E. The two series of elastic threads 10 and 20 in Figure Ib are arranged in such a way as to provide a mesh comprising cells, the side of which, measured in the warp direction 100, has a length of between 0.5 cm and 10 cm and preferably between 1 cm and 6 cm. During implementation of the method, it was noted that the embossing effect is particularly homogeneous and aesthetically more appreciable when the length of said side is comprised between 1.5 cm and 3 cm and, in particular, when it is 2.5 cm. It should be emphasized that the sizes just indicated are measured when the fabric and the elastic threads applied thereon are in a condition of maximum extension.
According to a preferred embodiment, the length of the sides of the cells in the weft direction 200 substantially corresponds to that of the side in the warp direction so as to generate cells of a substantially square shape or in any case a rectangular and/or trapezoidal shape. Falling moreover within the field of the inventive idea is the possibility of sewing and fixing the first series of elastic threads 10 and the second series of elastic threads 20, respectively, according to arrangements different from the one indicated above. In Figure Ic, for example, the elastic warp threads are sewn into the fabric 1 along just one part of its height H, whereas the elastic weft threads are fixed to the fabric along just one part of its extension E. Another task of the present invention is to provide an apparatus 2 for bestowing an appearance of an embossed type upon a fabric 1. Figures 2, 2a, 2b and 2c are schematic
illustrations indicating the essential parts constituting the apparatus 2 according to the invention.
With reference in particular to Figure 2, the apparatus 2 comprises stretching means 50 and translating means 55 acting on the fabric 1, which, by co-operating with one another, stretch and translate the fabric 1 substantially in the warp direction 100. With reference to Figure 2b, for said purpose a plurality of rollers 11, 12, 13 can be used, which stretch the fabric 1 on a framework 14. A first roller 11 is advantageously braked for the purpose of stretching the fabric 1 pulled in the warp direction 100 through a second roller 12 and a third roller 13 set adjacent to one another. Of course, what is illustrated schematically in Figure 2c is only one possible embodiment of the stretching means 50 and translating means 55 so that any other alternative embodiment must in any case be considered as forming part of the invention. A plurality of needles 15 is arranged on a needle-holder bar 38 along at least a part of the height H of the fabric 1 at the front of a first side A thereof (see Figure 2b). The needles 15 are used for sewing a first series 10 of elastic threads in the warp direction 100 and can advantageously be of the "lance" type particularly suitable for penetrating into the fabric 1 so as to apply stitches according to the "chain-stitch" modality already known in the sector. The needle-holder bar 38 is moved via first moving means 45, which basically impart a reciprocating motion on the needles 15 in a direction substantially orthogonal to the fabric 1, as may be noted again in Figure 2b.
The apparatus 2 further comprises first feeding means 16, which are used for feeding and tensioning each of said first elastic threads 10 in the location corresponding to one of said needles 15. These first feeding means 16 can be constituted by a plurality of reels or spools, each of which is designed to feed and tension an elastic thread operatively connected to one of said needles 15. These first means 16 can alternatively be replaced by beams, which are normally used in the textile industry in particular in weaving looms. Each of these means just indicated or other equivalent and known ones are advantageously integrated with friction clutch systems 18, which have the function of guaranteeing tensioning of the corresponding elastic threads.
With reference to Figures 2a and 2b, set at the front of a second side B of the fabric 1 is an array of guides 30, which is moved in the weft direction 200 for performing a series of translations having the purpose of fixing to the fabric 1 each thread of said second series of elastic threads 20 to a thread of said first series 10. According to a preferred embodiment, the second array of guides 30 preferably extends along a bar 35, and in particular each guide 30 is constituted by a tubular element oriented in the direction of the fabric according to an angle of
aperture φ of 90° or less measured with respect to the plane of the fabric 1. Like the plurality of needles 15, also the array of guides 30 is operatively connected to second feeding means 33 for the purpose of tensioning the second series 20 of elastic threads. These second means 33 can advantageously be altogether equivalent to the ones indicated above used for tensioning the elastic warp threads 10.
In the solution illustrated in Figure 2c, the fabric 1 is translated and worked in a substantially vertical plane, and moving of the needles 15 occurs in a substantially horizontal plane. Likewise to be deemed in any case as forming part of the invention is the possibility of translating the fabric in a different plane, for example the horizontal one, obviously varying the direction in which the needles 15 are moved.
The array of guides 30 is moved by the corresponding moving means 40 so as to perform predefined movements of translation. In particular, a first movement of translation has the purpose of fixing each thread of said second series 20 to the fabric 1 in the location corresponding to a first warp thread 10a. For said purpose, the first movement of the guides 30 is performed as a sort of reciprocating motion advantageously synchronized with the movement of translation of the fabric 1 and with the reciprocating movement of sewing of the needles 15. As may be inferred from Figure 2c, the combination of the movement of the fabric 1 with the motion of the guides 30 creates a substantially "zigzag" disposition of each weft thread 20 in the region around a warp thread 10. The simultaneous action of the needles 15 enables not only sewing of each warp thread 10 to the fabric 1, but also fixing of each weft thread 20 to the fabric itself. Basically, each weft thread 20 is fixed to the fabric 1 by sewing of a warp thread 10.
According to a preferred embodiment of the invention, the array of guides 30 is subjected to a second pre-defined movement of translation having the purpose of enabling fixing to the fabric 1 of each weft thread 20 in the location corresponding to another warp thread 10. For a better understanding of the meaning of this second movement of translation, reference may be made to Figures 2d, 2e and 2f, which illustrate the behaviour of two adjacent guides 30a and 30b subjected to the defined movements of translation. In Figure 2d, the two guides 30a and 30b undergo the first reciprocating movement of translation in the location corresponding to a first warp thread 10a and of a second warp thread 10b, respectively. Through this first movement, basically a first weft thread 20a is fixed to the fabric in the location corresponding to a first warp thread 10a, and a second weft thread 20b is fixed in the location corresponding to a second warp thread 10b.
This first movement lasts until each weft thread 20a and 20b has been fixed to the fabric for a
length Dl, after which the guides 30a and 30b are subjected to the second movement of translation of amplitude D2, which displaces the range of action of the two guides 30a and 30b. In particular, the range of action of the first guide 30a is displaced in the region corresponding to the second warp thread 30b, and that of the second guide 30b is displaced in the region around a third warp thread 30c adjacent to the second thread 30b (see Figure 2e). The guides 30a and 30b are then again subjected to the first movement of translation, enabling fixing for a stretch D3 of the first weft thread 20b in the location corresponding to the second warp thread 10b and fixing of the second weft thread 20b in the location corresponding to the third warp thread 10c. With reference to Figure 2f, the guides can then be brought back into the initial position of Figure 2d via said second movement of translation made in the direction opposite to the previous one.
The combination of the two movements of translation basically enables creation of a mesh of elastic threads on one side of the fabric 1, bestowing thereupon elasticity in the weft direction 200 and warp direction 100.
With reference once again to Figures 2d, 2e and 2f already referred to, the three operating distances designated as Dl, D2 and D3 can vary according to the operating requirements and the movements can be advantageously adjusted via the means 40 for moving the guides 30. A further task of what forms the subject of the present invention is to provide a fabric 1 with an appearance of an embossed type to be used preferably, but not exclusively, for the fabrication of covering elements for furnishing components, such as, for example, upholstery covers for armchairs, sofas, and the like.
Figure 4 shows a possible embodiment of the fabric 1 according to the invention, which is characterized in that it comprises a mesh of elastic threads constituted by a first series 10 of elastic threads sewn in a state of tension in the warp direction 100 and by a second series 20 of elastic threads arranged in the weft direction 200 and fixed to the fabric 1 in the location corresponding to the threads arranged in the warp direction. The mesh illustrated is constituted by cells in which each thread set in the weft direction 200 is fixed to the fabric 1 in two locations corresponding to two adjacent warp threads.
What has been just described is to be understood, however, as a preferred embodiment of the fabric 1; in fact, it is possible for each thread in the weft direction 200 to be fixed to the fabric 1 in two locations corresponding to two non-adjacent warp threads.
The mesh of elastic threads preferably comprises substantially rectangular cells, the side of which, measured in the warp direction, has a length of between 0.5 cm and 10 cm and preferably of between 1 cm and 6 cm. A particularly homogeneous embossing is achieved
when the length of said side is between 1.5 cm and 3 cm.
From Figure 4a, the two sides of an embossed fabric 1 according to the invention may be noted. In particular, on the side B of the fabric the mesh of elastic threads is evident, whilst on the side A the embossing generated by the mesh itself is, instead, evident.
Figures 4b and 4c are schematic illustrations of an embossed fabric according to the invention. In particular, Figure 4b corresponds to a fabric 1 subjected to a state of tension both in the weft direction 200 and in the warp direction 100. Figure 4c, instead, corresponds to a cross section of a fabric 1 in a condition of release of the tension. From a comparison of the two figures, it may be noted how, according to the invention, the length Ll of a stretch of weft thread 20 between two fixing stitches is less than the length L2 of the corresponding stretch of fabric 1 comprised between the same fixing stitches. This particular condition enables the embossed effect of the fabric 1 to be obtained, i.e., the desired curling.
The elastic threads used in the fabrication of the fabric 1 can be of a different structure and material. In a preferred embodiment, these are constituted by an elastomeric core coated on the outside with a spiral of nylon or polyethylene for bestowing thereon a higher mechanical resistance. Particularly advantageous has proven the use of elastomers made of latex or a material chosen between polyester and polyether. Falling in any case in the inventive idea is the use of any other functionally equivalent material.
The technical solutions adopted in the present invention enable the pre-set tasks and purposes to be fully achieved. In particular, the embossing method is applicable to any type of known fabric and is performed through a limited number of operations. The apparatus according to the invention enables the embossing effect to be obtained through a substantially "cold" processing of a fabric already formed without the use of treatments of hot finishing like the ones currently used.
In practice, the materials used, as well as the contingent dimensions and shapes, may be any whatsoever according to the requirements and the state of the art.