AU673580B2

AU673580B2 - Fabric, and apparatus and method for producing a fabric

Info

Publication number: AU673580B2
Application number: AU60573/94A
Authority: AU
Inventors: Tass Zorbas
Original assignee: Individual
Current assignee: Individual
Priority date: 1993-04-20
Filing date: 1994-04-20
Publication date: 1996-11-14
Anticipated expiration: 2014-04-20
Also published as: AU6057394A

Description

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (Original) APPLICATION NO:

LODGED:

COMPLETE SPECIFICATION LODGED:

ACCEPTED:

PUBLISHED:

tor .0 0 S.

S.

RELATED ART: NAME OF APPLICANT: ACTUAL INVENTOR(S): ADDRESS FOR SERVICE: INVENTION TITLE: TASS ZORBAS TASS ZORBAS KELVIN LORD AND COMPANY, Patent Trade Mark Attorneys, of 4 Douro Place, West Perth, Western Australia, 6005, AUSTRALIA.

"FABRIC, AND APPARATUS AND

METHODFORPRODUCINGAFABRIC"

ASSOCIATED PROVISIONAL APPLICATON DETAILS: Australian Provisional Application No. PL 8367 filed 20.4.93 The following Statement is a full description of this invention including the best method of performing it known to me/us: The present invention relates to an apparatus for producing a fabric, a method of producing a fabric, and a fabric.

In accordance with a first aspect of the present invention there is provided an apparatus for producing a fabric comprising: a first weft bar; a second weft bar; drive means to impart movement to said second weft bar; first weft yarn guides arranged to be provided on said first weft bar to guide first weft yams; second weft yam guides arranged to be provided at least at a first location on said second V. weft bar to guide second weft yarns; o*.o wherein said first weft yarns are crocheted with warp yarns to produce a main body portion of said fabric and said movement imparted to said second weft bar by said drive means enables said second weft yams to be crocheted with warp yams to produce a pattern which is relatively more open than that of said main body portion such that a substantially scallop or lace pattern is produced at least at one edge of said fabric.

In accordance with a second aspect of the present invention there is provided a method of producing a fabric comprising: providing a first weft bar; 20 providing a second weft bar; providing drive means to impart movement to said second weft bar; providing a warp bar; arranging first weft yam guides on said first weft bar to guide first weft yams; arranging second weft yam guides at least at a first location on said second weft bar to guide second weft yams; feeding first weft yams to said first weft yam guides; feeding second weft yearns to said second weft yam guides; feeding warp yams to said warp bar; crocheting said first weft yams and warp yams to produce a main body portion of said fabric; and imparting movement to said second weft bar via said drive means to crochet said second weft yarns with warp yarns to produce a pattern which is relatively more open than that of said main body portion such that a substantially scallop or lace pattern is produced at least at one edge of said fabric.

In accordance with a third aspect of the present invention there is provided a fabric comprising: first weft yarns extending between respective first and second warp yarns in a zig zag manner to form a main body portion of said fabric; and second weft yarns crocheted with warp yarns to produce a pattern which is relatively more open than that of said main body portion such that said fabric is provided with a substantially scallop or lace pattern at least at one edge of said fabric.

The present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a crochet machine incorporating an embodiment of an apparatus in accordance with one aspect of the present invention; Figure 2 is a cross-sectional side view of the first and second weft bars of the apparatus seen in Figure 1; *20 Figure 3 is a perspective view of the first and second drive mechanisms of the second weft bar of the apparatus seen in Figure 1; lrure 4(a) is a side view of a conventional crochet needle; Figure 4(b) is a side view of an embodiment of a modified crochet needle used in the apparatus seen in Figure 1.

Figure 5 is a side elevation view of a machine incorporating the apparatus of the present invention and a creel for making fabric in accordance with the present invention; Figures 6(a) to 6(d) are front and rear views of a blind slat having "double" lace pattern edges; Figures 7(a) to 7(d) are front and reward view of a blind slat having "single" lace pattern edges; and Figures 8(a) to 8(d) are front and rear views of a blind slat having "scallop" pattern edges.

In Figures 1 to 3 there is shown an apparatus 10 for producing a fabric. The apparatus 10 forms part of a crochet machine 100, which can be seen in Figure 1.

The apparatus 10 comprises a first weft bar 12, a second weft bar 14, first and second drive mechanisms 16 and 18 to impart movement to the second weft bar 14, and a first set and a second set of weft yam guides 20 and 22, respectively, arranged to be provided on the first weft bar 12 and the second weft bar 14, respectively.

In Figure 2, five alternative positions for the first weft bar 12 are shown at positions "1" to in Figure 2 the first weft bar 12 is shown at position The second weft bar 14 is shown at position The first weft bar 12 is a fixed movement weft bar, This means that its movement is restricted to reciprocating (in its longitudinal direction) from side to side in the direction across the machine 100. The second weft bar 14 is a controllable movement weft bar.

This means that its movement can be controlled to a greater degree to impart the desired movement to it.

The drive arrangements which impart movement to the first and second weft bars 12 and 14 are housed in a drive box 102 of the machine 100.

20 The drive arrangement of the first weft bar 12 may be of conventional type used in existing crochet machines and so will not be herein described.

The drive arrangement 24 of the second weft bar 14 is shown in Figure 3 and comprises the drive mechanism 16 and the drive mechanism 18, The drive arrangement 24 comprises a cam arrangement 26 provided on a rotatable shaft 28 which are common to the firs and second drive mechanisms 16 and 18, The cam arrangement 26 rotates with the rotatable shaft 28.

The drive mechanism 16 comprises a shaped arm arrangement 30 having three arms 30b and 30c, A cam follower (wheel) 32 is rotatably held by the arm 30a such that it is in contact with the cam arrangement 26. The arm 30b is pivotally attached to a linkage member 34 which forms part of the second weft bar 14.

The arm 30c is provided with a collar 36 which can turn about a rod 38. In this way, the arm 30c and thereby the arm arrangement 30 can pivot about the rod 38.

The drive mechanism 16, as hereinabove described, may be of conventional form as used in existing crochet machines.

The drive mechanism 18 comprises an shaped arm arrangement member 40 having two arms 40a and 40b, A cam follower (wheel) 42 is rotatably held by the arm 40a such that it is in contact with the cam arrangement 26. The arm 40b is pivotally attached to a linkage member 44 which forms part of the second weft bar 14. A slot 46 is provided in the arm 40b such that the point of attachment of the arm 40b to the linkage member 44 can be adjusted. This is done by way of a nut 48 which is threadedly engaged on a bolt which extends from the linkage member 44 through the slot 46. A rod 52 extends through a hole in the arm 40b, between the cam follower 42 and the slot 46. This allows the arm 40b and thereby the arm arrangement 40 to pivot about the rod 42.

With the two cam followers 32 and 42 of the respective first and second drive mechanisms 16 and 18 in contact with the rotating cam arrangement 26, the arms 30c and 40b of the drive mechanisms 16 and 18 are able to pivot independently to impart a double action movement effect to the second weft bar 14.

20 The machine 100 may be an automatic crochet machine, This type of machine is conventionally designed for producing a stretch fabric or elastic.

The apparatus 10 which is incorporated into the crochet machine 100 enables the fabric of the present invention to be produced.

Additionally, for the apparatus 10 of the present invention the gaps of the needle hooks 104 of the crochet machine 100 are reduced to prevent them from picking up weft yams when the crochet machine 100 is in operation. The difference between the needle hooks 104 before and after modification is shown in Figures 4(a) and respectively.

Further, fbr the apparatus 10 of the present invention the elastic feed is removed from the conventional crochet machine 100.

Figure 5 schematically shows a crochet machine 100 incorporating an apparatus 10 in accordance with the present invention and a creel 120 for feeding yam to the apparatus in the crochet machine 100. In conventional manner, the creel 120 comprises rollers 122 carrying the warp and weft the yam (60 and 62) that are to be fed to the machine 100.

However, in contrast to conventional creels, the creel 120 has a tensioning mechanism comprising tension springs and washers 124, through which the yarn (60 and 62) is fed, provided at the downstream end 126 of the creel 120.

This is in contrast to conventional creels which employ tension springs adjacent the actual yam rollers at the side of the creel, The yam tensioning mechanism of the creel 120 of the present invention provides reduced tension in the yam along with an even tension in the warp yam as it is fed from the creel 120 to the machine 100, in contrast to conventional creels.

The fabric is crochet stitched by the apparatus 10 in the crochet machine 100 in the appropriate pattern, as exemplified in Figures 6(a) to 8(d), The fabric made in accordance with the present invention may be used as vertical blind slats.

The present invention enables such blind slats to be produced with a scallop or lace pattern at the edges, and with substantially flat, "filled-in" main body portions.

20 Figures 6(a) to 8(d) show examples of scallop or lace pattern edges which can be produced.

Figures 6(a) to 8(d) show embodiments of blind lats made in accordance with the present invention, Figures 6(a) to 6(d) show a blind slat having "double" lace edges, Figures 7(a) to 7(d) show a blind slat having "single" lace edges, and Figures 8(a) to 8(d) show a blind slat having scallop edges.

The method of producing fabric in accordance with the present invention will now be described with particular reference to the fabric being blind slats as shown in Figures 6(a) to 8(d).

The machine 100 is arranged to receive warp yarns from the rollers 122 of the creel 120.

The warp yams are collectively represented in Figure 1 by the heavy arrow 60. the number of warp yams 60 provided is dependent upon the width of the fabric to be made, Further, the number of warp yams 60 determines the width of the fabric that will be made.

The warp yams 60 are fed to a warp bar (not shown) in conventional manner.

Similarly, weft yarns, collectively represented in Figure 1 by the heavy arrows 62a and 62b, are fed from the rollers 122 of the creel 120 to the first weft bar 12 and the second weft bar 14, respectively, The first weft bar 12 is provided with first weft yam guides 20 which extend along the first weft bar 12 For a distance M which will determine the width of the main body portion of the fabric to be made, As hereinbefore stated, the first weft bar 12 is a fixed movement weft bar and its movement creates the main body portion of the fabric. This is done by crocheting the weft yams 62a with the warp yams 60. This is done in accordance with the process described in the Applicant's co-pending Australian Complete Patent Application No.

44878/93, the disclosure of which is hereinto incorporated by way of reference thereto.

In accordance with the process described in Application No. 44878/93 weft yams 62a extend laterally between pairs of respective first and second warp yams 60 in a zigzag 20 manner, with the weft yarns 62a turning at each contact with the respective first and second warp yarns 60. This may be done such that there are other (third, fourth, etc) warp yams 60 intermediate the pairs of respective first and second warp yarns Alternatively, the warp and weft yams 60 and 62a, respectively, may be crocheted such that there are no warp yams 60 between the pairs of respective first and second warp yarns 60, In the case that there are third or fourth, etc warp yarns 60 intermediate the pairs of respective first and second warp yarns 60, the warp yams 60 are not distinct.

Thus, for example, if there is a single third warp yam 60 intermediate pairs of respective first and second warp yams 60, the third warp yams also form respective first and second I wa 'p yarns 60 with other warp yarns 60. Each weft yarn 62a is knotted, stitched or en( apsulated by the respective first and second warp yams 60 (and any intermediate warp yars The movement of the first weft bar 12 produces a main body portion of the fabric which is relatively dense and opaque.

The weft yams 62b are fed to the second weft bar 14, The second weft bar 14 is a controllable movement weft bar. The second weft bar 14 is provided with second weft yam guides 22 positioned at locations corresponding to where the scallop or lace pattern is desired on the fabric to be produced.

Where such a pattern is required at both edges of the fabric (which is normally the case), then the second weft yam guides 22 are provided at two locations on the second weft bar 14. The respective innermost ends of the second weft yarn guides 22 at the two locations are spaced apart by the distance M and are laterally in registration with the two ends of the first weft yarn guides 20, respectively, Alternatively, if the pattern is required at only one edge of the fabric, then the second weft yam guides 22 are provided in the same manner as above described but at only one of the two locations.

Due to the nature of the movement of the second weft bar 14, which is determined by the first and second drive mechanisms 16 and 18, the second weft yarns 62b arc crocheted 20 with the warp yrns 60 to produce a scallop or lace pattern.

The weft yars 62a and 62b are crocheted with the warp yarns 60 in a chain stitch macner with the weft yams 62a and 62b extending across the warp yams 60 in a zigzag manner.

The type of pattern which is produced by the second weft yarns 62b on the second weft bar 14 is determined by the number of second weft yarn guides 22 provided and also the number of warp yars 60 provided to crochet with the second weft yars 62b carried by those second weft yam guides 22, Additionally, the cam arrangement 26 may be provided with different cams to control the pattern created at the edges of the fabric, enabling a more open pattern to be c eated.

I By way of example, Figures 6(a) 6(d) show a blind slat 70 with "double" span lace edges. The main body portion 71 of the slat 70 is formed by warp yarns 60 and first weft yams 62a. The "double" lace edges shown by the letter D are formed by two warp yarns near the edges of the slat 70 and are spanned by second weft yarns G2b. As can be seen, the second weft yarns 62b are provided in a relatively more open pattern than the first weft yarns 62a which form the main body portion 71 of the slat 70. Second weft yams 62b extend across two warp yams 60 at each side edge of the main body portion 71 of the slat Figures 7(a) 7(d) show an embodiment of a slat 72 which has "single" span lace edges.

Such a slat 72 can be produced by removing one of the warp yams 60 from each side edge of the arrangement used to produce the slat 70. When these are removed, the second weft yarns 62b extend from each edge of the main body portion 73 of the slat 72 to span a single warp yam 60 to form a "single" lace pattern at each edge of the slat 72 shown by the letter S. This can be seen in Figures 7(a) where the second weft yams 62b extend at each side edge from the main body portion 73 across only a single warp yarn In Figures 8(a) there is shown a blind slat 74 with "scallop" pattern edges. These are produced by additionally removing another warp yarn 60 from each side edge of the arrangement used to make the blind slat 72.

Additionally, a bulkier second welt yam 62b is used as compared with the first weft yarn 20 62a which makes up the main body portion 75 of the blind slat 74. Since the outer warp yams 60 have been removed, the second weft yarns 62b cannot crochet with warp yarns and so the second weft yams 62b merely return to stitch with the warp yarns 60 which form the outermost warp yarns 60 of the main body portions 75 of the blind slat 74. This then produces the scallop pattern edges shown by the letter C which can been seen in Figures 8(a) 8(d).

In making the scallop pattern edged blind slat 74, the body portion 75 of the blind slat 74 can be made using first warp yam 62a of 150 X 2 denier whilst the second weft yar 62b can be a 600 1200 denier 2 ply yarn.

II

Due to the cam arrangement 26 and the provision of the first and second drive mechanisms 16 and 18, the second weft bar 14 is able to move in a manner which permits a more open fabric to be produced. This open fabric is created at the edges of the main body of the fabric to produce the lace and scallop pattern edges as shown in Figures 6(a) 8(d).

In this way, the main body portion of the fabric produced by the first set of weft yarns is substantially opaque. In contrast, the lace or scallop pattern at the edges is produced by the second weft yarns relatively open and can be seen through and provides an aesthetic feature to the fabric which is particularly appealing in vertical blind slats.

Modifications and variations such as would be apparent to a skilled addressee are deemed within the scope of the present invention, p li *e~ *r «r

Claims

1. An apparatus for producing a blind fabric comprising: a first weft bar; a second weft bar; drive means to impart movement t( said second weft bar; first weft yan guides arranged to be provided on said first weft bar to guide first weft yarns; second weft yar guides arranged to be provided at least at a first location on said second weft bar to guide second weft yarns; wherein said first weft yarns are crocheted with warp yarns in a zig zag manner to produce a main body portion of said blind fabric and said movement imparted to said second weft bar by said drive means enables said second weft yarns to be crocheted with warp yarns to produce a pattern which is relatively more open than that of said main body portion such that a substantially scallop or lace pattern a produced at least at one edge of said blind fabric.

2. An apparatus according to claim 1, wherein said second weft yarn grides on said S second weft bar have an innermost end which is laterally substantially in registration with an outermost end of said first weft yarn guides on said first weft bar.

3. An apparatus according to claim 1 or 2, wherein said srcond weft yarn guides are provided at two locations on said second weft bar, the respective innermost ends of said 0 0 sccond weft yarn guides at said two locations spaced by a distance substantially equal to the distance that the first weft yarn guides extend along said first weft bar and the respective innermost ends of said second weft yarn guides at said two locations being laterally substantially in registration with the two ends of said first weft yarn guides on said first weft bar.

4. An apparatus according to any one of claims 1 to 3, wherein said drive means provides a double action movement effect to said second weft bar.

An apparatus according to claim 4, wherein said drive mecns comprises rotatable cam means and first and second drive mechanisms, said first and second drive lr I~ n, _JI 12 mechanisms comprising respective first and second pivotal arm means connected with said second weft bar at respective first and second locations and provided with respective first and second cam followers arranged to contact said cam means such that as said cam means rotates said first and second pivotal arm means pivot independently to impart said double action movement effect to said second weft bar.

6. An apparatus according to claim 5, wherein said cam means may be provided witl, different cams to control the pattern created at said edge of said fabric.

7. An apparatus according to any one of claim 1 to 6, wherein the number of second weft yarn guides and the number of warp yarns provided to crochet therewith determines the said pattern produced at said edge of said fabric.

8. An apparatus according to claim 7, wherein a double lace pattern is produced at said edge of said fabric by providing a pair of warp yarns on at least one side of the warp yarns which are used to produce said main body portion of said fabric, said pair of warp yarns crocheting with second weft yarns.

9. An apparatus according to claim 7, wherein a single lace pattern is produced at said edge of said first fabric by providing a single warp yarn on at least one side of the warp yarns which are used to produce said main body portion of said fabric, said single warp yarns crocheting with second weft yarns. o

10. An apparatus according to claim 7, wherein no warp yarns are provided at each side of the warp yarns which a;e used to produce said main body portion of said fabric, said second weft yarns unable to crochet with warp yarns beyond the edges of said main body portion such that a scallop pattern is produced at said edge of said fabric.

11, An apparatus according to any one of claims 1 to 10 wherein the gaps of needle hooks used in the first and second weft yarn guides are reduced to prevent them from picking up weft yarns.

12, A method of producing a blind tabric using the apparatus according to any one of claims 1 to 11 comprising: providing a first weft bar; I I b C- providing a second weft bar; Providing drive means to impart movement to said second weft bar; providing a warp bar; arranging first weft yarn guides on said first weft bar to guide first weft yarns; arranging second weft yarn guides at least at a first location on said second weft bar to guide second we.t yarns; feeding first weft yarns to said first weft yarn guides; feeding second weft yarns to said second weft yarn guides; feeding warp yarns to said warp bar; crocheting said first weft yarns and warp yarns to produce a main body portion of said fabric; and imparting movement to said second weft bar via a said drive means to crochet said second weft yarns with warp yarns to produce a pattern which is relatively more open .han that of said main body portion such that a substantially scallop or lace pattern is produced at least at one edge of said blind fabric,

13. A blind fabric when made by the apparatus according to any one of claims 1 to 44 *4 a a

14, A blind fabric according to claim 13, wherein a pair of warp yarns are provided on at least one side of said main body portion and said second weft yarns are crocheted therewith such that a double lace pattern, is produced at said edge of said blind fabric.

A blind fabric according to claim 13, wherein a single warp yarn is provided on at least one side of said main body portion and said second weft yarns are crocheted o. therewith such that a single lace pattern is provided at said edge of said blind fabric.

16. A blind fabric according to claim 13, wherein no warp yarns are provided at each side of said main body portion and said second weft yarns are not crocheted with warp yarns beyond the edges of said main body such that a scallop pattern is produced at said edge of said blind fabric.

17. A blind fabric according to any one of claims 13 to 16, wherein said pattern is produced at both edges of said blind fabric, 1 \y I- O 14

18. An apparatus for producing a blind fabric substantially as hereinbefore described with reference to Figures 1 to 5 of the accompanying drawings.

19. A method of producing a blind fabric substantially as hereinbefore described. A blind fabric substantially as hereinbefore described with reference to Figures 6(a) to 7(a) to or 8(a) to 8(d) of the accompanying drawings. DATED THIS 8TH DAY OF AUGUST 1996 TASS ZORBAS By his Patent Attorneys LORD COMPANY PERTH, WESTERN AUSTRALIA S S S S.r .5 S i a ~1 P, ~i br P- I ABSTRACT Apparatus (10) for producing a fabric (70) having first and second weft bars (12,14) and drive means (24) to impart movement to the second weft bar First weft yar guides are provided on the first weft bar (12) and second weft yar guides (22) are provided on the second weft bar The second weft yarn guides (22) are provided such that their inner end is in registration with an outer end of the arrangement of the first weft yar guides (20) on the first weft bar The first weft yars (12) are crocheted with warp yarns (60) to produce a main body portion (71) of the fabric The second weft yarns (62) are crocheted with warp yarns (60) to produce a pattern at the edge of the fabric 10 (70) which is relatively more open than that of the main body portion A lace (D/S) or scallop pattern is thereby produced. go *go *O, *o oo* *oooo* *oo *o* ***oo I