Anti-slip material for contact fixation and method of manufacturing the sameTECHNICAL FIELD OF THE INVENTIONThe present invention relates to a novel design of a structure in knitted fabric of a non-slip contact-fixing fabric, which has the characteristic of adapting to the production and mass production of fabrics with a large width of surface having the flexibility, elasticity and light weight, and also offers the advantages of high air permeability and low manufacturing costs, and adapts to the combination with other materials being ideal to be attached to several felts, carpets, flannels, plush fabric (fabric , towel) to achieve non-slip contact closure.
State of the ArtThe commonly known types of hook and loop are Velero tapes (Velero is a Registered Trademark of Velero Industries BV) and these have the characteristic of non-slip contact closure. ' Known hook and loop tapes are often composed of a first band having a plurality of male hooks and a second band having a plurality of female loops that are linked by the male hooks when the two bands come into mutual contact. The male hook band has a surface that forms a felt-like face on which the plurality of protruding hooks with hooked ends are evenly distributed. The band with female loops has a surface that forms a velvet-like face in which the looped and entangled threads are evenly distributed. When the felt-like faces of the male and female bands come together to oppose and touch each other, the hooks link the looped and entangled threads to keep the two bands together. The known structure of contact fixing tape is effective atifixing items to be fastened, but conventional contact fastening bands have high manufacturing costs and difficulty in making wide-width products, and only suit the continuous manufacture of elongated tapes for small surfaces, making the performance of production is very poor. In addition, the conventional contact fixing tape is generally non-collapsible, making it more difficult to join articles or materials having a three-dimensional shape. British Patents GB 927828, GB 927828, GB 927828, and GB2049749, European Publication EP1698245A3, US Patent US4854136 and Japanese Publication JP 20040415 are known which describe the different types of hook and loop of contact fastening fabrics, but none of these discloses a fabric in warp knitting in which the synthetic threads of the hooks are joined in knitted fabric with the column of the fabric. Furthermore, none of these discloses the concept of knitted fabric with foldable textile yarns and synthetic filaments having totally different characteristics so that the flexible yarns are joined to form a base layer.
In the request of the. Patent describes and shows in the drawings a single contact fixing material, which is manufactured by joining synthetic fibers with synthetic threads of different characteristics or different diameter sizes in order to adjust the needles of different applications, wherein the length of the synthetic fibers used to form the male hooks can be placed according to the knitting method used. This application describes in more detail the method of making the fabric.
SUMMARY OF THE INVENTIONOne of the objects of the present invention is to provide a lightweight, flexible, expandable, air-permeable, mass-produced, massive fabric with a simplified anti-slip structure that provides effective slip resistance for use with various materials, including felts,carpets, flannels and plush fabric (terry cloth) that have looped or matted structures to form a contact closure.
One of the objects of the present invention is to provide a non-slip contact-fixing fabric formed in knitted fabric where the fabric is flexible and elastic, and which is formed by weaving flexible yarns simultaneously with synthetic filaments or fibers forming the wefts and They have different characteristics to the flexible threads, so a base layer joined in knitted fabric is formed by including a large number of synthetic fibers that protrude from there and that are used to form hooks.
A further objective is to provide a contact fastening fabric that can be manufactured in the mass production form with excellent characteristics of light weight, air permeability, elasticity and easy processing.
Another object of the present invention is to provide an anti-slip fabric, having excellent elongability and flexibility that offers excellent characteristics of easily applying to three-dimensional surfaces so that the anti-slip material can be easily molded to form an excellent bonding surface for the three-dimensional configuration.
A further object of the present invention is to provide a non-slip contact fixation material that can be used with felts, carpets, flannels, and plush fabric (terry cloth) for non-slip purposes.
According to one of the aspects of the present invention, a non-slip knitting fabric is provided by contact fastening which consists of a base layer having cloth columns comprising the flexible base yarns and a plurality of discrete synthetic filaments. knitted together, where each seam of the synthetic filament is tied around an anterior seam of the filament in the same column and which is subsequently cut to form adiscrete length of the filament consisting of a loop in the base layer and two frames protruding from the base layer.
Preferably the synthetic fibers are monofilaments which are selected from the following synthetic materials: polyamides, polyesters, polypropylene and polyethylene. Preferably each synthetic filament has a diameter ranging from 0.02mm to 0.5mm. and has an elastic hardness between 35 A to 90A or between 40D to 90D.
Preferably the flexible yarns are synthetic spun yarns selected from the group comprising acrylic, cotton, cellulose, or polyester cotton, or a mixture of these fibers.
Preferably the synthetic filaments and yarns are woven so that each seam of the synthetic filament is bonded around an anterior seam in the synthetic filament together with the fabric to form a column of synthetic filament loops extending transversely to an adjacent seam of the filament. cloth.
The base layer of the fabric may have openings and openings and the shape of the openings is selected from the following shapes namely: polygonal, circular, hexagonal, rectangular, or quadrangular. Alternatively, the base layer must not have woven openings in its structure.
According to a further aspect of the invention there is provided a warp knitting method of a contact fastening fabric having hooks for linking the loops or catching the structure of another structure, wherein the method comprises the steps of: (a) Joining in warp knitting simultaneously a plurality of continuous stretches of the flexible yarns together with a plurality of continuous lengths of the synthetic monofilaments on a double-bed knitting machine to form two base layers each of which are made in knitted fabric on one of the stitches and has columns of fabric having the seams of the synthetic filament joined to the column of the base layers along and between the columns by the flexible threads, and where the two layers are joined by the stitches. seams of the synthetic filaments that extend between the two base layers; Y , .(b) Cutting the seams of the synthetic filaments that extend between the base layers to form two separate fabrics each of which has a base layer with discrete lengths of filaments having a loop attached to the next seam of the filament along with each column of the base layer and two frames that protrude from the base layer.
Preferably the knitting process begins by weaving pairs of adjacent columns together with the flexible yarn passing from a column to the following columns of the pair.
Preferably the base layer consists of columns which are joined in knitted fabric as the flexible yarns pass between the adjacent columns of the base layer.
The openings can be formed in the base layer by weaving a set of first pairs of columns into knit fabric, dividing each of the first pairs of columns into two columns and passing the flexible threads to an adjacent column of each division of first pairs of columns. columns and joining the columns in knitted fabric to form a second set of pairs of columns, dividing the second pair of columns into two columns and joining the columns in knitted fabric to form the set of the first pairs of columns and thus define the openings in the base layer between the columns. .
The present invention provides a non-slip contact-fixing material, consisting of a base layer woven into knitted fabric and a plurality of fibers or threads that are woven collectively into the base layer and secured together. Synthetic filaments have a predetermined stiffness to provide strong wefts that protrude from the base layer while the flexible yarns make a base layer that is flexible, elastic and lightweight. Along with the contrasting characteristics of the filaments and yarns a fabric is produced which when put into contact with the felts, carpets, flannels and plush fabric (towel cloth), the non-slip material of the present invention provides excellent resistance against glide.
The above objectives and the summary provide only a brief introduction of the present invention. To fully appreciate these and other objects of the present invention as well as the invention itself, all of which will become apparent to those skilled in the art, the following detailed description of the invention and the claims should be read in conjunction with the accompanying drawings. Throughout the specification and the drawings the identical reference numerals refer to identical or similar parts.
Many other advantages and features of the present invention will become apparent to those skilled in the art upon reference to the detailed description and accompanying drawings of the drawings in which preferred structural embodiments embodying the principles of the present are shown. invention in the form of illustrative examples.
BRIEF DESCRIPTION OF THE DRAWINGSFigure 1 shows a knitted fabric having a network of openings X and which has been constructed according to the following invention;Figure 2 shows a second fabric in warp knitting by contact fixing that does not have the network of openings like those in Figure I X. and which has been constructed in accordance with the present invention;Figures 3 and 4 show, schematically, the steps of the knitted part of the fabrics of figures 1 and 2;Figure 5 shows schematically a cross-sectional view taken together with one of the columns of the fabric shown in Figures 4 and 5;Figure 6 shows schematically the steps of the knitted fabric of the openings in the fabric of Figure 1;Figures 7 and 8 show in greater detail a portion of the knitted fabric shown in Figure 6;Figure 9 is a schematic view showing the wefts of the fabric of Figure 1 or Figure 2 that have been subjected to heat to melt the tips of the wefts to form the hooks; Y,Figure 10 is a schematic view showing the wefts of the fabrics of Figures 1 or 2 that have been subjected to heat and deformation to form the hooks.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTSThe following descriptions are exemplary embodiments only, and are not intended to limit the scope, application or configuration of the invention in any way. Rather, the following description provides a convenient illustration for implementing exemplary embodiments of the invention. Various changes can be made to the embodiments described in function and arrangement of the described elements without departing from the scope of the invention set forth in the appended claims.
Referring to Figures 1 and 2 the fabrics 10 and 10a consist of a base layer 40 having a plurality of hooks 22 protruding from the plane of the base layer 40. In use, when the fabrics 10 or 10a come into contact with another fabric or surface (not shown) having a looped or tangled structure such as felts, mats, flannels and terry cloth (towel cloth), the hooks 22 are linked and entangled with another fabric or surface to grasp it and thus create a contact closure that can be separated.
The difference between the fabric of Figure 1 compared to the fabric of Figure 2 is that the knitted base layer of the fabric of Figure 1 has a network of "X" openings formed during the knitting process while that the fabric of figure 2 does not.
For simplicity, in the following description of Figures 3 to 10 of the drawings, only a few ribs or columns are shown extending along the fabrics 10 or 10a. These columns are identified by the references "A" and "B". It is also understood that the pattern of the seams shown in the drawings is repeated throughout and width of the fabrics 10 and 10a, thus making it possible to produce fabrics of different widths and elongabilities.
Both the fabric of figure 1 and 2 are made in warp knitting in a double-bed knitting machine in which two base layers 40 are made in knitted fabric simultaneously (one layer 40 in each frame) ate one unique structure with the seams 20a and 20b made in knitted fabric through the two edges. Once the knitted fabric structure is removed from the knits of the knitting machine the seams 20a and 20b extending between the base layers 40 are cut to separate the base layers 40 and form two identical fabrics 10, or 10a as they are shown respectively in Figure 1 or Figure 2 while at the same time the frames 22 of the cutting seams are used to form the hooks of the fabric. By varying the tension of the seams 20 and 20b through the seams, it is possible to make longer or shorter wefts 22.
To make the double structure in knitted fabric that is cut to form two fabrics 10 or 10a of the present invention, the continuous length of the two types of textile yarns used are fibers 20a and 20b forming wefts 22 that are used to make " hooks "of the fabric 10, and flexible fibers 30a and 30b forming each base layer 40 of the fabric 10 and keeping the weft 22 in place in the base layer 40.
Fibers 20a and 20b are preferably monofilaments (sometimes called "Textured Textile Yarns (DTY) or extracted filaments) selected from one or more of the following synthetic plastics materials, namely: polyamides (e.g. Nylon - a registered trademark of Du- Pont Corporation), polyesters, polypropylene, and polyethylene.Preferably the monofilaments have a diameter ranging from 0.02mm to 0.5mm, and have an elastic hardness between 35A to 90A or an elastic hardness between 40D to 90D.
The flexible yarns 30a and 30b are preferably made of natural or synthetic yarns, for example: acrylic, cotton, cellulose or cotton polyester blends, and are more flexible than the fibers 20a and 20b.
Referring to Figures 3 and 4, two adjacent columns A, and B of the base layer 40 of the fabric of Figure 2 are shown schematically. Each alternating column A is started by joining a pair of continuous strands 20a, 20b by knitting. , and 30a to form the first seams of each column (Al, A2, A3, and so on) of each of the two base layers 40. Simultaneously the alternate column (Bl, B2, B3 and so on) of each base layer is started by joining a portion of the continuous threads 20a, 20b, and 30b together by knitting.
As explained above when the two base layers 40 are separated, the seams 20a or 20b extending between the two base layers 40 are cut to leave discrete lengths of the filament 20a or 20b, each of which consists of a bonded loop 21 to an anterior seam and two wefts 22 projecting from the base layer 40 and these are modified as shown in figures 9 and 10 to constitute the hooks of the fabric 10 or 10a.
For reasons of clarity, Figure 3 only shows the wires 20a, 20b, and 30a, and Figure 4 only shows the wires 20a, 20b and 30b. Actually, the columns Al, A2, A3 and Bl, B3 of the fabric 10a of figure 2 are joined by knitting as the flexible yarns 30a and 30b pass transversely between the adjacent columns A and B and joined by knitted fabric with the seams of the strands 20a and 20b as discussed below:In Figure 3 the loops 21 of the alternating seams (2nd, 4th, 6th and so on) are formed together with the column of each base layer 40 using continuous lengths of threads 30a and threads 20b, while the loops 21 of the seams alternate (3rd, 5th, and 7th and so on) together with the column B of the base layers 40 are formed using continuous lengths of the wires 20a and thread 30a. In Figure 4 the loops 21 of the alternating seams (2nd, 4th, 6th and so on) along the column B of the base layer 40 are formed using the thread 30b and thread 20a, while the loops 21 of the alternating seams (3rd, 5th, and 7th and so on) along the column B of the base layer are formed with thread 20a and thread 30a. A transverse view taken along the length of each column is shown schematically in Figure 5.
The pattern of the seam shown in Figures 3 and 4 is repeated in the direction of the width in the needles of the two stitches for all the columns of the base layer 40 using multiple threads 30a and 30b and multiple filaments 20a and 20b and along the length of the base layer 40, thus making it possible to knit two fabrics 10 as shown in Figure 2 of any desired width when the seams 20a and 30b are cut. . «Figures 6 to 8 show the knitting method of the fabric of Figure 1 with openings or gaps "X" in the layer 40 of the fabric 10. The openings "X" can be of any desired geometric shape, such as circle, honeycomb, hexagonal or quadrangular or other geometric shape. The presence of the openings X improves the elongability and deformability in the longitudinal and transverse directions of fabric 10 compared to the fabric 10a of Figure 2.
Referring to Figure 6, the knitting process begins by knitting together a first set of pairs of columns (Al, Bl), (A2, B2) and (A3, B3) with space through of thewidth of each base layer 40 of the fabric 10 using yarns 30a and 30b and yarns 20a and 20b, following the pattern of the seams shown in Figures 3 to 5.
Initially the alternating pairs of the first set of columns is not linked to the next adjacent pairs of columns in the base layer 40. Instead, as shown in Figure 7 and the bottom of Figure 6, each of the joined pairs of the first set of columns in each base layer is joined by knitting using the seam pattern shown in Figures 3 and 4 by a short distance.
After joining by knitting a short distance along the pair of columns, each pair of the first set of columns ((A 1, B 1), (A2, B2) and (A3, B3) and so on) in each base layer 40 is divided into two separate columns and is joined by fabric of point with one of the columns of an adjacent pair of columns (as shown at the top of Figure 6 and Figure 8) to form a second set of column pairs ((B 1, A2), and (B2 , A3) and so on)). The pairs of columns ((Bl, A2), and (B2, A3) and so on) in each base layer 40 are joined by knitting at intervals along the length of the base layer 10 as the strands extend. 30a and 30b. in the adjacent columns and joining them by knitting with the seams of the strands 20a and 20b for a short distance along the length of the base layer 40.
Subsequently the pairs of columns in the second set of columns are divided into two columns and the divided columns (Al, Bl), (A2, B2) and (A3, B3) are joined by knitted fabric as shown in the lower part of figure 6, to reform the first set of columns. The pattern of seams is repeated along the length and width of the base layer 40 to produce the desired size of the fabric 10 and thus form "X" openings in the two layers 40.
As explained above, the knitted fabric structure is removed from the knives of the knitting machine and the two base layers 40 are separated by cutting the seams of the filaments 20a or 20b extending between the base layer 40 to leave two. fabrics having discrete lengths of the filaments 20a or 20b consisting of a loop 21 attached to an anterior seam and two wefts 22 joined by knitting in the base layers 40, and the two wefts of each seam are used to form the hooks of the 10 or 10a fabric, which protrude from. the base layer 40 of the fabric 10.
It will be noted that as the knit fabric progresses, the base flexible yarns 30a and 30b are allowed to extend transversely to an adjacent column of the base layer 40 and are knitted together alternately with the seams 20a and 20b for making a base layer 40 but the loops 21 of the synthetic threads 20a, 20b are joined to each other along the length of the columns of. the base layer 40 so that the loops 21 of each previous seam loop around the loops 21 of the next seam, and the ends of the sheets forming the short frames 22 of the predetermined length protrude from the base layer 40.
Referring to Figures 9 and 10 a further feature of the present invention is shown here, after the filaments 20a and 20b are cut to form two separate pieces of fabric 10 or 10a, the fabric 10 or 10a is further processed as the fabric passes. through a tunnel homo (not shown) to heat and melt the free ends of the wefts 22 of each synthetic yarn 20a, 20b to form rounded ends 23 that constitute the "hooks" (see Figure 9). Alternatively, the free ends of the wefts 22 of each synthetic yarn 20a, 20b may be subjected to heat and compression to deform the ends to form hooks 24 as shown in Figure 10. With the fabrics 10, 10a of Figures 1 and 2 the short wefts 22 of the synthetic filaments extend beyond the surface of the base layer 40 and protrude outside the base layer 40 and the distance or length of the wefts 22 of the synthetic yarns 20a, 20b may be adjusted as desired during the knitting step by looping the yarns 20a and 20b extending through the knits of a looser or tighter knit fabric by controlling the pressure of the monofilaments as they are woven. The elastic hardness of the filaments 20a and 20b determines the rigidity and hardness of the webs 22.
Thus, the non-slip contact-fixing fabrics 10 and 10a of the present invention have the advantages of being lightweight, having high air permeability and flexibility and are adapted for bulk production of wide-width products.
To summarize, the present invention offers a non-slip contact-fixing material that has been structured to have synthetic filaments 20a, 20b of short wefts made by knitting together with flexible yarns 30a, 30b, which form the base layer of the fabric for provide the anti-slip effect which when it comes into contact with felts, carpets, flannels and plush fabric (cloth towels) that have a looped or tangled structure, will adhere to the other materials. In addition, the synthetic yarns 20a, 20b, are knitted together tightly with the flexible yarns 30a and 30b, so that they do not separate from the base layer 40 when the felts, carpets, flannels and plush fabrics (towel cloth) separate or separate from the other fabric. The present invention has excellent characteristics of contact fixation and better grip and resistance against sliding when it comes into contact with other looped or entangled structures.
While certain novel features of this invention have been shown, described and pointed out in the appended claims, this will not be limited to the foregoing details, since it will be understood that several omissions, modifications, substitutions and changes in forms and details of the device illustrated and in its operation can be performed by those skilled in the art without departing in any way from the essence of the present invention.