Variable color or texture expression knitting, weaving, and laminating system, method and fabric
11047068 · 2021-06-29
Inventors
Cpc classification
D04H3/04
TEXTILES; PAPER
D02G1/0286
TEXTILES; PAPER
D03D13/00
TEXTILES; PAPER
D02G3/346
TEXTILES; PAPER
D04B1/14
TEXTILES; PAPER
D02G3/06
TEXTILES; PAPER
D02G3/00
TEXTILES; PAPER
D04B21/14
TEXTILES; PAPER
International classification
D02G1/02
TEXTILES; PAPER
D02G3/00
TEXTILES; PAPER
D03D13/00
TEXTILES; PAPER
D04H3/04
TEXTILES; PAPER
D04B21/14
TEXTILES; PAPER
Abstract
Disclosed is a method of producing a variable-color textile, the method comprising: providing a plurality of filaments into a commercial textile-production machine, the plurality filaments having at least a first color and a second color; and twisting at least one of the plurality of filaments to display a first color on a first side of a fabric surface and a second color on an opposite side of the fabric surface.
Claims
1. A method of producing a variable-color textile fabric, the method comprising: providing a plurality of filaments into a commercial textile production machine, wherein at least a one of the plurality of filaments is a tape of film having a first color on a first side of said tape and a second color on a second side of said tape; directing the at least said one filament through a single guide such that as said at least one filament is randomly engaged and twisted by the tools of the machine in the production process the said first and second colors of the sides of the tape will be randomly presented to the surfaces of each side of the textile fabric to display said first and second colors in a randomly repeated manner.
2. The method of claim 1, wherein at least two of said plurality of filaments comprise tapes of film having selected different colors on opposite sides of said filaments which are twisted by the tools of the machine in the production process to randomly display said selected different colors on the surfaces of both sides of the textile fabric.
3. The method of claim 1, wherein twisting of the tapes is performed by a twister prior to directing the at least one filament through said single guide.
4. The method of claim 3, wherein the twister is controlled by a computer.
5. A method of producing a randomly variable-color textile fabric, the method comprising: providing a multiple number of filaments into a commercial textile-production machine, wherein at least a first plurality of said filaments include at least one tape of coextruded film having a first color on a first side of said tape and a second color on a second side of said tape, directing said first plurality of said filaments through a single guide such that as said first plurality of said filaments are randomly engaged and twisted by the tools of the machine in the production process the colors on the two sides of said at least one filament tape will be randomly presented to the surfaces of each side of the textile fabric whereby both sides of the fabric will display said first and second colors in a randomly repeated manner.
6. The method of producing a randomly variable-color textile fabric of claim 5, wherein at least a second plurality of said filaments include at least one tape of coextruded film having a third color on one side of said at least one tape and a fourth color on an opposite side thereof, wherein as said first and second pluralities of filaments are respectively directed through said single guides and randomly engaged and twisted by the tools of the machine in the production process the colors of the two sides of said at least one tapes of said first and second pluralities of said filaments will be randomly presented to the surfaces of each side of the textile fabric whereby both sides of the fabric will display the said first, second, third and fourth colors in a randomly repeated manner.
7. The method of producing a randomly variable-color textile fabric of claim 6, wherein said at least first and second pluralities of said filaments each include a third plurality of filaments selected from at least one of the group of filaments consisting of thread, yarn, and plastic monofilament.
8. The method of claim 7, wherein said third plurality of filaments are of a plurality of selected colors.
9. A method of producing a randomly variable-color textile fabric, the method comprising: providing pluralities of filaments into a commercial textile production machine, the pluralities of filaments including at least two different colored extruded tapes of a width to effectively display their distinct colors when positioned on the surface of a fabric, directing selected pluralities of said tapes through single guides such that as the tapes are individually randomly engaged and twisted by the tools of the machine in the production process two different colors of the plurality of filaments will be randomly provided on each side of the textile fabric to display its colors in a randomly repeated manner.
10. The method of claim 9, wherein at least one of the filaments of the plurality of different colored filaments is a tape of coextruded film having a first color on a first side of said tape and a second color on a second side of said tape, whereby the plurality of filaments will randomly display at least three colors on each side of the textile fabric.
11. The method of claim 9 wherein each of the plurality of colored filaments is a tape of coextruded film having a selected first color on a first side of the tape and a selected second color on a second side of the tape whereby each said plurality of colored filaments can randomly display twice as many colors as its number of tapes on each side of the textile fabric.
12. The method of claim 9 further comprising; providing a plurality of different colored filaments of a width to effectively display their colors when positioned on the surface of a fabric into said commercial textile production machine, the plurality of filaments each being separately directed as a one of a composite warp or composite weft through a single guide of the machine such that as the composite plurality of different colored filaments are randomly engaged and twisted by the tools of the machine in the production process each of the composite warp and weft filaments will be randomly presented to the surfaces of each side of the resulting fabric to display its color in a randomly repeated manner.
13. The method of claim 12, wherein one or more of the plurality of filaments is a coextruded tape having two sides of different colors such that as each of said coextruded two color tapes are randomly engaged and twisted by the tools of the machine in the fabricating process each of the two colors will be randomly displayed on both sides of the resulting fabric.
14. The method of claim 1, wherein the at least one of a plurality of filaments is a tape slit from a sheet of coextruded polyethylene laminar film having a first sheet with a first color expressed on a first side surface of said film and a second sheet having a second color expressed on an opposite second side surface of said film.
15. The method of claim 14, wherein the sheet of coextruded polyethylene laminar film from which the tape is slit has a third center sheet having a third color provided between the first side sheet and the second side sheet.
16. The method of claim 15 wherein the said third center sheet of said coextruded laminar film has an extruded film thickness of approximately 40 to 60 microns, and the said first and second side sheets of said coextruded laminar film have an extruded polyethylene sheet thickness of approximately 10 to 20 microns each, whereby the entire coextruded laminar film may be approximately 50-100 microns in thickness, and wherein the coextruded film sheets can be slit to form tapes of a desired width, which tapes can be stretched to a much thinner selected filament width and thickness for the resulting textile fabric.
17. The method of claim 15 wherein the said third center sheet of said coextruded laminar film has an extruded film thickness of approximately 50-55 microns, and the said first and second side sheets of said coextruded laminar film have an extruded polyethylene sheet thickness of approximately 14-16 microns each, whereby the entire coextruded film may be approximately 75-85 microns in thickness, and wherein the coextruded film sheets can be slit to form tapes of a desired width, which tapes can be stretched to a thinner selected filament width and thickness for the resulting textile fabric.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1) Various examples of embodiments of the systems, devices, and methods according to this invention will be described in detail, with reference to the following figures, wherein:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14) It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
(15) Referring to the Figures, a system and method for producing a fabric having multiple color or texture expression is disclosed. The system and method according to one or more examples of embodiments includes providing multiple filaments in a traditional industrial fabric production system which are then twisted in order to produce expression of a desired color or texture. This system, method, and device can be used or integrated with a number of types of textile machines configured to produce knit, laminated, or woven materials, such as, but not limited to, Raschel machines (knit), applicator (laminated), or looms (woven). An example of a Raschel machine can be seen in U.S. Pat. No. 3,523,431. An example of an applicator machine can be seen in U.S. Pat. No. 3,276,938. These are merely given as example types of machines, and the present disclosure should not be construed to be limited to these particular example machines.
(16) Turning to
(17) Continuing with
(18) The twisted group of tapes or yarns 245, 247 may then be fed to a single guide 261, which may take the form of needles 263, hooks 265, or other appropriate means 267. Next, a single thread line comprised of the group of yarns or tapes 245, 247 (filaments 103) may be fed by a single guide 261 to a pattern bar 271 on the machine, whether used on the warp 273 or weft 275 side. The relevant weaving, knitting, or laminated machine (e.g. commercial textile-production machine 105) then proceeds to weave, knit, or laminate the provided group of yarns or tapes. The finished product 281 is then a knitted 283, woven 285, or laminated 287 product comprised of the selectively twisted yarns or tapes to express the colors or textures in a desired random or predetermined pattern. If woven or laminated, the fabric may undergo edge trimming 289, winding, or cutting. The fabric likewise may be wound by a winder 291.
(19)
(20)
(21) Continuing with
(22) The twisting 111 of the filaments 103 (whether effected by way of a twister 151, other intervention, or through normal operation of the industrial textile machine) should be understood to allow for intermittent expression of certain colors. For example, if three colors are provided on the filaments, the twisting allows for intermittent and, in various embodiments, random expression of three colors. While three colors are provided as an example, two, four, five, six, etc. should be understood as within the scope of this disclosure.
(23) As shown in
(24) In addition, as shown in
(25) A twister 151 controlled by a servo 153 may provide for pre-programmed motions, which in various embodiments is instructed by a special software 157 provided on a computer 145 or like processing unit. At appropriate intervals to interact with the machine 105 or textile-production process (for example, between groups of three or four yarns 129 or tapes 131), a servo motor 153 (or other appropriate moving mechanism) may be provided by mounting on the machine or a freestanding frame, and may have connection rods 155 (or other electronic communication mechanism including by mechanical or wireless transmission) to each twister 151. In various embodiments, one servo 153 may control multiple twisters 151. The servo-controlled twisting device or twister 151 may further comprise synchronizing means (or speed) with the machines 105 that are looping, weaving, or laminating the yarns or tapes (filaments 103) to produce the correct designed material 101. In various embodiments, the finished fabric may be wound on a winder 191. In greater detail, the connection between the servo motor 153 to the twister 151 involves electronic communication means. The twister 151 may take the form of any appropriate shape, including, but not limited to, a circle with holes, a flat shape, tube, hooks, or other shape. In various embodiments, the twister 151 has apertures for accepting the yarns 129 or tapes 131 (filaments 103) to be twisted. All three filaments 103 may be provided through a same needle 163 in the commercial textile-production machine 105.
(26) The twister 151 may be able to rotate or pivot using any known appropriate rotational mechanical components, for example, an axle. If mounted, the twister may be mounted using any appropriate means, including clamps, screws, bolts, or other suitable mechanism. If freestanding, any appropriate supporting device or mechanism can be used, for example, a stand. Similarly, the servo may be attached to the system using mounting or supporting mechanisms. The communication between the servo and twisting device may be a one-to-many ratio, as may be appropriate. Though the connection may require electronic communication components, necessary cabling, wiring, etc. and supporting structure should be contemplated as within the scope of this disclosure. Similarly, communication between the servo and computerized logic component should be understood to include cabling, wiring, etc. and any accompanying supporting structure such as tubing. It should likewise be understood that there may be multiple logic pieces in lieu of a single centralized logic component. This may allow for distributed computing at the point of the servo. In various embodiments the electronic communication may be made wirelessly.
(27) For example, the separator 141 may provide to the twister 151 three filaments 103 (yarns 129/tapes 131), all having a different color (first color 107, second color 109, third color 110). In this example, one is green, another red, and another blue. The servo 153 instructions 157 may call for a 120 degree rotation of the twister 151, changing the color expression on the fabric surface, for example, from red to blue. Another instruction 157 may cause the servo 151 to rotate the twister 151 another 120 degrees from blue to green for some time. Finally, the servo 153 may rotate the twister 151 backwards 120 degrees, causing blue to express again. The result is a fabric 101 having a section which is blue, then green, then back to blue. In various embodiments, the back side of the fabric may, for example, show red, then blue, then red again. In other words, a first side of a fabric 113 may be the opposite of a second side of a fabric 115. To that end, a similar pattern is provided on the back side of the fabric 115 in a different color. In a woven 135 or tightly-knitted 133 fabric, this may create a two-dimensional or two-sided image fabric; in a looser-knit 133 fabric this may create a three-dimensional or three-sided image fabric where loose yarn or loose loops are used. It should be understood that various tape or yarn types can be used for each tape or yarn in a group, including materials having particular attributes. For example, two non-reflective and two reflective filaments can be formed to create a particular pattern using the system and method disclosed based on the material types.
(28) In
(29) Twisted yarns or tapes may interact with a typical knitted fabric 133. For example, a warp-knitting process using a single guide bar may allow for use of twisted yarns 129 or tapes 131 (filaments 103) on either the warp 123 or weft 125. As another example, a known warp and weft-knitting process requiring two guide bars may use the disclosed system and method herein. Knitting using the disclosed system and method may include creating fabric by transforming continuous twisted strands of yarns (filaments 103) to a series of interlocking (2) loops. As seen in
(30)
(31) Similarly,
(32)
(33)
(34) Similarly,
(35) Of particular relevance in the laminating process is that the number of tapes can be limited by the use of dual-extruded dual-colored slit tapes. In various embodiments, a film could be used, for example a 30 inch film, could be sent to a printer and different colors could be printed and slit to create colors on each tape to create a variable-expression fabric.
(36)
(37) As indicated, the methods, systems, and devices described herein may be implemented in part by software. To this end, the methods, systems, and devices may be implemented in a general purpose software package. In one or more examples of embodiments the method, system, or device, or such method, system, or device embodied by software, may be implemented by a computer system or in combination with a computer system. The computing system may also be a known computing system suitable for interaction with textile production systems.
(38) The computer system may be or include a processor. The computers for use with the methods and various components described herein may be programmable computers which may be special purpose computers or general purpose computers that execute the system according to the relevant instructions. The computer system can be an embedded system, a personal computer, notebook computer, tablet computer, server computer, mainframe, networked computer, handheld computer, personal digital assistant, workstation, and the like. Other computer system configurations may also be acceptable including, cell phones, mobile devices, multiprocessor systems, microprocessor-based or programmable electronics, network PC's, minicomputers, and the like. Preferably, the computing system chosen includes a processor suitable in size to efficiently operate one or more of the various systems, devices, or functions.
(39) The system or portions thereof as described herein may be linked to a distributed computing environment, where tasks are performed by remote processing devices that are linked through a communications network. To this end, the system may be configured or linked to multiple computers in a network, including, but not limited to a local area network, a wide area network, a wireless network, and the Internet. Accordingly, information and data is transferred within the network or system by wireless means. Such wireless means include any now known or future developed system, examples of which include Wi-Fi, Bluetooth, GPRS, RF, and cellular data systems. It is also contemplated that certain aspects of the system may be implemented through hardwire connection, such as computer to computer communication.
(40) The computer can also include a display, provision for data input and output, etc. Furthermore, the computer or computers may be operatively or functionally connected to one or more mass storage devices, such as, but not limited to a database or cloud storage medium. The memory storage can be volatile or non-volatile and can include removable storage media. The system may also include computer-readable media which may include any computer readable media or medium that may be used to carry or store desired program code that may be accessed by a computer. The invention can also be embodied as computer readable code on a computer readable medium. To this end, the computer readable medium may be any data storage device that can store data which can be thereafter read by a computer system. Examples of computer readable medium include read-only memory, random-access memory, CD-ROM, CD-R, CD-RW, magnetic tapes, and other optical data storage devices. The computer readable medium can also be distributed over a network coupled computer system so that the computer readable code is stored and executed in a distributed fashion.
(41) These devices may include a graphical user interface (GUI) or a communication means by which commands may be entered and content may be displayed or communicated. For example, the computer may include a user interface that allows navigation of objects. The computer may implement or include an application that enables a user to display and interact with text, images, videos, data, and other information and content.
(42) Aspects of the method, system, and devices described herein can be implemented on software running on a computer system. The system or method herein, therefore, may be operated by computer-executable instructions, such as but not limited to program modules, executable on a computer. Examples of program modules include, but are not limited to, routines, programs, objects, components, data structures and the like which perform particular tasks or implement particular instructions. The software system may also be operable for supporting the transfer of information within a network.
(43) As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.
(44) It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.
(45) For the purpose of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.
(46) It is also important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various examples of embodiments without departing from the spirit or scope of the present inventions.
(47) Moreover, some portions of the detailed descriptions herein are presented in terms of procedures, steps, logic blocks, processing, and other symbolic representations of operations on data bits that can be performed on computer memory. These descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. A procedure, computer executed step, logic block, process, etc., is here, and generally, conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a computer system. It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the discussions herein, it is appreciated that throughout the present invention, discussions utilizing terms such as “receiving,” “sending,” “generating,” “reading,” “invoking,” “selecting,” and the like, refer to the action and processes of a computer system, or similar electronic computing device, including an embedded system, that manipulates and transforms data represented as physical (electronic) quantities within the computer system.
(48) While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.
(49) The technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.