Laminar Velour Knitwear

Abstract

Methods of producing a laminar velour knitted fabric include: providing at least one pile yarn made of a pile material consisting only of polyester and at least one base yarn made of a base material consisting only of polyester, wherein the at least one pile material includes individual filaments with a fineness of at most 2 dtex per fibril; knitting the pile yarn and the base yarn to form a raw knitted fabric of pile yarn and base yarn having a top side and a bottom side, the top side including the pile yarn; and forming a raised pile in the absence of alkaline dissolution, wherein forming the raised pile includes napping the top side of the raw knitted fabric, whereby the pile yarn at the top side of the knitted fabric is cut and a pile is formed and raising the pile to form the laminar velour knitted fabric.

Claims

1-21. (canceled)

22. A method of producing a laminar velour knitted fabric comprising the steps of: Providing at least one pile yarn made of a pile material consisting only of polyester and at least one base yarn made of a base material consisting only of polyester, wherein the at least one pile material comprises individual filaments with a fineness of at most 2 dtex per fibril; Knitting the pile yarn and the base yarn with a knitting machine to form a raw knitted fabric of pile yarn and base yarn, wherein the raw knitted fabric has a top side and a bottom side and wherein the top side comprises the pile yarn; and Forming a raised pile in the absence of alkaline dissolution, wherein forming the raised pile comprises napping the top side of the raw knitted fabric, whereby the pile yarn at the top side of the knitted fabric is cut and a pile is formed and raising the pile to form the laminar velour knitted fabric.

23. The method according to claim 22, wherein the at least one base yarn has a fineness of at most 5 dtex and/or the pile yarn has a fineness of at most 1 dtex.

24. The method according to claim 22, wherein the knitting is performed with a combined lapping comprising at least two lappings of the base yarn and one lapping of the pile yarn.

25. The method of claim 22, wherein knitting is performed such that the raw knitted fabric and/or the laminar velour knitted fabric has a stich density of 400 to 800 mesh/cm.sup.2.

26. The method according to claim 22, wherein the bottom side of the raw knitted fabric is free of an adhesive.

27. The method according to claim 22, wherein the knitting is performed with a knitting machine having a fineness of E20 to E32.

28. The method according to claim 27, wherein the knitting is performed with a knitting machine having a fineness of E28 to E32.

29. A method of producing a laminar velour knitted fabric comprising the steps of: Providing at least one pile yarn made of a pile material and at least one base yarn made of a base material, wherein the at least one pile material comprises individual filaments with a fineness of at most 2 dtex per fibril; Knitting the pile yarn and the base yarn with a knitting machine to form a raw knitted fabric of pile yarn and base yarn, wherein the raw knitted fabric has a top side and a bottom side and wherein the top side comprises the pile yarn; and Forming a raised pile comprising napping the top side of the raw knitted fabric, whereby the pile yarn at the top side of the knitted fabric is cut and a pile is formed and raising the pile to form the laminar velour knitted fabric.

30. The method according to claim 29, wherein forming the raised pile is performed in the absence of alkaline dissolution.

31. The method according to claim 29, wherein the at least one base yarn has a fineness of at most 5 dtex and/or the pile yarn has a fineness of at most 1 dtex.

32. The method according to claim 29, wherein the knitting is performed with a combined lapping comprising at least two lappings of the base yarn and one lapping of the pile yarn.

33. The method according to claim 32, wherein at least one lapping of the base yarn consists of a satin lapping and/or wherein at least one lapping of the base yarn consists of a fringe lapping and/or wherein the lapping of the pile yarn consists of a satin lapping or a velvet lapping.

34. The method according to claim 29, wherein the raw knitted fabric is dyed by strand dyeing prior to raising the pile.

35. The method according to claim 29, wherein the knitting is performed with a knitting machine having a fineness of E20 to E32.

36. The method according to claim 35, wherein the knitting is performed with a knitting machine having a fineness of E28 to E32.

37. The method according to claim 29, wherein the knitting is performed with a combined lapping wherein the combined lapping comprises one lapping of the pile yarn and at least two lappings of the base yarn.

38. The method according to claim 37, wherein the combined lapping consists of a satin-fringe-satin lapping or a satin-fringe-velvet lapping.

39. The method of claim 29, wherein knitting is performed such that the raw knitted fabric and/or the laminar velour knitted fabric has a stich density of 400 to 800 mesh/cm.sup.2.

40. The method according to claim 29, wherein the bottom side of the raw knitted fabric is free of an adhesive.

41. The method according to claim 29, wherein the pile material consists only of polyester and wherein the at least one base material consists only of polyester.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] FIG. 1a shows a combined lapping of a laminar velour knitted fabric according to one embodiment of the invention.

[0051] FIG. 1b shows the combined lapping of FIG. 1a as a single lapping.

[0052] FIG. 2a shows a combined lapping of a laminar velour knitted fabric according to the invention in accordance with a further embodiment of the invention.

[0053] FIG. 2b shows the combined lapping of FIG. 2a as a single lapping.

[0054] FIG. 3 shows a top view of the bottom side of a laminar velour knitted fabric according to a further embodiment of the invention.

[0055] FIG. 4 shows a top view of a raw knitted fabric for the production of a velour knitted fabric according to the invention.

[0056] FIG. 5 shows a photograph of a cross-section of a laminar velour knitted fabric according to one embodiment of the invention.

[0057] FIG. 6 shows a photograph of the pile of a laminar velour knitted fabric according to one embodiment of the invention.

DETAILED DESCRIPTION

[0058] FIG. 1a shows a combined lapping of a laminar velour knitted fabric according to the invention with two lappings of the base yarn 1a, 1b and 2a, 2b as well as one lapping of the pile yarn 3a, 3b. For each single lapping, 5 individual yarns are shown. The combined lapping consists of a satin-fringe-satin lapping. The first lapping bar knits a closed satin lapping (see 1a, 1b), the second lapping bar knits an open fringe lapping (see 2a, 2b) and the third lapping bar knits a closed satin lapping (see 3a, 3b). The open fringe lapping of the base yarn blocks the satin lapping of the pile yarn, which means that the pile yarn cannot escape during subsequent raising and thus an optimum surface finish of the pile can be provided with high efficiency.

[0059] In FIG. 1b, the combined lapping from FIG. 1a is shown, but only one single yarn is shown per lapping for a better overview.

[0060] FIG. 2a shows a combined lapping of a laminar velour knitted fabric according to the invention with two lappings of the base yarn 1a, 1b, and 2a, 2b. In addition, the combined lapping comprises a further lapping of the pile yarn 3a, 3b. For each single lapping, 5 single yarns are shown. In contrast to the combined lapping shown in FIGS. 1a and 1b, the combined lapping consists of a satin-fringe-velvet lapping. By comparison with the combined lapping in FIGS. 1a and 1b, it is clear that after the raw knitted fabric has been napped, i.e. after the velvet lapping of the pile yarn has been cut, a pile with longer individual fibrils is produced than in a satin-fringe-satin lapping.

[0061] FIG. 2b shows the combined lapping of FIG. 2a, but only one single yarn 1a, 2a and 3a is shown per lapping.

[0062] FIG. 3 shows a top view of the bottom side 11 of a velour knitted fabric 10 according to the invention. The bottom side 11 comprises a knitted fabric of a pile material, which is formed as a pile yarn 3, and of a base material, which is formed as a first base yarn 1 and a second base yarn 2. Due to the very tight knitting, the pile yarn 3 is firmly anchored in the knitted fabric so that the individual fibrils of the pile are firmly anchored in the knitted fabric on the averted top side of the velour knitted fabric and do not disengage from the velour knitted fabric even without additional adhesive. For example, a polyester yarn dtex 33F15 can be used as the base yarn and a polyester yarn dtex 78F300 as the pile yarn.

[0063] FIG. 4 shows the top side 12 of a raw knitted fabric according to an embodiment of the invention. The surface of the top side 12 consists essentially of pile yarn 3, or is formed from it. Since the raw knitted fabric has not yet been napped and thus the pile yarn on the top side has not yet been cut, the pile has also not yet been formed.

[0064] The following table shows some relevant comparative values between the Alcantara imitation suede known in the prior art and a laminar velour knitted fabric according to the present invention:

TABLE-US-00001 Velour knitted fabric according to Comparative value Alcantara the invention Norm Residual shrinkage 2.0 3 DIN EN ISO 6330 40 C. Length [%] Residual shrinkage 2.5 1 DIN EN ISO 6330 40 C. Width [%] Heat shrinkage 2.0 6.0 DIN EN ISO 6330 length [%] Heat shrinkage 2.0 2.5 DIN EN ISO 6330 width [%] Washing 40 C. 4-5 4-5 DIN EN ISO 105 C10 Sweat fastness 4-5 4.5 DIN EN ISO 105 E04 alkaline Sweat fastness 4-5 4-5 DIN EN ISO 105 E04 sour Rubbing fastness 4-5 4-5 DIN EN ISO 105 X12 dry Rubbing fastness 3 4 DIN EN ISO 105 X12 wet Water hard 4 4-5 DIN EN ISO 105 E01 fastness Pilling 4-5 4-5 DIN EN ISO 12945 Scrub test 50 000 Slightly No thread DIN EN ISO 12974-1 tours scuffed breakage, surface, slight no hole pile loss formation Tearing force 222 204 ISO 3341:2000-05 length [N] Tearing force 360 1026 ISO 3341:2000-05 width [N] Elongation at 89.8 80.5 ISO 3341:2000-05 break length [%] Elongation at 57.1 67.9 ISO 3341:2000-05 break width [%] Force 10% length 18.6 65.7 DIN 53835-14:1992-11 [N] Force 10% width 116.0 89.2 DIN 53835-14:1992-11 [N] Continued tear 17.5 23.0 DIN EN ISO 13937 force length [N] Continued tear 13.0 11.9 DIN EN ISO 13937 force width [N]