Textile structure, and manufacturing process related thereto
12546036 · 2026-02-10
Assignee
Inventors
Cpc classification
D10B2403/0114
TEXTILES; PAPER
D03D11/00
TEXTILES; PAPER
D03D13/004
TEXTILES; PAPER
International classification
D03D13/00
TEXTILES; PAPER
Abstract
In a base fabric (2) having a front surface (F) and a back surface (B) at mutually opposite sides with respect to a median lying plane (P), weft yarns (4a, 4b, 4c) interlace with warp yarns (3) at respective interlacing points (IPa, IPb, IPc) at which the weft yarns cross the median lying plane (P) to override at least one of the warp yarns. At least one functional thread (5) extending along a pre-established pattern at the back surface (B) of the base fabric (2), without crossing the median lying plane (P), and is linked with the weft yarns (4a, 4b, 4c) at stitching points (SP) positioned between the median lying plane (P) and the back surface (B) of the base fabric (2), so that the stitching points (SP) are not visible from a front surface (F) opposite to the back surface (B).
Claims
1. Textile structure comprising: a base fabric including warp yarns extending along a warp direction and weft yarns extending along a weft direction; wherein the base fabric presents a front surface and a back surface at mutually opposite sides with respect to a median lying plane of the base fabric; wherein the weft yarns interlace with the warp yarns at respective interlacing points at which the weft yarns cross the median lying plane to override at least one of the warp yarns; further comprising at least one functional thread extending according to a pre-established pattern at the back surface of the base fabric; wherein the at least one functional thread lies on the base fabric without crossing the median lying plane; and wherein the functional thread is linked with one or more of the weft yarns at stitching points positioned between the median lying plane and the back surface of the base fabric, so that the stitching points are not visible from the front surface opposite to the back surface.
2. Textile structure according to claim 1, wherein the weft yarns include: mutually parallel basic weft yarns; anchoring weft yarns configured for linking the at least one functional thread with the base fabric; wherein interlacing points formed by the anchoring weft yarns are staggered along the weft direction, with respect to interlacing points formed by the basic weft yarns.
3. Textile structure according to claim 1, wherein on the front surface of the base fabric, the basic weft yarns present floating stretches each extending straight over a group of the warp yarns between respective interlacing points, the floating stretches of mutually adjacent basic weft yarns covering the interlacing points of the anchoring weft yarns.
4. Textile structure according to claim 1, wherein the weft yarns further include pattern weft yarns having exposed stretches facing at the front surface of the base fabric over the basic weft yarns, and hidden stretches facing at the back surface of the base fabric.
5. Textile structure according to claim 1, further comprising at least one fixing yarn interlaced with said weft yarns and at least one functional thread at the back surface of the base fabric, to link the functional thread with the base fabric.
6. Textile structure according to claim 5, wherein the at least one fixing yarn is interlaced with said anchoring weft yarns.
7. Textile structure according to claim 5, wherein the at least one fixing yarn extends according to a zig-zag pattern overriding the functional thread along the longitudinal development thereof.
8. Textile structure according to claim 1, wherein each of said at least one functional thread is interlaced with the anchoring weft yarns by a plurality of mutually parallel fixing yarns, each substantially extending along the warp direction.
9. Textile structure according to claim 5, wherein at least one of the fixing yarns extends according to a zig-zag pattern overriding warp-wise stretches of the functional thread.
10. Textile structure according to claim 5, wherein at least one warp-wise stretch of the functional thread extends according to a zig-zag pattern overriding one of the fixing yarns.
11. Textile structure according to claim 1, wherein the weft yarns directly engage with the functional thread at the back surface of the base fabric.
12. Process for manufacturing a textile structure comprising: arranging warp yarns extending along a warp direction, according to a first series of warp yarns mutually alternated with a second series of warp yarns; inserting weft yarns along a weft direction transverse to the warp direction, across an open shed formed by the first series and second series mutually converging at a weaving region along the warp direction; mutually swapping the first series and second series to interlace the weft yarn with the warp yarns at the weaving region, whereby a base fabric is formed by the weft yarns interlaced with the warp yarns at respective interlacing points; laying at least one functional thread on the warp yarns near the weaving region, the functional thread lying on a back surface of the base fabric, without crossing a median lying plane of the base fabric; linking the at least one functional tread to the weft yarns by stitching points placed between the median lying plane and the back surface, so that the stitching points are not visible from a front surface of the base fabric opposite to the back surface.
13. Process according to claim 12, wherein inserting the weft yarns includes inserting basic weft yarns and inserting anchoring weft yarns across the open shed at respectively subsequent weaving cycles, the functional thread being linked to the anchoring weft yarns.
14. Process according to claim 12, wherein linking the at least one functional thread comprises forming by a fixing yarn at least one stitching point engaging the anchoring weft yarn and the functional thread.
15. Process according to claim 12, further comprising: inserting the functional thread in the open shed across one of said first series and second series of the warp yarns, and interlacing the functional thread by the weft yarns introduced across the open shed.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Additional features and advantages will be better clarified by the detailed description of a preferred but not exclusive embodiment of a textile structure and a manufacturing method thereof, in accordance with the present invention. Such description will be set forth hereinbelow with reference to the set of drawings, merely provided as a non-limiting example, wherein:
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DETAILED DESCRIPTION
(12) With reference to the attached figures, a textile structure according to the present invention is indicated by the reference number 1. The textile structure 1 comprises a base fabric 2 including warp yarns 3 extending along a warp direction WR and weft yarns 4a, 4b, 4c extending along a weft direction WF. The weft direction WF is substantially perpendicular or anyway transverse to the warp direction WR.
(13) In the examples herein shown, the warp yarns 3 lay preferably on a common plane, and a median lying plane P of the base fabric 2 is defined, containing the longitudinal geometric axes of the warp yarns 3. In possible alternative embodiments, the warp yarns 3 may be mutually staggered. In this latter case, the median lying plane P of the base fabric 2 is equidistant from the longitudinal geometric axes of the mutually staggered warp yarns 3.
(14) The base fabric 2 presents a front surface F and a back surface B extending mutually parallel and equidistant to the median lying plane P, at respective opposite sides with respect to this latter.
(15) The weft yarns 4a, 4b, 4c interlace with the warp yarns 3 at respective interlacing points IP. At each interlacing point IPa, IPb, the respective weft yarn 4a, 4b, 4c crosses the median lying plane P. Each weft yarn 4a, 4b, 4c may interlace with the warp yarns 3 according to any desired sequence wherein, between every two mutually subsequent interlacing points IPa, IPb, the respective weft yarn 4a, 4b, 4c overrides one or more of the warp yarns 3, alternatively shifting from the front surface F side to the back surface B side, and vice-versa, across the median lying plane P. Preferably, at least basic weft yarns 4a and anchoring weft yarns 4b are discernible among the weft yarns 4a, 4b, 4c.
(16) The basic weft yarns 4a are preferably formed according to one or more groups, each consisting of two or more basic weft yarns 4a, extending mutually parallel to engage the warp yarns 3 according to a same basic interlacing sequence which is identical for all the basic weft yarns 4a belonging to the same group. Basic interlacing points IPa formed by the basic weft yarns 4a, or each group thereof, are therefore respectively aligned along the warp direction WR. Preferably, at least on the front surface F of the base fabric 2, the basic weft yarns 4a present floating stretches FS each extending straight over a group of the warp yarns 3, between the respective basic interlacing points IPa.
(17) The anchoring weft yarns 4b interlace with the warp yarns 3 according to an anchoring interlacing sequence, preferably different from the basic interlacing sequence. According to the anchoring interlacing sequence, anchoring interlacing points IPb formed by the anchoring weft yarns 4b are staggered along the warp direction WR, with respect to basic interlacing points IPa formed by the basic weft yarns 4a.
(18) If required, the basic weft yarns 4a and the anchoring weft yarns 4b may be obtained from a same continuous thread that is supplied during the weaving process so to interlace with the warp yarns 3 according to the 5 mutually distinct basic interlacing sequence and anchoring interlacing sequence, to define the basic weft yarns 4a and the anchoring weft yarns 4b, respectively. In a further embodiment, distinct continuous threads, possibly differing in material, diameter, color etc., may be provided to form the basic weft yarns 4a and anchoring weft yarns 4b, respectively.
(19) The anchoring interlacing points IPb may be covered by the basic weft yarns 4a at the front surface F of the base fabric 2. Indeed, the floating stretches FS of mutually adjacent basic weft yarns 4a may cover all the anchoring interlacing points IPb of the anchoring weft yarns 4b, or a part of them, as schematically shown in
(20) The weft yarns 4a, 4b, 4c may further include pattern weft yarns 4c. Each pattern weft yarn 4c exhibits exposed stretches ES superimposed over the basic weft yarns 4a in such a manner to face at the front surface F of the base fabric 2, as well as hidden stretches HS facing at the back surface B of the base fabric 2. Pattern interlacing points IPc are provided along the pattern weft yarn 4c, each between one of the exposed stretches ES and the consecutive hidden stretch, across the median lying plane P. Each exposed stretch extends between two respective pattern interlacing points IPc and overrides one or more warp yarns 3 according to a desired pattern interlacing sequence. Preferably, the pattern weft yarns 4c are obtained from one or more respective pattern continuous threads, which are distinguished from the weft continuous thread used for the basic weft yarns 4a. Different interlacing sequences for the respective pattern weft yarns 4c may be selected and combined according to a pre-established weaving program, to form any desired figures, symbols or writes over the front surface F of the base fabric 2.
(21) Preferably, the pattern weft yarns 4c cover by their exposed stretches ES the underlying basic weft yarns 4a and/or anchoring weft yarns 4b with their interlacing points IPa, IPb. These measures further improve concealing of the anchoring interlacing points IPb, to make them not visible looking at the textile structure 1 from the front surface F side. Efficient concealing may be improved by choosing for the pattern weft yarns 4c a diameter greater than that of the basic weft yarns 4a and/or anchoring weft yarns 4b.
(22) The textile structure 1 further comprises one or more functional threads 5, which extend according to a pre-established pattern at the back surface B of the base fabric 2. The functional threads 5 may for example consist of electric conductive threads which function as an antenna, to form an RFID system in combination with an RFID chipset to be associated with the textile structure 1. In such a case, the functional threads 5 may extend each according to a waveform pattern, exhibiting warp-wise stretches 5a extending along the warp direction WR interspersed in alternate sequence with weft-wise stretches 5b extending along the weft direction WF or anyway transverse to the warp direction WR.
(23) In different embodiments, the functional threads 5 may be used for transporting electric current or signals. The functional threads 5 may also be realized in the form of optical fiber.
(24) Each functional thread 5 lies at the back surface B of the base fabric 2, without crossing the median lying plane P, and is linked with one or more of the weft yarns 4a, 4b, 4c. More particularly, linking of the functional thread 5 with the base fabric 2 is preferably achieved by the anchoring weft yarns 4b. Indeed, the functional thread 5 is preferably linked to one or more of the anchoring weft yarns 4b by stitching points SP positioned between the median lying plane P and the back surface B of the base fabric 2. The functional thread 5 and the stitching points SP are therefore not visible from the front surface F opposite to the back surface B, even in the absence of the pattern weft yarns 4c. Moreover, the positioning of the stitching points SP is such that their presence does not affect the correct positioning of the basic weft yarns 4a and/or pattern weft yarns 4c at the front surface F.
(25) More particularly, in the first, second and third embodiments better shown in
(26) According to the first embodiment better shown by
(27) As clearly derivable from
(28) The textile structure 1 may be conveniently produced by a textile machine 7 equipped with a device for incorporating additional knitting and/or cover threads. Only some parts of the textile machine 7 will be discussed in the following description. Other parts are not shown nor described herein in detail, as they can be made in any convenient manner. The textile machine 7 may be, for example, a needle loom, a rapier loom, or other kind of weaving loom. For example, a weaving loom of the type already known from WO 2017/042015 A1 in the name of the same applicant may be used to achieve the present invention.
(29) The basic operational cycle for forming the base fabric 2 occurs in a known manner, whereby the warp yarns 3 extending along a warp direction WR, are arranged to form a first series S1 of warp yarns 3 and a second series S2 of warp yarns 3, mutually alternated according with a pre-established weaving program. The warp yarns 3 respectively belonging to the first series S1 and second series S2 are mutually diverged, to form an open shed 8 across which at least one weft yarn 4a, 4b, 4c is inserted by a weft insertion device 9, along the weft direction WF transverse to the warp direction WR.
(30) The warp yarns 3 belonging to the first series S1 and second series S2 are then mutually swapped to interlace with the weft yarn 4a, 4b, 4c at a weaving region 10, at which the first series S1 and second series S2 of warp yarns 3 mutually converge. The base fabric 2 is thus formed by the weft yarns 4a, 4b, 4c interlaced with the warp yarns 3 at the respective interlacing points IPa, IPb, IPc. A movable reed 11 provides for compacting the weft yarn 4a, 4b, 4c against the previously formed base fabric 2 at the weaving region 10.
(31) During the weaving process, changes in the mutual distribution sequence among the warp yarns respectively assigned to the first series S1 and second series S2, and/or insertion in the open shed 8 of a distinct weft thread in addition or substitution to a weft thread used to form the basic weft yarns 4a, allow to achieve the insertion of the anchoring weft yarns 4b according to a desired sequence into the base fabric 2.
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(33) In
(34) In
(35) In
(36) In
(37) In
(38) In
(39) In
(40) In a subsequent operating cycle, the functional thread 5 may be laid and fixed to the base fabric 2 in a similar manner.
(41) In a known manner, the basic weft yarns 4a and pattern weft yarns 4c may be inserted across the open shed 8 together with the anchoring weft yarn 4b and/or during subsequent weaving cycles, to form the textile structure 1. The functional thread guide 12 and fixing yarn guide 13 are independently movable one with respect to the other, so that the deposition pattern of the functional thread 5 and fixing yarn 6 may be independently changed at each operation cycle, to confer any desired final shape to the functional thread 5. In particular, when the warp-wise stretch 5a of the functional thread 5 is formed, the movement of the functional thread guide 12 in the weft direction WF is stopped and the fixing yarn 6 is interlaced by the weft yarns 4a, 4b, 4c at stitching points SP distributed at opposite sides of the functional thread 5, along the longitudinal development of the latter.
(42) In the second and third embodiments of
(43) According to
(44) Several phases of the engagement of the functional thread 5 and fixing yarn 6 to the base fabric 2 according to the manufacturing process of the embodiment of
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(46) Fixing yarn guides 13, one for each respective fixing yarn 6, and the functional thread guides 12 are at their raised positions over the weaving region 10. The hook member 14 is raised over the weaving region 10 too.
(47) The fixing yarn guides 13 slightly move along the weft direction WF to shift each fixing yarn 6 over the respective warp yarn 3 in the base fabric 2. The functional thread guides 12 move along the weft direction WF to extend the weft-wise stretch 5b of the respective functional threads 5 over the weaving region 10. The hook member 14 starts moving down toward the weaving region 10.
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(49) Meanwhile, the hook members 14 move down toward the base fabric 2, so to engage the functional threads 5 over the weaving region 10. Each functional thread 5 is therefore held at the weaving region 10, over the warp yarns 3, without crossing the median lying plane P, whereas the respective fixing yarns 6 are dipped into the shed 8 through the warp yarns 3 and stitched over the respective functional threads 5, e.g. at the weft-wise stretches 5b thereof. Thereafter, the weft insertion device 9 inserts the anchoring weft yarn 4b along the weft direction WF through the open shed 8, so to interlace with the fixing yarns 6.
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(51) In this embodiment too, the basic weft yarns 4a and pattern weft yarns 4c are inserted across the open shed 8 along with the anchoring weft yarn 4b and/or during subsequent weaving cycles, to form the textile structure 1.
(52) The independent movement of the functional thread guides 12 and fixing yarn guides 13, especially along the weft direction WF, allows the deposition design of the functional thread 5 and fixing yarn 6 to be changed as desired at each operation cycle. In particular, movement of the functional thread guides 12 in the weft direction WF can be stopped during several subsequent weaving cycles, to form the warp-wise stretches 5a of the functional threads 5, while the fixing yarns 6 are interlaced by the weft yarns 4a, 4b, 4c at stitching points SP distributed at opposite sides of the functional thread 5, along the longitudinal development of the latter.
(53) A possible alternative embodiment shown in
(54) In the further alternative embodiment shown in
(55) As shown in
(56) This embodiment may simplify the construction and manufacturing of the textile structure 1, especially when the functional thread 5 is strong enough to bear greater stresses applied during manufacturing.
(57) Embodiment such as illustrated in