Fabric having a decorative textured surface

• US 6,823,900 B2
• Filed: 08/17/2001
• Issued: 11/30/2004
• Est. Priority Date: 08/17/2001
• Status: Expired due to Fees

• Current Assignee: Tietex International Limited
• Original Assignee: Tietex International Limited
• Inventors: Carpenter, Jeffrey, Carpenter, Glenda, Wildeman, Martin
• Primary Examiner(s): Calvert, John J.
• Assistant Examiner(s): Muromoto, Jr., Robert H.
• Application Number:
  US09/932,274
• Publication Number:
  US 20030033698A1
• Time in Patent Office: 1,201 Days
• Field of Search: 139/383.R, 139/391, 139/420.R, 139/426.R
• US Class Current: 139/391
• CPC Class Codes: D06C 11/00 Teasing, napping or otherwise roughening or raising pile of textile fabrics for making patterns or designs D06C23/02
• CPC Class Codes: D06C 13/00 Shearing, clipping or cropping surfaces of textile fabrics; Pile cutting; Trimming seamed edges for making patterns or designs D06C23/02
• CPC Class Codes: D06C 23/02 by singeing, teasing, shearing, etching or brushing

Abstract

A fabric material having a textured surface and a process for producing the fabric material are disclosed. The fabric material is made from a woven fabric substrate including a warp yarn and at least first and second pick yarns. The first pick yarn is woven into the fabric substrate to provide integrity. The second pick yarn, on the other hand, is a yarn that is nappable from the surface of the fabric substrate. In accordance with the present invention, the fabric substrate is fed through a napping process which naps the second pick yarn appearing on the face of the fabric. The fabric substrate is then fed through a shearing process which shears the napped yarns. The napped and sheared yarns form pile-like tufts on the surface of the fabric. Ultimately, the napped and sheared yarns produce a velvet-like fabric having an improved aesthetic appearance.

Claims

1. A fabric material comprising:

a woven fabric having a weave design repeat including a warp yarn and only two pick yarns comprising a first pick yarn and a second pick yarn, said second pick yarn being more loosely woven into said fabric in comparison to said first pick yarn, said second pick yarn being napped and subsequently sheared.

2. A fabric material as defined in claim 1, wherein said second pick yarn comprises a spun yarn.

3. A fabric as defined in claim 1, wherein said woven fabric comprises a jacquard fabric.

4. A fabric material as defined in claim 1, wherein said warp yarn is present in said woven fabric in an amount of from about 88 warp yarns per inch to about 250 warp yarns per inch, and said first pick yarn is present in said fabric in an amount from about 34 yarns per inch to about 38 yarns per inch.

5. A fabric material as defined in claim 1, wherein said second pick yarn comprises a spun cotton yarn having a yarn count of from about 6/2 t about 6/1.

6. A fabric material as defined in claim 1, wherein said second pick yarn comprises a continuous filament polyester yarn.

7. A fabric material as defined in claim 1, wherein said woven fabric comprises an air jet woven fabric.

8. A fabric material as defined in claim 2, wherein said second pick yarn contains synthetic fibers.

9. A fabric material as defined in claim 4, wherein said warp yarns have a denier of from about 100 to about 2,000.

10. A fabric material as defined in claim 1, wherein said second pick yarns form a visible pattern on said fabric.

11. A fabric material as defined in claim 1, wherein said woven fabric includes from about 3 to about 7 pick yarns per inch.

12. A fabric material as defined in claim 1, wherein said first pick yarn is woven into said fabric using a plain weave, a tabby weave, or a taffeta weave.

13. A fabric material as defined in claim 1, wherein said first pick yarn has a yarn count from about 12/1 to about 6/1 or equivalent count thereof.

14. A fabric material having a weave design repeat including a textured surface comprising:

a jacquard fabric having a warp yarn, a first pick yarn and a second pick yarn, said second pick yarn being more loosely woven into said fabric in comparison to said first pick yarn, said second pick yarn comprising a spun yarn, said second pick yarn being napped from the surface of said fabric and subsequently sheared, said second pick yarn being woven into said fabric so as to form a visible pattern on said fabric and wherein said warn yarn is present in said woven fabric in an amount of from about 88 warp yarns per inch to about 250 warn yarns per inch, and said first pick yarn is present in said fabric in an amount from about 34 yarns per inch to about 38 yarns per inch.

15. A fabric material as defined in claim 14, wherein said second pick yarn comprises a spun cotton yarn having a yarn count from about 6/2 to about 6/1.

16. A fabric material as defined in claim 14, wherein said first pick yarn is woven into said fabric using a plain weave, a tabby weave, or a taffeta weave.