This invention relates to a device and a method for the controlled removal of piles from a pile fabric.
The term pile fabric is used to mean a fabric comprising a base textile support on which a plurality of piles of variable length extends on one side. The piles are fixed to the base support by various techniques known in the sector, such as, for example, by forming knots between the piles and the patterns of the base support, folding each individual pile substantially in a "U" shape in such a way that both ends of the pile pass beyond the base support.
Currently, in order to remove predetermined portions of pile, for example for aesthetic and decorative purposes, there are different types of operations.
A first prior art type consists in the use of so-called Jacquard frames. Jacquard frames are a type of frame for weaving which allow complex patterns to be executed on the fabric being processed.
With respect to the traditional frame, a station is added which allows the automatic movement of the individual warp threads creating the decorated portions according to predetermined patterns.
In practice, the Jacquard frames doe not operate by removing pile where it is not desired, but during the step for producing the fabric they allow the "insertion" of pile only allow where it desired by the user according to the required pattern.
This type of frame is very widespread in the textile sector and it was the first to have allowed the execution of surface decorations on the fabric through a frame; however, it has major drawbacks.
A first major drawback is due to the fact that the complete machinery to achieve a processing on a fabric is very complex and therefore very expensive.
A second equally major drawback is due to the fact that the production by means of the Jacquard frames is very slow.
A second type of procedure known for removing portions of pile from pile fabrics involves the use of hot cylinders (or steam cylinders) which allow the piles to be flattened and folded in predetermined areas.
In practice, the pile fabric is made to pass in contact with hot a cylinder bearing in relief the decorations to be executed and this, by means of the heat and the pressure of the fabric against it (for example, generated by a second cylinder) executes the flattening and folding of the piles located in the portions to be decorated.
This type is functional and fast but it also has considerable drawbacks.
An example of prior art is described in patent document
A first major drawback is due to the operating cost; in fact, since the operation is to be performed "hot", a large quantity of energy is necessary for heating the cylinder or for generating the steam.
A second equally major drawback is due to the fact that the piles are simply flattened and not completely removed.
As a result, the pattern is not permanent but only temporary; it is fact known that after a few washes of the fabric decorated by this procedure the piles tend to lose the flattening, therefore rendering the patterns less visible.
Moreover, the cylinders used for this purpose are made of metal and their construction is very expensive.
The aim of this invention is to provide a device and a method for controlled removal of piles from a pile fabric which overcomes the drawbacks of the prior art.
In this context, a first aim of the invention is therefore to provide a device and a method for the controlled removal of piles from a pile fabric which is able to optimise the timing and costs for the production of a decorated pile fabric.
A further aim is to provide a device and a method for controlled removal of piles from a pile fabric which allows a permanent decoration of the pile fabric to be obtained which is not subject to decay over time and during use.
The above aims are achieved by a device for the controlled removal of piles from a pile fabric comprising the technical features described in one or more of the accompanying claims.
Further features and advantages of the invention are more apparent in the non-limiting description of a preferred embodiment of it, as illustrated in the accompanying drawings, in which:
With reference to the accompanying drawings, the numeral 1 denotes in its entirety a device for controlled removal of piles 8 from a pile fabric 7.
The term pile fabric means a fabric 7 comprising a base support 13 which is passed through by a plurality of piles 8.
The piles 8 in particular pass entirely through the thickness of the support 13 of the fabric 7.
The fabric 7 has two surfaces, a lower surface 9, without piles 8 which project out from the support 13 but equipped with portions 12 for fastening the piles 8; and an upper surface 14, which is the visible surface of the finished fabric 7 and which comprises a plurality of piles 8 which project from the base support 13 typically in a range of between 1 mm and 50 mm, preferably between 2 mm and 25 mm.
The piles 8 pass through the entire thickness of the support fabric 7 and are connected by techniques known in the textile sector on the lower surface 9.
However, regardless of the specific type of processing, a plurality of portions 12 for mechanical type fastening the piles 8 are created on the surface 9.
The fabric 7 therefore has a plurality of piles 8 extending for a few millimetres on the visible side of the fabric 7 and with the same plurality of piles 8 but not extended, that is to say, in the form of fastening portions 12, relative to the support 13 in the lower surface 9.
A possible schematic representation of a fabric 7 designed to be processed with a device 1 and the method according to the invention is shown in
A device 1 for the controlled removal of piles 8 from a pile fabric 7 according to the invention and in its basic embodiment comprises a first cylinder 2 rotating relative to a respective axis X.
The first cylinder 2 comprises a plurality of relief portions 6, which extend from the side surface 5 and which are designed to come into contact with a surface 14 having a plurality of piles 8 of the pile fabric 7.
The relief portions 6 constitute the positive of the decoration to be obtained on the fabric 7.
The device 1 also comprises a second cylinder 3 rotating relative to a respective axis Y, parallel to the axis X.
The second cylinder 3 is movable towards the first cylinder 2 in the direction indicated in
The second cylinder 3 comprises a plurality of rigid bristles 4, preferably metallic, designed and shaped for making contact with the surface 9 of the fabric 7, that is to say, the surface opposite to that with the plurality of piles 8, or more precisely the surface facing the fastening portions 12 of the piles 8.
The first cylinder 2 and the second cylinder 3 define a zone 11 for processing the fabric 7 where the actual removal of the piles 8 occurs at the relief portions 6, that is, in the zones planned by the specific pattern 10 desired on the finished fabric 7.
The rigid bristles 4 or the metal brush, impacting in rotation on the surface 9 of the fabric 7, and therefore on the fastening portions 12, remove the piles 8 pulling them out from the support 13, according to the direction indicated in
In order to optimise and modulate the effect of removal of the piles 8 from the support 13 of the fabric 7 it is possible to configure the device 1 in such a way as to vary their extraction force.
More specifically, it is possible for the two cylinders 2, 3 to rotate with different or the same directions.
Moreover, again with the same purpose, it is possible to rotate the two cylinders 2, 3 at different angular speeds or at substantially equal speeds. Advantageously, moreover, depending on, for example, the type of fabric 7 being processed, it is possible for the bristles 4 to be made of different materials, in any case substantially rigid, for example metal or plastic. The bristles 4 may also, as well as having a linear extension, end with an at least partly hooked portion.
In this way, an easier removal of the piles 8 from the support 13 of the fabric 7 is obtained.
A fundamental importance for the purposes of processing fabric 7 by means of a device 1 according to the invention is that all the processing steps may performed "cold", that is to say, without the need for heating the processing zone 11, the first cylinder 2 and the second cylinder 3.
A further aspect of the invention consists in a method for the controlled removal of piles 8 from a pile fabric 7, of the type described above, comprising the steps of:
Advantageously, the step of rotating the first cylinder 2 and the second cylinder 3 can occur with the same or different directions and at different or substantially equal angular speeds.
The invention overcomes the drawbacks of the prior art and brings major advantages.
A first major advantage consists in providing a device and a method for removing piles 8 from a pile fabric 7 in a inexpensive and fast manner.
A second major advantage consists in the fact that the processing occurs "cold", that is to say, without the need to provide any heat outside the system.
A further advantage consists in the fact that the processing according to the invention makes it possible to obtain a definitive decorative effect.
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