Patent ID: 6579815
Filing Date: 2003-06-17
Classification: A41D,B32B,B63H,D04H,F41H,Y10S,Y10T

Abstract:
A method of forming a fabric of interlaced yarn, comprising:(a) providing an elongated fabric support surface having an elongated axis and opposed lateral edges parallel to the axis, and arranging the surface adjacent a plurality of yarn guide blocks arranged along opposed lateral edges of the elongated surface; (b) providing a plurality of guides on said guide block, each guide adapted to guide a yarn from a yarn source to the support surface; (c) engaging the yarns at one edge of said support surface; (d) providing relative motion between the support surface and each of the plurality of guide blocks so that the guide blocks deposit yarn from the guides onto the surface in a first diagonal direction relative to the edge of the surface and in a predetermined direction along the support surface to sparsely cover a predetermined support surface area with Yarns in said first diagonal direction at a repeating cell distance of three or more yarn widths; (e) engaging the yarns at an opposed edge of said support surface; (f) reversing the relative motion of the guide blocks and support surface so that the guide blocks deposit yarn from the guides onto the surface in a second diagonal direction relative to the edge of the surface and in said predetermined direction to sparsely cover said predetermined support surface area with yarns in said second diagonal direction at a repeating cell distance of three or more yarn widths, the second diagonal direction crossing the first diagonal direction; (g) arranging said guide blocks and guides along said elongated surface and arranging said relative motion so that when said yarns from said blocks are deposited on said surface, the diagonal positions of the yarns from one block are offset from a direct overlapping alignment with the yarns from the remaining blocks to thereby densely cover the support surface with said yarns in one cycle of said relative motion from one edge to the opposite edge and back to the one edge during repeated cycles of said relative motion; (h) connecting a portion of the yarns deposited in the first direction to yarns deposited in the second direction where they cross.