Patent Abstract:
A sueded knitted fabric is provided, comprising a technical face, a technical back, and a knitted body extending between the technical face and the technical back. The technical face, technical back, and knitted body comprise sueded yarns throughout.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the priority to U.S. patent application Ser. No. 11/485,514 filed on Jul. 12, 2006, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/738,482, filed Nov. 21, 2005, the contents of which are incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention is related to sueded fabrics that are knitted with needles having at least one abrasive surface. 
     2. Description of Related Art 
     In the textile industry, it is known to finish certain woven, weft knitted, and warp knitted fabrics by abrading one or both surfaces of the fabric. The knitted fabric is abraded using sandpaper or a similarly abrasive material to cut and raise the constituent surface of the yarns knitted in the fabric into a closely raised nap, producing a soft, smooth surface texture resembling suede leather. This operation is commonly referred to as sueding, sanding, brushing, emerising, or napping (hereinafter “sueding” or “sueded”). 
     Sueding is conventionally performed by a specialized fabric machine that passes a knitted fabric over one or more finishing rolls, normally after the fabric has been dyed. The finishing rolls are covered with abrasive material and are rotated rapidly against the surface of the fabric. Unfortunately, conventional sueding operations have several significant disadvantages. 
     For example, conventional sueding processes require the knitted fabric to undergo one or more separate sueding processes after the knitting process, which can increase the cost of the resultant fabric. 
     In addition, conventional sueding machines necessarily cause a substantial amount of fibrous lint and fly, abrasive dust, and the like to be released from the fabric and the abrasive rolls (hereinafter “debris”). The debris can become airborne, posing a health hazard to machine operators. In addition, the debris may become embedded in the interstices of the fabric, detracting from its surface finish. Still other of the debris may accumulate on the abrasive surface of the finishing rolls, tending to negate at least somewhat their abrasive sueding effect. 
     Further, conventional sueding machines are typically limited in their operational widths to the processing of fabrics no greater on average than 60 to 65 inches in width. On the other hand, many conventional weaving and warp knitting machines are available for producing fabrics in widths two to three times or more greater in width than the effective operating width of conventional sueding equipment. Thus, when it is desired to produce a suede finish on fabrics of such greater widths than the maximum widthwise finishing capability of sueding machines, it is necessary to initially cut the fabric lengthwise into a least two smaller width lengths which are then individually processed through a sueding machine. Subsequently, the cut fabric must then be rejoined. 
     Still further, conventional sueding machines can produce streaks within the resultant fabric. These are relatively lighter or darker lines that appear in the warp direction. While these may be due to fabric or yarn irregularities, they may also occur due to random variation in the grit particles on the sueding machine. If a particularly large or aggressive particle is present in a particular location on the sueding machine, more fibers will be cut in that area such that lighter colored fibers in the yarn core may be exposed in that area, producing a streak. One method of mollifying the effect of individual grit particles to make the abrasive drum very large so that the effect of a single grit particle is not continuous. However, this method reduces the pressure of the fabric against the treatment roll, requiring either relatively coarse grit, or some other means to create pressure, such as through the utilization of flaps, backup rolls, or air pressure. Another method to make the streak more difficult to observe is to oscillate the treatment rolls along the rotational axis, which creates a sinusoidal pattern on the fabric, so that the effect of single grit particles is spread out. Oscillation is often used in multi-roll treatment machines, with the oscillations timed so as not to be superimposed. All of these processes require specialized equipment that tends to further increase the cost of the resultant fabric. 
     Another common problem with conventional sueding processes is that the cutting of fibers reduces the tensile properties of the fabric, regardless of yarn type. 
     In addition, since the sueding is conventionally performed after the fabric has been dyed there is also typically a shade change from the dyed product to the sueded one, which can be difficult to control. 
     Accordingly, there is a need for sueded fabrics and methods of knitting such fabrics that overcome and/or mitigate one or more of the aforementioned deleterious effects of the prior art. 
     BRIEF SUMMARY OF THE INVENTION 
     It is another object to provide a method of knitting a sueded fabric that includes using a knitting needle having an abrasive surface and moving a yarn across the abrasive surface while knitting the fabric. 
     It is yet another object to provide a sueded knitted fabric that includes sueded yarns throughout the body of the fabric. 
     These and other objects and advantages of the present invention are provided by a method of knitting a sueded fabric that includes forming an abrasive surface on a knitting needle, moving said knitting needle through a knitting cycle, and moving a yarn across said abrasive surface to form fibrils on said yarn as said knitting needle is moving through said knitting cycle. 
     Still other objects and advantages of the present invention are provided by a suede knitted fabric having a technical face, a technical back, and a knitted body. The technical face, technical back, and knitted body each include sueded yarns. 
     The above-described and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a side view of an exemplary embodiment of a knitting needle according to the present disclosure shown in a casting off position of the knitting cycle; 
         FIG. 2  is a block diagram of a method of knitting a sueded fabric according to an exemplary embodiment of the present disclosure; 
         FIG. 3  is a top perspective view of a suede knitted fabric according to an exemplary embodiment of the present disclosure; 
         FIG. 4  is a side view of the knitting needle of  FIG. 1 , shown in a rest or ground position of the knitting cycle; 
         FIG. 5  is a side view of the knitting needle of  FIG. 1 , shown in a tuck height position of the knitting cycle; 
         FIG. 6  is a side view of the knitting needle of  FIG. 1 , shown in a clearing height position of the knitting cycle; 
         FIG. 7  is a side view of the knitting needle of  FIG. 1 , shown in a yarn feeding position of the knitting cycle; 
         FIG. 8  is a side view of the knitting needle of  FIG. 1 , shown in a cast off position of the knitting cycle; 
         FIG. 9  is a side view of the knitting needle of  FIG. 1 , shown in a knock over position of the knitting cycle; and 
         FIG. 10  is a side view of the knitting needle of  FIG. 1  illustrating one or more regions of the needle having an abrasive surface. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the drawings and in particular to  FIG. 1 , a knitting needle according to the present disclosure is generally illustrated by reference numeral  10 . Advantageously, needle  10  includes at least one abrasive surface  12  defined thereon for abrading a yarn  14  during the knitting process. In this manner, needle  10  can be used to knit sueded fabrics. 
     Needle  10  includes a shank  16 , hook  18 , and a latch  20 . Abrasive surface  12  can be formed on the shank  16 , hook  18 , latch  20 , or combinations thereof. 
     In the embodiment illustrated in  FIG. 1 , abrasive surface  12  is defined on shank  16  at least at a front region  22  of the shank. Front region  22  is the side of needle  10  proximate the open side of hook  18 . It is also contemplated by the present disclosure for abrasive surface  12  to be defined circumferentially about shank  16 . 
     Abrasive surface  12  has a predetermined surface roughness. In one embodiment, abrasive surface  12  can be formed by knurling, scuffing, or otherwise roughing the surface finish of shank  16  in region  22 . In another embodiment, abrasive surface  12  can be formed by applying an abrasive coating or paint to region  22  of shank  16 . In still another embodiment, abrasive surface  12  can be formed by applying an abrasive element such as, but not limited to, a layer of emery paper (not shown) to region  22  of shank  16 . Thus, abrasive surface  12  can be integral to and/or attached to shank  16 . 
     The predetermined surface roughness abrasive surface  12  is dependent upon, at least in part, the desired hand feel in the resulting fabric and the composition of yarn  14 . Preferably, the predetermined surface roughness abrasive surface  12  is sufficient to only mildly suede yarn  14 . Specifically, the predetermined surface roughness of abrasive surface  12  is sufficient to form fibrils  32  at the surface of yarn  14 , without cutting through the yarn. 
     As will be described in detail below, during a loop casting off portion of the knitting operation, needle  10  is moved in a first direction  26  so that yarn  14  is pulled across region  22  to cast off a knitted loop  30 . As needle  10  is used to form knitted loop  30 , yarn  14  is in contact with abrasive surface  12  while the needle is moving in the first direction  26  and the loop is pulled in a second direction  28 . It has been found that the movement of needle  10  and loop  30  in first and second directions  26 ,  28 , respectively, while yarn  14  is in contact with abrasive surface  12  suedes the yarn during the formation of the knitted loop  30  to form fibrils  32  at the surface of the yarn. 
     Accordingly, needle  10  having abrasive surface  12  at region  22  allows knitted loop  30  to be sueded directly on the knitting machine during the casting off of the knitted loop from the needle. Yarns  14  may initially, i.e., prior to knitting, have a non-sueded outer surface. Advantageously, the resulting fabrics knitted with needle  10  are sueded with no extra labor costs or process costs. Further, the resulting fabrics knitted with needle  10  have yarns  14  that are sueded throughout the body of the fabric. In contrast, fabrics exposed to a sueding process after knitting merely have sueded surfaces (i.e., face and/or back). 
     Since needle  10  provides yarns  14  that are sueded throughout the body of the fabric, the resulting fabric can be produced with substantially no face-to-back differentiation in color and/or hand-feel. 
     Referring now to  FIG. 2 , a method of knitting a sueded fabric according to the present disclosure is generally illustrated by reference numeral  40 . Method  40  includes a first step  42  and a second step  44 . First step  42  includes forming abrasive surface  12  on needle  10 . Second step  44  includes moving yarn  14  across abrasive surface  12  to form fibrils  32  at the surface of the yarn as needle  10  is forming loop  32  from the yarn. Second step  44  is repeated until a plurality of loops  30  are knitted to result in the sueded fabric being knitted. 
     Forming abrasive surface  12  on needle  10  of first step  42  can include knurling and/or scuffing region  22  of shank  16 . In another embodiment, forming abrasive surface  12  on needle  10  of first step  42  can include applying an abrasive coating or paint to region  22  of shank  16 . In still another embodiment, forming abrasive surface  12  on needle  10  of first step  42  can include applying an abrasive element, such as a layer of emery paper, to region  22  of shank  16 . 
     Referring now to  FIG. 3 , a sueded knitted fabric according to the present disclosure is generally illustrated by reference numeral  50 . Fabric  50  includes a technical face  52 , a technical back  54 , and a knitted body  56 . Fabric  50  is knitted from yarns that are sueded throughout body  56  of the fabric. Thus, fabric  50  has sueded yarns at technical face  52 , technical back  54 , and fabric body  56 . Preferably, fabric  50  has substantially the same color and/or hand-feel at face and back  52 ,  54 . Fabric  50  can be a weft knitted fabric or a warp knitted fabric. 
     It should be recognized that needle  10  is described herein by way of example as having abrasive surface  12  at front region  22  so that the needle suedes loop  30  during the casting off of the knitted loop. Of course, it is contemplated for needle  10  to have abrasive surface  12  at any desired region of the needle so that the needle suedes yarn  14  during any part of the knitting cycle. 
     Needle  10  is illustrated in  FIGS. 4 through 9  during various stages of the knitting cycle. 
       FIG. 4  shows needle  10  in a rest or ground position of the knitting cycle. Here, needle  10  is stationary with a previously knitted loop  30  enclosed in hook  18  by latch  20 , which is in a closed position. 
       FIG. 5  shows needle  10  moving upwards in first direction  26  and in a tuck height position of the knitting cycle. In the tuck height position, knitted fabric  32  is held stationary as latch  20  is moved to an open position. Needle  10  continues to move upward until it reaches a clearing height position as shown in  FIG. 6 . In the clearing height position, needle  10  is ready to receive a new yarn  14 . 
     Needle  10  is shown in a yarn feeding position of the knitting cycle in  FIG. 7 . Here, needle  10  is moved downwards in first direction  26  so that the new yarn  14  is laid into hook  18  and latch  20  is moved to its closed position, forming a new loop therein. As the new loop is pulled downward by needle  10 , the needle pulls the new loop through the old loop. Once needle  10  reaches its cast off position as shown in  FIG. 8 , the old loop is cast off into fabric  32  and the needle continues downward to the knock over position of the knitting cycle as shown in  FIG. 9 . 
     Advantageously, needle  10  can include abrasive surface  12  at any region so that yarn  14  is sueded as the needle is moved through all, or any selected portion of the knitting cycle. For example as shown in  FIG. 10 , needle  10  can include abrasive surface  12  at an inner region  34  of hook  18  and/or an inner region  36  of latch  18  so that yarn  14  is sueded as the needle is moved between the rest position to the clearing height position, or any portions thereof. Also, needle  10  can include abrasive surface  12  at an outer region  38  of latch  18  so that yarn  14  is sueded as the needle is moved between the clearing height position and the cast off position, or any portions thereof. Accordingly, the abrasive surface  12  in contact with yarn  14  during knitting causes the yarn  14  to be partially sueded in a continuous path along the eater surface of the yarn as the yarn forms the loops during the knitting cycle. As can he understood, then, the loops formed during knitting would have partially sueded outer surfaces. 
     It should also be noted that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated. 
     While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the appended claims.

Technology Classification (CPC): 3