Textile fabric roll and method
United States Patent Lee, Jr.  
 Apr. 8, 1975 [75] Inventor: Charles D. Lee, lr.. Charlotte. NC  
 [73] Assignee: Parks-Cramer Company, Fitchburg.  
 Mass.  
 [22] Filed: Oct. 10, 1973 (211 Appl. No: 404,865  
  Related U.S. Application Data [63] Continuation-impart of Ser. No. 389.034. Aug. 21. 1973, which is a continuation-in-part of Serv No. 283 l65, Aug. 23. I972. abandoned [52] U.S. Cl. 139/291 C; 28/72 CS [51] Int. Cl B65h 35/10 [58] Field of Search 139/291 C: 28/76 T. 72 CS; 128/155. 170, 171.56, 57; 117/122; 206/59; 161/167; 242/562, 56.4, 56.5  
 [56] References Cited UNITED STATES PATENTS 1,065,654 6/1913 Bauer l28/155 TEXTILE FABRIC ROLL AND METHOD ELECTRICAL 2.435543 2/1948 Johnson et a]. 28/76 T Primary limminer-Henry S. .laudon AHOY/1U). Agent. or Firm-Parrott. Bell, Seltzer, Parks &amp; Gibson [57] ABSTRACT A segment of a textile fabric is separated by rolling the fabric while at least substantially weakening at least one predetermined portion of the yarns of the fabric. In the roll. a plane of weakness generally perpendicular to the axis about which the fabric was rolled permits the segment of the roll to one side of the plane to be readily separable from the segment to the other side thereof. In a preferred arrangement. at least one separable segment is a disposable fringed edge formed during interweaving of strands of warp and filling yarns. so that the fringed edge is readily taken-up during formation of the fabric and yet is readily separated when no longer desired or necessary.  
 5 Claims, 4 Drawing Figures TEXTILE FABRIC ROLL AND METHOD This application is a continuation-in-part of copending application Ser. No. 389,034, filed Aug. 21. I973 and entitled Apparatus and Method for Severing Textile Fabric&#34; which application is in turn a continuationin-part of application Ser. No. 283,165, filed Aug. 23, 1972, entitled Shuttleless Textile Loom Yarn Severing Apparatus and Method&#34;, and now abandoned.  
  Textile fabrics are commonly formed by interengagement of strands of yarn. As pointed out in the aforementioned related applications, which are hereby incorporated by reference to the extent required for full understanding of this invention, the technology of textile fabric formation now includes the use of weaving machines which interweave warp and filling yarns. Such weaving machines, and particularly the DSL weaving machine produced by the Draper Division of Rockwell International, produce a textile fabric in which the filling yarns have free end portions extending from one or both sides of the fabric and defining at least one fringed side edge thereof.  
  It has heretofore been considered desirable to sever such a fringed side edge from the fabric, but certain difficulties have been encountered in accomplishing that function. One such difficulty, of particular interest with regard to the invention to be described hereinafter, lies in the taking-up or winding-up of that segment of the fabric which includes the fringed side edge which has been severed or separated from the remainder of the fabric. While many arrangements have been attempted or proposed heretofore, most are overly complicated and few have successfully dealt with the problem of disposal of such a severed fabric segment.  
  Having in mind the difficulties and deficiencies encountered heretofore. it is an object of this invention to package textile fabric in such a manner that a segment including a fringed side edge is easily handled while being readily separable from the remainder of the fabric. In accordance with this invention. such a package is formed by a length of textile fabric being convolutely wound about a longitudinal axis. The fabric has an at least substantially weakened portion at a predetermined location along the axis for defining a plane generally perpendicular to the axis at which the segment of the roll to one side of the plane is readily separable from the segment to the other side thereof upon rupture of the weakened portion. Preferably, the fabric is formed by interwoven strands of yarn which are at least partially composed of thermoplastic material, the filling yarns extend longitudinally of the roll, and substantially all the filling yarns have had thermoplastic material expelled therefrom by melting and fluid flow impingement.  
  Yet a further object of this invention is to handle a disposable fringed edge by directing a woven fabric having such an edge to pass along a predetermined path of travel while melting and expelling thermoplastic material from a lengthwise zone of the fabric closely adjacent the fringed edge. The fabric is then convolutely wound into an elongate roll, with the roll having a plane of weakness defined by the lengthwise zone. Thereaf ter, the fabric may be ruptured at the plane for separating the fringed edge from the remainder of the roll. However, the fringed edge is wound during packaging with the remainder of the fabric body.  
  Some of the objects of the invention having been stated, other objects will appear as the description proceeds, when taken in connection with the accompanying drawings. in which FIG. I is a view, partly schematic and party perspective, illustrating a weaving machine packaging a roll of textile fabric in accordance with this invention:  
  FIG. 2 is a perspective view ofa roll of textile fabric in accordance with this invention;  
  FIG. 3 is a view similar to FIG. 2, showing the separation of a disposable fringed side edge portion; and  
  FIG. 4 is an enlarged scale perspective view of a portion of a woven textile fabric, illustrating the manner in which separation in accordance with this invention occurs.  
  At the outset of the description which follows. it is to be understood that this description and the accompa nying drawings illustrate a particular form ofthis invention which is the best form contemplated at the time that this description is written. However, it is contemplated that this description and accompanying drawings will permit persons skilled in the textile arts to which this invention relates to apply this invention more broadly. Accordingly, the description and drawings are to be understood as a broad teaching of the invention and are not to be taken restrictively.  
  In the accompanying drawings, a roll of textile fabric formed in accordance with this invention is generally indicated at 10. The fabric F of which the roll 10 is formed is itself formed by interengaging strands of yarn Y (FIG. 4). At least certain of the yarns Y are at least partially composed of thermoplastic material, so that the fabric F is characterized as being formed at least partially by strands which are least partially composed of thermoplastic material. By way ofexample, the warp yarns may be wholly composed of natural fibers such as cotton while the filling yarns are composed of a blend of that natural fiber with a thermoplastic fibers such as polyester. Alternately, the warp yarns may be wholly composed of wholly thermoplastic fibers with the filling yarns being wholly composed of natural fibers. Various natural and thermoplastic fibers conventionally used in textile fabric constructions will be easily recognized by persons skilled in textile arts. In one actual embodiment of this invention, the fabric F has warp and filling yarns wholly composed of cotton throughout most of the fabric, with certain warp yarns of wholly thermoplastic fibers being inserted into the conventional construction of the fabric at specific locations where planes of weakness are to be formed. The presence of thermoplastic material is believed significant for this invention, as will be described more fully hereinafter.  
  The roll 10 is formed by a length of textile fabric F which is convolutely wound about a longitudinal axis (the axis being indicated at 11 in FIGS. 2 and 3). Typically, such convolute winding ofa length of fabric F occurs during formation of the fabric on a weaving machine, such as the machine generally indicated at I2 and illustrated in FIG. 1. Through the use of such a machine, known to persons familiar with the aforementioned DSL machine, warp and filling yarns are interwoven to produce a fabric. Further, free end portions of the filling yarns project from one side of the fabric and define a fringed side edge thereof, indicated along the left side edge 14 of the fabric F in FIG. 1. Similar functions of other fabric forming machines will be recognized by persons skilled in the textile arts.  
  in order to provide for ready handling of the fringed side edge portion [4, while accommodating satisfactor disposal thereof at a later time. the present invention contemplates that the woven fabric F be passed along a predetermined path of travel while thermoplas tic material is melted and expelled from a predetermined portion of the filling yarns in accordance with the invention described in the previously mentioned re lated applications. melting and expulsion of thermoplastic material occurs by impingement of a heated fluid stream. In this manner. an at least substantially weakened portion is formed at a predetermined location along the yarns. FIG 4 is an illustration of such at least substantial weakening of filling yarns which. depending upon the thermoplastic content of the warp and filling yarns. may include substantially complete severance thereof.  
  In accordance with this invention. it is significant that the severance of the filling yarns is not so complete as to entirely separate the fringed side edge segment from the remainder of the fabric F. Instead. the segment including the fringed side edge and the remainder of the fabric are wound together in the roll and the roll has defined therein a plane generally perpendicular to the longitudinal axis ll (and indicated in FIG, 2 at 15). at which the segment ofthe roll including the fringed side edge is readily separable from the segment on the other side of the plane [5 by rupture of the weakened portions.  
  As is indicated by the presence in the roll ofa second plane 16 spaced medially of the length of the roll 10 along the axis H. the present invention contemplates separation of the fabric F into segments of generally equal width while accommodating simultaneous formation of the dual widths. By this application of the present invention. a single fabric forming machine capable of forming fabric of relatively great width may be used to produce two or more narrower widths of fabric, thereby achieving improved efficiency.  
  In the drawings and specification. there has been set forth a preferred embodiment of the invention, and although specific terms are employed. they are used in a generic and descriptive sense only and not for purposes of limitation.  
 That which is claimed is:  
  l. A method of separating segments of textile fabric formed at least partially by interengaging strands of yarn which are at least partially composed of thermoplastic material comprising the steps of convolutely winding a length of the fabric about a longitudinally extending axis while impinging a heated fluid stream against the fabric and melting and expelling the thermoplastic material from a lengthwise zone of the fabric to at least substantially weaken a predetermined portion of the fabric. the winding and impinging forming of the fabric an elongate roll having a plane of weakness generally perpendicular to the axis thereof. and thereafter rupturing the weakened portion of the fabric and separating the segment of the roll on one side of the plane from the segment on the other side thereof.  
  2. A method of separating segments of textile fabric formed at least partially by interengaging strands of yarn which are at least partially composed of thermo plastic material comprising the steps of convolutely winding a length ofthe fabric about a longitudinally extending axis while at least substantially weakening at least one predetermined portion of substantially all of the yarns which extend longitudinally of the axis by impinging a heated fluid stream against the fabric and melting and expelling thermoplastic material therefrom, the winding and weakening forming of the fabric an elongate roll having at least one plane of weakness generally perpendicular to the axis thereof, and thereafter rupturing the weakened portions of the yarns and separating the segment of the roll on one side of the plane from the segment on the other side thereof.  
  3. A method according to claim 2 wherein the step of weakening a portion of the longitudinally extending yarns comprises weakening a portion defining a lengthwise zone medially of the width of the fabric for facilitating separation of the fabric into segments of generally equal widths while accommodating simultaneous formation of the dual widths.  
  4. A method according to claim 2 wherein the step of weakening at least one portion comprises weakening first and second portions respectively defining first and second lengthwise zones, one of the zones located medially of the width of the fabric for facilitating separation of the fabric into segments of generally equal width while accommodating formation of the dual widths and the other of the zones located adjacent one edge of the fabric for facilitating ready separation and disposal of an end segment of the roll.  
  5. A method of forming a roll of textile fabric while handling a disposable fringed edge comprising the steps of interweaving strands of warp and filling yarn which include yarns which are at least partially composed of thermoplastic material while disposing free end portions of the filling yarns to project from one side of the fabric and define a fringed edge, directing the woven fabric to pass along a predetermined path of travel while melting and expelling thermoplastic material from a lengthwise zone of the fabric closely adjacent the fringed edge, then convolutely winding the fabric about a longitudinally extending axis for forming an elongate roll having a plane of weakness generally per pendicular to the axis thereof and defined by the lengthwise zone, and thereafter rupturing the fabric at the plane for separating the fringed edge from the remainder of the roll.