Multi-ply fabric, uses and manufacture thereof

Abstract

In the proces of defining quilted fabric, non-stretchable, stretchable and interior layers of materials are wound on separate rollers. Then the layers are positively fed from the rollers to a bi-directional acting sewing assembly wherein the non-stretchable layer is provided with zero elongation and the stretchable layer is provided with 25 to 300 percent stretch. Next, the arranged layers are sewn in sets of sinusoidal-like seam patterns. Finally the stretched layer is permitted to relax to a natural state wherein a series of puffs are formed in rows across the layer normal to stretch direction of the stretchable layer. Result: columns of puffs of even numbered rows are aligned with each other but are laterally offset with respect to puffs of odd numbered rows by a constant amount.

What is claimed is:  
     
         1 . A process for forming a puffed, smock-like quilted fabric comprising an exterior layer of non-stretchable material and bi-axial stretchable material overlaying a soft interior layer stitched together in automated manner, comprising the steps of: 
 (a) winding non-stretchable and stretchable layers on separate rollers,    (b) after placing the rollers in a quilting arrangement, positively feeding the layers from the rollers to sewing head arrangement to provide essentially zero elongation for the non-stretchable layer and to provide both axial and lateral elongation for the bi-xial stretchable layer simultaneously such that elongation factors Ax and Ay are additive to define a total elongation in the range of 1.25 to 3.00 times the relaxed state of the stretchable layer,    (c) sewing the arranged layers in sets of sinusoidal-like seam patterns across the layers wherein each of said sinusoidal like seam patterns has an axis of formation essentially parallel to said axial stretch direction of the bi-axial stretchable layer,    (d) relaxing the stretchable layer to relax to a natural state wherein a series of puffs are formed in rows across the layers normal to said axial stretch direction the stretchable layer, and columns of puffs of even numbered rows are aligned with each other but are laterally offset with respect to puffs of odd numbered rows a constant amount thereby creating an aesthetically pleasing finished fabric.    
     
     
         2 . The process of  claim 1  in which side-by-side seam patterns are complementary, wherein said seam patterns are each laterally aligned in a direction normal to the stretch direction of the stretchable layer relative to said each axis of formation of the seam patterns.  
     
     
         3 . The process of  claim 1  in which said non-stretchable layer has an ultimate tensile strength of known value and wherein tensioning stretch force applied to the non-stretchable and stretchable layers is less than said ultimate tensile strength for the non-stretchable layer.  
     
     
         4 . A process for forming a puffed, smock-like quilted finished fabric comprising an exterior layer of non-stretchable material and an interior layer of bi-axial stretchable interior material, stitched together in automated manner, comprising the steps of: 
 (a) winding non-stretchable and stretchable layers on separate rollers.    (b) after placing the rollers in a quilting arrangement, positively feeding the layers from the rollers to sewing head arrangement to provide essentially zero elongation for the non-stretchable layer and to provide both axial and lateral elongation for the biaxial stretchable layer simultaneously such that elongation in the axial and lateral direction are additive to define a total elongation in the range of 100 to 250 per cent    (c) sewing the arranged layers in sets of sinusoidal-like seam patterns across the layers wherein each of said seam patterns has an axis of formation essentially parallel to said axial stretch direction of the bi-axial stretchable layer,    (d) allowing the stretchable layer to relax to a natural state wherein a series of puffs are formed in rows across the layers normal to said axial stretch direction of the stretchable layer thereby creating an aesthetically pleasing finished fabric.    
     
     
         5 . The process of  claim 4  in which puffs of even numbered row are columnarly aligned with each other but being laterally offset with respect to puffs of odd numbered rows by a constant amount thereby creating an aesthetically pleasing finished fabric.  
     
     
         6 . The process of  claim 5  in which each of said series of puffs is defined by a length L parallel to said axial stretch direction of the stretchable layer and wherein said constant offset amount is equal to L/2.  
     
     
         7 . A puffed, smock-like quilted finished fabric comprising an exterior layer of non-stretchable material and an interior layer of bi-axial stretchable material stitched together in automated manner having a series of puffs and columns of even number in a constant amount, formed by the steps of: 
 (a) winding non-stretchable and stretchable layers on separate rollers.    (b) positively feeding the layers from the rollers to sewing head arrangement to provide essentially zero elongation for the non-stretchable layer and to provide both axial and lateral elongation for the bi-axial stretchable layer simultaneously such that elongation in the axial and lateral direction are additive to define a total elongation in the range of 25 to 300 per cent of the stretchable layer,    (c) sewing the arranged layers in sets of sinusoidal-like seam patterns across the layers wherein each of said sinusoidal-like seam patterns have an axis of formation essentially parallel to said axial stretch direction of the bi-axial stretchable layer,    (d) allowing the stretchable layer to relax to a natural state wherein a series of puffs are formed in rows across the layers normal to said axial stretch direction the stretchable layer, and columns of puffs of even numbered rows are aligned with each other but are laterally offset with respect to puffs of odd numbered rows a constant amount thereby creating an aesthetically pleasing finished fabric.    
     
     
         8 . The fabric of  claim 7  in which each of said series of puffs is defined by a length L parallel to said axial stretch direction of the stretchable layer and wherein said constant offset amount is equal to L/2.  
     
     
         9 . The fabric of  claim 7  in which side-by-side seam patterns are complementary wherein maximum peaks and troughs of each are laterally aligned in a direction normal to said axial stretch direction of the stretchable layer relative to said each axis of formation of the seam patterns.  
     
     
         10 . The fabric of  claim 7  in which said non-stretchable and interior layers have separate ultimate tensile strengths and wherein tensioning stretch force app lied to the non-stretchable and stretchable layers is less than said ultimate tensile strength for the non-stretchable layer.  
     
     
         11 . The fabric of  claim 7  formed into a jacket with attached collar comprising an outer shell having a pair of front panels attached to a waistband, a rear panel attached to said front panels via a pair of shoulder seams, and sleeves attached via arcuato seams to said front and rear panels, said puffs associated with said front and rear panels and said sleeves defining said rows wherein said rows run generally vertically between said waistband and said collar wherein the vertical pattern of said puffs are generally slimming for the user and pleasing to the eye of the on-looker.  
     
     
         12 . The fabric of  claim 7  formed into a cover for use in forming a pillow.  
     
     
         13 . The fabric of  claim 7  formed into a cover for use in covering an automotive seat.