Insect Screen

Abstract

An insect screen comprised of knitted synthetic yarns and having a knitted pattern incorporated therein. First and second groups of yarns, such as polypropylene, are knitted with the first group of yarns forming a grid or mesh while the second group of yarns form a pattern. Once the insect screen is knitted, the insect screen is subjected to a finishing operation. In finishing the insect screen is stretched and placed in tension using selvages formed of a third group of yarns. The tensioned insect screen is heated causing the yarns to at least slightly plasticize and causing heat fusion of at least some stitches. Thereafter the insect screen and yarns are cooled, resulting in the insect screen becoming more rigid and generally assuming the stretched configuration in the absence of stretching.

1 . A device for use in doors, windows and enclosures, comprising:
 a. a knitted insect screen;   b. the insect screen including first and second groups of knitted yarns;   c. the first group of knitted yarns forming a grid in the insect screen;   d. a pattern knitted into the insect screen and wherein the second group of yarns forms the pattern; and   e. wherein the knitted insect screen is mounted within a frame.   
   
   
       2 . The device of  claim 1  wherein the first and second groups of yarns of the knitted insect screen comprise polypropylene yarns. 
   
   
       3 . The device of  claim 1  wherein the yarns form stitches that are heat fused. 
   
   
       4 . The device of  claim 3  wherein the first and second groups of yarns include plasticized yarns. 
   
   
       5 . The device of  claim 3  wherein the insect screen includes patterned areas and non-patterned areas, and wherein in the non-patterned areas the second group of yarns generally lie adjacent yarns of the first group and the first and second group of yarns form the grid, and in the patterned areas the second group of yarns divert from the first group of yarn and form the pattern. 
   
   
       6 . The device of  claim 3  wherein the first group of yarns includes a first subgroup of yarns that zigzag and at least partially overly each other to form openings in the grid; and the first group of yarns further including a second subgroup of yarns that bind the yarns of the first subgroup together. 
   
   
       7 . The device of  claim 6  wherein the yarns of the first subgroup are inlayed and the yarns of the second subgroup form connecting stitches with the yarns of the first subgroup. 
   
   
       8 . The device of  claim 7  wherein the yarns of the second group form both tricot and pillar stitches. 
   
   
       9 . The device of  claim 6  wherein in some areas of the insect screen the yarns of the second group generally align with the yarns of the first group that form the grid, and in other areas the yarns of the second group divert from the first group of yarns to form the pattern. 
   
   
       10 . The device of  claim 9  wherein the insect screen includes patterned areas and non-patterned areas, and wherein in the patterned areas the yarns of the second group form tricot stitches, and in the non-patterned area the yarns of the second group form pillar stitches. 
   
   
       11 . The device of  claim 3  wherein the first group of yarns includes two sub-groups that form opposed inlays. 
   
   
       12 . A method of knitting and forming an insect screen, comprising:
 a. knitting a first group of yarns and forming a fabric mesh; and   b. with a second group of yarns knitting a pattern into the fabric mesh to form an insect screen having a knitted pattern.   
   
   
       13 . The method of forming the insect screen of  claim 12  wherein the yarns are synthetic yarns and including heating the insect screen and plasticizing the yarns of the insect screen. 
   
   
       14 . The method of forming the insect screen of  claim 12  wherein the yarns are synthetic yarns and including forming heat fused stitches that connect yarns. 
   
   
       15 . The method of  claim 12  including stretching the insect screen to a selected size; directing the stretched insect screen into a heated area; holding the stretched insect screen in the heated area for a selected time; and cooling the insect screen such that the insect screen remains substantially the same size in the absence of stretching. 
   
   
       16 . The method of  claim 12  wherein the yarns are synthetic yarns and including forming side selvages on the insect screen and utilizing a third group of yarns for forming the side selvages having a melting point temperature higher than the melting point temperature of the first and second group of yarns. 
   
   
       17 . The method of  claim 12  including mounting the insect screen having the knitted pattern in a frame. 
   
   
       18 . The method of  claim 12  wherein the insect screen includes patterned areas and non-patterned areas and the method includes the second group of yarns adjacent the first group of yarns in the non-patterned area, and in the patterned areas diverting at least some of the yarns of the second group of yarns to form a pattern. 
   
   
       19 . The method of  claim 15  including heating the insect screen for a sufficient period of time to plastically relax the insect screen. 
   
   
       20 . A method of knitting and forming an insect screen, comprising:
 a. knitting a first group of synthetic yarns to form a mesh;   b. knitting opposed side selvages onto the mesh with a second group of synthetic yarns where the melting point of the second group of yarns is higher than the melting point of the first group of yarns; and   c. heating the insect screen, plasticizing the mesh, and fusing yarns that intersect in the insect screen.   
   
   
       21 . The method of  claim 20  including utilizing the side selvages to tension the mesh and heating the mesh while tensioned and cooling the insect screen. 
   
   
       22 . (canceled) 
   
   
       23 . The method of  claim 20  wherein the first group of yarns includes a series of inlayed yarns that at least slightly overlap to form at least a part of the mesh; and a series of connecting yarns for connecting the inlayed yarns. 
   
   
       24 . The method of  claim 23  wherein the first group of yarns includes two sub-groups and including forming opposing inlays utilizing the two sub-groups of yarns. 
   
   
       25 . The method of  claim 20  wherein the second group of yarns includes a series of yarns that connect to the mesh and which form a pattern on the mesh. 
   
   
       26 . (canceled) 
   
   
       27 . The method of  claim 20  including mounting the insect screen in a frame.