BRIEF DESCRIPTION OF THE FIGURES
Other objects and advantages of the invention will become apparent from a study of the following specification when viewed in the light of the accompanying drawing, in which:
FIG. 1 is a sectional view of a fabric used to manufacture the pot holder/mitt according to the invention;
FIG. 2 is a top plan view of the fabric of FIG. 1;
FIG. 3 is a perspective view of the fabric of FIG. 2 folded into a Z-shaped configuration;
FIG. 4 is a side view of the holder/mitt after folding;
FIG. 5 is a front plan view of the holder/mitt after folding and stitching of a fabric binding;
FIG. 6 is a plan view of a T-shaped insert print mask which is used during finishing of holder/mitt;
FIG. 7 is a plan view of the holder/mitt of FIG. 5 with the insert arranged therein; and
FIG. 8 is a plan view of the holder/mitt having a decorative pattern applied to the first surface thereof.
DETAILED DESCRIPTION
Referring first to FIG. 1, there is shown a longitudinal cross section of the fabric 2 according to the invention. The fabric includes a support web 4 formed by a plurality of picks 6 across which two warp ends 8, 10 are woven. In the drawing, the warp ends are woven around every third pick, although alternate weaving patterns may be used as is known in the art to form the web. The array of picks and warp ends defines the web 4 which has top and bottom surfaces.
An additional warp 12 of hydrophobic material is interlaced in the support web to define a plurality of loops 14 which extend from the top surface of the web. The loops extend along the entire top surface. Similarly, a warp 16 of hydrophilic material is interlaced in the support web to define a plurality of loops 18 which extend from the bottom surface of the web opposite the loops 14 of hydrophobic material. As shown in FIG. 2, two transition areas 18, 20 are provided along the support web in which the warps 12 and 16 are tightly woven to avoid any elongated loops. The transition areas divide the fabric into first 22, second 24 and third 26 portions. As will be developed in greater detail below, the length of the first portion is less than the length of the second and third portions, with the length of the second and third portions being equal.
Hydrophilic materials absorb fluids while hydrophobic materials repel fluids. Suitable hydrophilic materials for the warp 16 are cellulosic or cotton materials. Suitable hydrophobic materials for the warp 12 are polyester, nylon, acrylic, or microfiber. By providing different materials for the warps, a fabric for making an article such as a pot holder or mitt can be provided with surface portions having different characteristics to increase the use and versatility of the article as will be developed in greater detail below.
The surface texture of each area of the fabric is defined by the size and treatment of the loops. Referring to FIG. 1, the loops 14 of the hydrophobic material are preferably smaller than the loops 18 of the hydrophilic material. The uncut loops define a terry cloth surface. If the loops are cut, the fabric will have a velour finish which is softer than a terry finish. The cut loops or velour finish can be added to only one or both surfaces, depending on the end use desired.
Referring now to FIG. 3, the fabric 2 is folded at the transition areas 18, 20 into a Z-shape. When completely folded, the portion 24 is sandwiched between the portions 26 and 22 with the portion 22 being shorter than the portions 24 and 26 as shown in FIG. 4. When folded as shown, the fabric first portion 22 has a first surface 28 of hydrophobic material and a second surface 30 of hydrophilic material. The second portion 24 has a third surface 32 of hydrophilic material and a fourth surface of hydrophobic material, and the third portion 26 has a fifth surface 34 of hydrophobic material and a sixth surface 36 of hydrophilic material. The first and sixth surfaces define the outer surfaces of the holder/mitt with the second and third surfaces being arranged opposite one another and the fourth and fifth surfaces being arranged opposite one another.
After Z-folding the fabric as shown in FIGS. 3 and 4, the edges of the folded fabric may be trimmed if desired to provide rounded corners as shown in FIG. 5. Next, a high temperature heat activated non-woven adhesive sheet is inserted between the surfaces 34 and 36 of portions 24 and 26. A fabric binding 40 is sewn down one of the sides of the pot holder 42, around the bottom and up the other side. If desired, the binding may extend beyond the other side to and then looped back and stitched to define a hanging loop 44.
In order to complete the pot holder or mitt, the mitt is printed and pressed under heat and pressure to activate the adhesive layer and to print a decorative pattern on the first surface of the holder/mitt as shown in FIG. 8. In order to control the heat press and printing operation, a T-shaped print mask board 46 as shown in FIG. 6 is partially inserted into the pocket defined between the first and second portions of the fabric as shown in FIG. 7. The board serves as a mask for the top portion of the third surface 32 of the fabric to prevent printing thereon. A vapor transfer print sublimation paper is placed against the first surface 28, with the sublimation dye/ink side facing the surface. Next, a heat transfer press is closed about the holder/mitt to simultaneously heat the adhesive layer and transfer a decorative pattern 48 from the vapor transfer print sublimation paper to the fabric first surface 28, which surface is printed with 100% ink/dye coverage. As a result, the top of the mitt/holder is left unprinted as shown in FIG. 8 and comprises a double thickness of terry cloth since portions 24 and 26 have been joined by the adhesive.
If desired, the fabric can be overdyed with a selected color so that the hydrophilic fiber loop pile on the second and third portions are dyed into a solid color fabric. Thus, when the finished holder/mitt is printed, the top of the holder/mitt will be a solid color to coordinate with the design element printed on face 28, as well other articles in an ensemble such as a towel.
Other printing techniques may be used to form the decorative pattern on the first surface 28. These include vapor transfer dye sublimation printing, pigment dye silk screen printing, wet process fiber reactive printing, embroidery and applique. In addition, different textures for the surfaces of the fabric may be provided by modifying the length of the loops extending from opposite sides of the support web, particularly in different sections of the first, second and third portions.
While the preferred forms and embodiments of the invention have been illustrated and described, it will be apparent to those of ordinary skill in the art that various changes and modifications may be made without deviating from the inventive concepts set forth above.
Patent Application
20080022435
