Abstract: Denim fabric and articles of clothing having a “washed” or heather look/effect are produced in a manner that retains color intensity and substantially avoids the waste of chemicals and/or water inherent in conventional washing processes. A first coarse feeder yarn of cotton and/or other natural fiber by ring or open end spinning, and then is continuously dyed (such as by indigo rope dyeing, slasher dyeing, or sheet dyeing). The dyed yarn is dried and then cut up into lengths of about four inches long or less (and opened if necessary) into individual fibers. The fibers are blended with other fibers (e.g. about 10-90% greige fibers) to produce a blended composite. The blended composite is then carded, spun into yarn, and woven into denim fabric having a washed look, or a heather effect, which then can be made into any suitable article. A second coarse yarn made similar to the first coarse yarn may be added to the blending station.

Abstract: Denim fabric and articles of clothing having a “washed” or heather look/effect are produced in a manner that retains color intensity and substantially avoids the waste of chemicals and/or water inherent in conventional washing processes. A first coarse feeder yarn of cotton and/or other natural fiber by ring or open end spinning, and then is continuously dyed (such as by indigo rope dyeing, slasher dyeing, or sheet dyeing). The dyed yarn is dried and then cut up into lengths of about four inches long or less (and opened if necessary) into individual fibers. The fibers are blended with other fibers (e.g. about 10-90% greige fibers) to produce a blended composite. The blended composite is then carded, spun into yarn, and woven into denim fabric having a washed look, or a heather effect, which then can be made into any suitable article. A second coarse yarn made similar to the first coarse yarn may be added to the blending station.

Abstract: A colored yarn is made in an inexpensive manner that allows a wide variety of different colors or hues within the product line, and also allows a wide variety of different effects to be produced including yarns with minimal leather effect, or yarns with a distinct and desired heather effect. A first coarse feeder yarn, e.g. a 1/1 semi worsted yarn, is ring or open end spun with about 2.5 turns per inch. The coarse feeder yarn is dyed, dried, and then cut and opened up into individual fibers about four inches long or less (preferably two inches long or less). The individual fibers are blended with differently colored or hued fibers produced in the same way, and/or with greige or colored staple fibers, to produce a blended composite of fibers. The blended composite is then spun, for example ring spun or open end spun, into a final colored yarn. Rayon fibers may especially effectively and uniquely be utilized, although almost any fiber or mix of fibers can be used.

Abstract: A woven or non-woven fibrous material has a substrate formed of first and second thermoplastic fibers. The fabric is passed through an oven at a temperature sufficient to melt the first fibers thereby fusing at least some of the first fibers and second fibers one to the other. The second fibers retain their discrete definition within the composite whereby the composite is provided such that, when cut for use, for example, to form a slat of a vertical blind or a wall panel, the composite retains its shape. A foam backing is provided and cured in the oven simultaneously with the melting of the first fibers.

Abstract: A non-woven substrate is combined with warps and wefts in a warp-knit, weft-insertion machine to form a decorative fabric and later combined with a foam backing. The substrate is substantially uniformly even over its entire surface and has an opacity sufficient to substantially preclude any visual perception of the substrate from the technical backside of the fabric.

Abstract: A woven or non-woven fibrous material has a substrate formed of first and second thermoplastic fibers. The fabric is passed through an oven at a temperature sufficient to melt the first fibers thereby fusing at least some of the first fibers and second fibers one to the other. The second fibers retain their discrete definition within the composite whereby the composite is provided such that, when cut for use, for example, to form a slat of a vertical blind or a wall panel, the composite retains its shape. A foam backing is provided and cured in the oven simultaneously with the melting of the first fibers.

Abstract: Warp and weft yarns are alternately laid one on top of the other and the weft yarns are stitched to provide a woven-like fabric appearance. At least one weft yarn is provided in each stitch course between the stitch loop and the underlap, the stitching forming no part of the interlacing and the woven-like fabric appearance.

Abstract: A weft insertion warp knit fabric having a terry or boucle effect is produced by overfeeding at least some of the wrap yarns to a conventional weft inserted warp knitting machine, such as a Raschel, (e.g.) Liba, or Mayer. Terry loops extend outwardly from the technical back side of the fabric, and the loops may be continuous over the entire fabric face, or discontinuous, i.e. being disposed in an intermittent pattern. A substrate may be provided to which the warp and weft yarns are stitch bonded, or the fabric may be substrate-free. By varying the knitting yarn denier and/or stitch length, the erectness of the terry loops may also be varied. The fabric is especially suitable for draperies and upholstery.

Abstract: Aesthetic warp-knit, weft-inserted fabrics are produced having multiple substrate layers, warp yarns extending in the warp-wise direction of the fabric, and weft yarns extending in the weft-wise direction of the fabric. The warp and/or weft yarns are interposed between the multiple substrate layers. Warp stitching yarns forming stitch wales spaced-apart along the warp-wise direction of the fabric and stitched through the substrate layers hold the warp and weft yarns in position relative to one another and relative to the substrates. The substrates may also be provided in juxtaposed relationship to one another so as to increase the opacity, esthetics, and dimensional stability of the resulting fabric. Thermoplastic fibers may be incorporated in the fabric such that upon plasticization and subsequent cooling, they assist in binding of the resulting fabric.

Abstract: An aesthetic dimensionally stable fabric suitable for use as drapery and upholstery or other decorative fabric is produced utilizing a weft inserted warp knitting machine having two or more stitching bars. A substrate that is dimensionally stable warp-wise (such as a 100 percent polyester nonwoven fabric that is dimensionally stable both warp-wise and weft-wise) is fed to the machine, as are weft yarns. The weft yarns are stitched in place by stitching thread fed to the stitching bars, the two main stitching bars moving in opposite directions in a basically zigzag form to create an aesthetically pleasing effect, but forming a pattern which is not dimensionally stable. However the end fabric produced is dimensionally stable as a result of the substrate properties. Stitching thread is preferably fed to a third stitching bar which is utilized to provide a dimensionally stable stitching pattern in the selvage areas of the fabric to facilitate finishing operations on the fabric.

Abstract: An aesthetic dimensionally stable fabric suitable for use as drapery and upholstery fabric, or like decorative fabrics, is produced utilizing a weft inserted warp knitting machine having three or more stitching bars. A substrate that is dimensionally stable warp-wise (such as a 100 percent polyester non-woven fabric that is dimensionally stable both warp-wise and weft-wise) is fed to the machine, as are weft yarns. The weft yarns are stitched in place by stitching thread fed to the stitching bars, the two main stitching bars moving in opposite directions in a basically zigzag form to create an aesthetically pleasing effect, but forming a pattern which is not dimensionally stable. However the final fabric produced is dimensionally stable as a result of the substrate properties. The intermediate fabric has selvage areas.

Abstract: An improved warp knit fabric that can use conventional warp knit base fabric constructions or instead produce novel sheer base fabrics and apply top effect yarns in the warp direction to produce novelty effects using standard yarn ends. Also, full weight, self-lined fabrics can be formed. This top effect yarn can be fed with varying tension control so that a relatively wide variety of effects can be created together with base fabric which is chosen.

Abstract: An improved warp knit fabric that can serve as a base fabric for producing full weight, self-lined drapery material as well as sheer drapery material and the process and apparatus therefor. The base fabric is primarily comprised of three groups of yarns knit together to form a sheer fabric that creates the visual effect of being woven. The full weight is formed by incorporating one or more additional groups of yarns into the base fabric. One group is added to produce a self-lining on the rear side of the material while another group can include a "laid-in" top effect yarn. This top effect yarn can be fed with varying tension control so that a relatively wide variety of effects can be created.

Abstract: An improved warp knit fabric that can serve as a base fabric for producing full weight, self-lined drapery material as well as sheer drapery material and the process and apparatus therefor. The base fabric is primarily comprised of three groups of yarns knit together to form a sheer fabric that creates the visual effect of being woven. The full weight is formed by incorporating one or more additional groups of yarns into the base fabric. One group is added to produce a self-lining on the rear side of the material while another group can include a "laid-in" top effect yarn. This top effect yarn can be fed with varying tension control so that a relatively wide variety of effects can be created.