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: The top treatment includes a fabric sleeve having a pleating tape sewn along a backside with sections of one of hooks and loops spaced one from the other along the pleating tape and forming a part of a Velcro.TM.-type fastener. A header is secured to a headrail of a vertical blind and includes along an outer face an elongated strip of the other of the hooks and loops of the Velcro.TM.-type fastener. The fabric sleeve has a drawstring to form a pleated valance which is applied to the header by engaging the hooks and loops one with the other. In another form, a groover valance receives short lengths of slats having tapes containing another of the hooks and loops of the fasteners. By inserting the slats along the groover valance, the fabric valance may be applied to the groover valance. The slats and fabric sleeve may be provided separately in small soft packages.

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: Stain-resistant nylon, especially cationic-dyeable carpet nylon, is prepared by dyeing and/or printing cationic-dyeable nylon fibers with acid or premetallized dye. Lightfastness and depth of shade of an apparent value equal to acid dyeable nylons is obtained with superior stain resistance equal to commercially available solution dyed nylon carpeting.

Abstract: A cotton room-size rug, having dimension between 3 feet.times.5 feet, and 12 feet.times.15 feet, is made from a heat set blend of about 70-90% cotton fibers and about 30-10% low melting temperature polyester fibers. The polyester impregnates the cotton fibers to give them enhanced properties. The fibers are tightly tufted to a primary backing, and latex adhesive connects the primary backing to an open weave polypropylene secondary backing. A stain resistant finish is applied and the sides serged, and fringe attached. A cabled 3.0/2/2 yarn configuration is preferred.

Abstract: A single or multiple needle bar tufting machine provided with loop forming fingers above the substrate or base fabric is used to form variable gauge fabrics by laterally shifting the needles during tufting. In this manner rows of loop stitches are formed over the loop forming fingers on the face of the substrate and rows of pile loops are formed on the back side. A variety of novel fabrics and fabrics simulating patterns heretofore only made on looms and knitting machines can be manufactured by utilizing such a tufting machine in connection with yarn feed pattern control devices, pattern control needle bar positioners, and a controllable fabric feed. The resulting fabrics offer many advantages including lower stitch rates, better substrate coverage, less resistance to sliding traffic, increased abrasion resistance, and improved draping characteristics.

Abstract: Tufting apparatus includes servomotors driving front and back yarn feed rolls for feeding yarns to the needles of the front and back needle bars, respectively. Incremental servomotor control for each stitch enables a height differential between immediately adjacent stitches in excess of 3/32 inch (2.38 mm). By providing yarns of multiple colors and textures, a variety of patterns and textured surface effects are provided in the surface of the tufted pile fabric.

Abstract: A stiff fabric comprises a woven synthetic fabric coated with a latex compound aerated to provide a weight upon application to the fabric of between 0.63-0.89 gms./ml. The compound is pressed into the fabric by a knife blade having a rounded convex lower edge whereby the compound applied to one side of the fabric passes into the interstices but remains substantially clear of the face side. The compound is cured on the fabric in an oven at approximately 149.degree. C. for 45-60 seconds.

Abstract: Denim fabric suitable for use as apparel is made from about 40-100% fibers produced from denim waste (pre-consumer and/or post-consumer). The denim waste is collected, starch and size are optionally removed, and it is subjected to garnetting to produce denim fibers, the vast majority of fiber lengths greater than about 0.4 inches, and an average length greater than 0.5 inches. The denim fibers are then opened, and subjected to low-tension carding, as by using a Rieter C-4 type card with conveyor belt. The carded denim fibers are spun into filling yarn having a yarn count between about 4.0/1 to 16.0/1, and/or a warp or knitting yarn having a yarn count between about 4.0/1 to 16.0/1. The warp or knitting yarn may be plied with like reclaimed warp yarn, or with virgin fiber warp yarn.

Abstract: Fabric suitable for the manufacture of rental shirts that are capable of being industrially laundered are made by air jet spinning an intimate blend of about 50--50 polyester/cotton (having wrapper fibers holding the yarn bundle together), vat dyeing the cotton component of the yarn (and disperse dyeing the polyester component), and then knitting the dyed yarn to produce a fabric with tightly formed stitches. The yarn is also preferably scoured and finished prior to knitting. The knit fabric is preferably made into a rental shirt or like garment, the fabric having a maximum shrinkage of about 8% both in length and width unrestored after five wash and tumble dry sequences per AATCC Test Method 135, a colorfast rating of 4.0 or higher when subjected to AATCC Test Method 61-IIA, has a rating of 4.0 or higher when tested for pilling, and a life expectancy of at least 50 industrial laundering wash-dry-wear cycles.

Abstract: Fabric suitable for the manufacture of rental shirts that are capable of being industrially laundered are made by air jet spinning an intimate blend of about 50--50 polyester/cotton (having wrapper fibers holding the yarn bundle together), vat dyeing the cotton component of the yarn (and disperse dyeing the polyester component), and then knitting the dyed yarn to produce a fabric with tightly formed stitches. The yarn is also scoured and finished prior to knitting. The knit fabric is preferably made into a rental shirt or like garment, the fabric having a good shrinkage, a colorfast, pilling, and life expectancy properties, and a soft hand. At the end of scouring in a jet machine, cationic softener is added which chemically bonds with the fabric cotton fibers, to provide softer hand over the life of the fabric.

Abstract: Open end spun cotton yarns are ring dyed with a thickened dyebath to limit dye penetration to the outer circumference of the yarn leaving a substantial undyed core. Stonewashed indigo dyed denim fabrics and garments are prepared.

Abstract: Fabric suitable for the manufacture of rental shirts that are capable of being industrially laundered are made by air jet spinning an intimate blend of about 50-50 polyester/cotton (having wrapper fibers holding the yarn bundle together), vat dyeing the cotton component of the yarn (and disperse dyeing the polyester component), and then knitting the dyed yarn to produce a fabric with tightly formed stitches. The yarn is also scoured and finished prior to knitting. The knit fabric is preferably made into a rental shirt or like garment, the fabric having a good shrinkage, a colorfast, pilling, and life expectancy properties, and a soft hand. At the end of scouring in a jet machine, cationic softener is added which chemically bonds with the fabric cotton fibers, to provide softer hand over the life of the fabric. The finish formula includes amphoteric and hydrophilic silicone softeners to also provide soft hand, and a sewing lubricant to reduce the possibility of needle cutting during the garment sewing process.

Abstract: Denim fabric suitable for use as apparel is made from about 40-100% fibers produced from denim waste (pre-consumer and/or post-consumer). The denim waste is collected, starch and size are optionally removed, and it is subjected to garnetting to produce denim fibers, the vast majority of fiber lengths greater than about 0.4 inches, and an average length greater than 0.5 inches. The denim fibers are then opened, and subjected to low-tension carding, as by using a Rieter C-4 type card with conveyor belt. The carded denim fibers are spun into filling yarn having a yarn count between about 4.0/1 to 16.0/1, and/or a warp or knitting yarn having a yarn count between about 4.0/1 to 16.0/1. The warp or knitting yarn may be plied with like reclaimed warp yarn, or with virgin fiber warp yarn.

Abstract: Fabric suitable for the manufacture of rental shirts that are capable of being industrially laundered are made by air jet spinning an intimate blend of about 50-50 polyester/cotton (having wrapper fibers holding the yarn bundle together), vat dyeing the cotton component of the yarn (and disperse dyeing the polyester component), and then knitting the dyed yarn to produce a fabric with tightly formed stitches. The yarn is also preferably scoured and finished prior to knitting. The knit fabric is preferably made into a rental shirt or like garment, the fabric having a maximum shrinkage of about 8% both in length and width unrestored after five wash and tumble dry sequences per AATCC Test Method 135, a colorfast rating of 4.0 or higher when subjected to AATCC Test Method 61-IIA, has a rating of 4.0 or higher when tested for pilling, and a life expectancy of at least 50 industrial laundering wash-dry-wear cycles.

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: Denim fabric is made from warp yarn which is at least 30% novelty cotton yarn having irregularly spaced effects (e.g. slubs) about one-half inch to two inches in length. The cotton novelty yarn is made by separating cotton sliver into cotton fibers, and acting on the cotton fibers with a negative wire combing roll, and then twisting the cotton fibers into the cotton novelty yarn. The negative wire combing roll has a tooth angle of about -0.01 to -15.degree. (e.g. about -2.degree.). The novelty cotton yarn is combined with at least 10% conventional novelty yarn or non-slub open end or ring spun yarn and made into a warp of about 54-100 ends per inch, and may be ring dyed (with indigo, vat, sulphur, pigment or reactive dye) so that the core of the yarn remains white. The warp is woven with a filling yarn to produce a denim fabric with a weight of about 5 oz. -17 oz. per sq. yd. having the weave and yarn size selected so that a tight construction is provided which highlights the slubs.

Abstract: Denim fabric is made from novelty cotton yarn having irregularly spaced irregularities (e.g. slubs) about one-half inch to two inches in length. The cotton novelty yarn is made by separating cotton sliver into cotton fibers, and acting on the cotton fibers with a negative wire combing roll, and then twisting the cotton fibers into the cotton novelty yarn. The negative wire combing roll has a tooth angle of about -0.01.degree. to -15.degree.. The novelty cotton yarn is made into a warp of about 54-100 (e.g. 54-78) ends per inch, and is ring dyed so that the core of the yarn remains white. The warp is woven with a filling yarn to produce a denim fabric with a weight of about 5 oz.-17 oz. per sq. yd. having the weave and yarn size selected so that a tight construction is provided which highlights the slubs. The fabric is subjected to surface abrasion to remove the surface of dye on the slubs to show a lighter slub than body of the fabric.

Abstract: A method for spinning yarn produce the yarn having properties generally comparable to those of ring spun yarn. A rotatable hollow shaft having an entrance at one end and an exit at the other is rotatable about an axis extending in a direction A. A number of free fibers are fed in the linear direction A in a fiber mass, certain of the fibers having free trailing ends. The fiber mass is passed into the interior of the hollow rotatable shaft through the entrance. An air flow is established with respect to the shaft to effect separation of the free trailing ends of the fibers, preferably by establishing an air flow path that is initially substantially unidirectionally in direction A and then is deflected to move at an angle with respect to the direction A away from the shaft. The shaft is rotated at high speed about its axis so that the trailing ends of the fibers wrap around other portions of the fiber mass to produce a yarn, and the yarn is withdrawn through the exit of the shaft.

Abstract: Tufting apparatus includes servomotors driving front and back yarn feed rolls for feeding yarns to the needles of the front and back needle bars, respectively. Incremental servomotor control for each stitch enables a height differential between immediately adjacent stitches in excess of 3/32 inch (2.38 mm). By providing yarns of multiple colors and textures, a variety of patterns and textured surface effects are provided in the surface of the tufted pile fabric.