Twin ply fabric, uses and manufacture thereof

Claim 2

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) placing the rollers in a quilting arrangement, positively feeding the layers from the rollers to a bidirectional acting sewing assembly to provide essentially zero elongation for the non-stretchable layer and essentially 25 to 300 per cent stretch for the bi-axial stretchable layer in an axial stretch direction parallel to advancement of said stretchable, non-stretchable layers, (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.

Claim 3

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.

Claim 4

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.

Claim 5

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) positively feeding the layers from the rollers in an alignable quilting arrangement to a bidirectional acting sewing assembly to provide essentially zero elongation for the non-stretchable layer and essentially 100 to 250 per cent stretch for the bi-axial stretchable layer in an axial stretch direction parallel to advancement of said stretchable and non-stretchable layers, (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.

Claim 6

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) positively feeding the layers from the rollers in an alignable quilting arrangement to a bidirectional acting sewing assembly to provide essentially zero elongation for the non-stretchable layer and essentially 100 to 250 per cent stretch for the bi-axial stretchable layer in an axial stretch direction parallel to advancement of said stretchable and non-stretchable layers, (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.

Claim 7

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.

Claim 8

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.

Claim 9

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 in a quilting arrangement to a bidirectional acting sewing assembly to provide essentially zero elongation for the non-stretchable layer and to provide essentially 25 to 300 per cent stretch for the bi-axial stretchable layer in an axial stretch direction parallel to advancement of said stretchable and non-stretchable layers, (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.

Claim 10

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 in a quilting arrangement to a bidirectional acting sewing assembly to provide essentially zero elongation for the non-stretchable layer and to provide essentially 25 to 300 per cent stretch for the bi-axial stretchable layer in an axial stretch direction parallel to advancement of said stretchable and non-stretchable layers, (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.

Claim 11

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.

Claim 12

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.

Claim 13

The fabric of claim 7 in which said non-stretchable and interior layers have separate ultimate tensile strengths 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.

Claim 14

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 arcuate 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.

Claim 15

The fabric of claim 7 formed into a pillow without the need of gathering and cabling the fabric, wherein the pillow comprises front and rear panels of rectangular cross section each defining top and bottom edges and a pair of side edges, top and bottom seams for attaching together said top and bottom edges of said front and rear panels, a pair of side seams for attaching together said pairs of side edges of said front and rear panels, and an interior filler layer, said puffs associated with said front and rear panels defining rows wherein said rows run generally horizontally between said pair of side seams wherein the horizontally pattern of said puffs are pleasing to the eye of the on-looker, puffs are generally slimming for the user and pleasing to the eye of the on-looker.