Method for constructing a double face fabric and fabric produced thereby

A method of constructing a double face fabric comprising the steps of:

• knitting a three dimensional base fabric having two parallel layers formed of stitch yarns, said layers being interconnected by pile yarns, each pile yarn being formed of several filaments, each pile yarn being plaited around at least one stitch yarn of each of said layers;
• separating said base fabric by cutting said pile yarns to form two intermediate fabrics, each intermediate fabric having one of said fabric layers, a technical face and a technical back, with said pile yarns extending away the respective fabric layer along said technical face;
• and
• pulling some of the filaments of said pile yarns through said fabric layer.

A method of making a double faced fabric comprising the steps of:

• knitting a base fabric on a double bar knitting machine, said base fabric having two independent fabric layers interconnected by a plurality of pile yarns, said layers being structured to allow said layers in a predetermined direction;
• cutting said pile yarns to form to intermediate fabrics, each intermediate fabric having a fabric layer with a technical face and a technical back with said pile yarns extending outwardly of said technical face;
• raising said technical back by pulling portions of said pile yarns through said fabric layer to said technical back;
• stretching one of said intermediate fabrics in said predetermined direction to form a stretched fabric;
• and
• stabilizing said stretched fabric.

A method of making a knitted fabric comprising the steps of:

• knitting a fabric on a double bar knitting machine, said fabric being stretchable in a predetermined direction, said fabric including a base, a first set of wales and a second set of wales, said first and second set of wales being interlaced, said first set of wales being connected to said base and said second set of wales being unconnected and a plurality of pile yarns looped around said base and extending outwardly at least along one face of said fabric;
• stretching said base fabric in said predetermined direction, with the pile yarns corresponding to said first set of wales being bent during said stretching to produce a three dimensional pattern;
• and
• stabilizing the stretched fabric.

A method of making a double-faced fabric with three dimensional patterns on at least one face, said method comprising the steps of:

• knitting a base fabric on a double bar knitting machine, said base fabric including two parallel layers constructed of courses and wales, including a first set of wales and a second set of wales and a substrate, said first set of wales being connected to said substrate and said second set of wales being unconnected, and a plurality of interconnecting pile yarns, each yarn being plaited through each of said layers;
• cutting said pile yarns to form two intermediate fabrics, each having a technical front with said pile yarns extending outwardly of said technical face to form a velvet, and a technical back;
• processing said technical back by drawing some of said pile yarns through said substrate to form a fleece;
• stretching said intermediate fabrics after said processing to force some of said yarns to bend while others of some yarns remain substantially normal to said substrate;
• and
• stabilizing said stretched intermediate fabrics.