U.S. patent application number 09/752306 was filed with the patent office on 2002-07-04 for loop textile.
Invention is credited to Hayes, Heather J., Morin, Brian G., Sasser, Michael P..
Application Number | 20020086133 09/752306 |
Document ID | / |
Family ID | 25025735 |
Filed Date | 2002-07-04 |
United States Patent
Application |
20020086133 |
Kind Code |
A1 |
Morin, Brian G. ; et
al. |
July 4, 2002 |
Loop textile
Abstract
A base substrate having a first side and a second side, and a
loop extending from the first side of the base substrate. The loop
is formed of a yarn having at least one filament with a
cross-section having an aspect ratio of greater than about 1.2, a
corner edge, and/or at least a concave portion.
Inventors: |
Morin, Brian G.; (Greer,
SC) ; Sasser, Michael P.; (Cowpens, SC) ;
Hayes, Heather J.; (Chesnee, SC) |
Correspondence
Address: |
Terry T. Moyer
P.O. Box 1927
Spartanburg
SC
29304
US
|
Family ID: |
25025735 |
Appl. No.: |
09/752306 |
Filed: |
December 29, 2000 |
Current U.S.
Class: |
428/92 ; 264/146;
428/95 |
Current CPC
Class: |
D04B 1/04 20130101; D04B
21/04 20130101; Y10T 428/23979 20150401; D04H 11/04 20130101; D01D
5/426 20130101; D03D 27/00 20130101; Y10T 428/23957 20150401 |
Class at
Publication: |
428/92 ; 428/95;
264/146 |
International
Class: |
D04H 011/00 |
Claims
What is claimed is:
1. An article comprising: a base substrate; and a plurality of
loops extending from said base substrate, said loops including at
least one filament of at least about 10 denier per filament and
having a cross-section with an aspect ratio of greater than about
1.2.
2. The article according to claim 1, wherein the filament is at
least about 20 denier per filament.
3. The article according to claim 1, wherein the cross-section of
the filament has an aspect ratio of greater then about 2.
4. The article according to claim 1, wherein the height of said
loop extending from said base substrate is between about 0.1
millimeters and about 5 millimeters.
5. The article according to claim 1, wherein the width of said loop
is between about 0.1 millimeters and about 5 millimeters.
6. The article according to claim 1, wherein the height of said
loop extending from said base substrate is between about 0.3
millimeters and about 3 millimeters.
7. The article according to claim 1, wherein the width of said loop
is between about 0.3 millimeters and about 3 millimeters.
8. The article according to claim 1, wherein the height of said
loop extending from said base substrate is about 1.0
millimeters.
9. The article according to claim 1, wherein the width of said loop
is about 0.8 millimeter.
10. The article according to claim 1, wherein the cross-section of
the filament comprises an oblong shape.
11. The article according to claim 1, wherein the cross-section of
the filament comprises a rectangular shape.
12. The article according to claim 1, wherein the cross-section of
the filament comprises a square shape.
13. The article according to claim 1, wherein the cross-section of
the filament comprises a tear-drop shape.
14. The article according to claim 1, wherein the cross-section of
the filament comprises a multi-lobe shape.
15. The article according to claim 1, wherein the cross-section of
the filament comprises a crescent shape.
16. The article according to claim 1, wherein the filament
comprises a polymer material.
17. The article according to claim 16, wherein the polymer material
of the filament comprises a polyester material.
18. The article according to claim 1, wherein said base substrate
comprises a knitted material.
19. The article according to claim 1, wherein said base substrate
comprises a woven material.
20. The article according to claim 1, wherein said base substrate
comprises a nonwoven material.
21. The article according to claim 1, wherein said base substrate
comprises a foam material.
22. The article according to claim 21, wherein the foam material
comprises a closed cell foam.
23. The article according to claim 21, wherein the foam material
comprises an open cell foam.
24. The article according to claim 1, wherein said base substrate
comprises a film.
25. The article according to claim 1, wherein said loops comprise a
mono-filament yarn.
26. The article according to claim 1, wherein said loops comprise a
multi-filament yarn.
27. The article according to claim 26, wherein the multi-filament
yarn comprises a plurality of filaments having the same
cross-sectional shape.
28. The article according to claim 26, wherein the multi-filament
yarn comprises a plurality of filaments having at lease two
different cross-sectional shapes.
29. The article according to claim 1, wherein said loops comprise a
yarn having a denier per yarn of less than about 1000.
30. The article according to claim 1, wherein said loops comprise a
yarn having a denier per yarn of less than about 500.
31. An article comprising: a base substrate; and a plurality of
loops extending from said base substrate, said loops comprising a
yarn having at least one filament with at least 10 denier per
filament and including a cross-section with at least one corner
edge, and wherein the yarn has a total denier of less than
1000.
32. The article according to claim 31, wherein the filament is at
least about 20 denier per filament.
33. The article according to claim 31, wherein said loops comprise
a yarn having a denier per yarn of less than about 500.
34. The article according to claim 31, wherein the height of said
loop extending from said base substrate is between about 0.1
millimeters and about 5 millimeters.
35. The article according to claim 31, wherein the width of said
loop is between about 0.1 millimeters and about 5 millimeters.
36. The article according to claim 31, wherein the height of said
loop extending from said base substrate is between about 0.3
millimeters and about 3 millimeters.
37. The article according to claim 31, wherein the width of said
loop is between about 0.3 millimeters and about 3 millimeters.
38. The article according to claim 31, wherein the height of said
loop extending from said base substrate is about 1.0
millimeters.
39. The article according to claim 31, wherein the width of said
loop is about 0.8 millimeter.
40. The article according to claim 31, wherein the cross-section of
the filament comprises a rectangular shape.
41. The article according to claim 31, wherein the cross-section of
the filament comprises a square shape.
42. The article according to claim 31, wherein the cross-section of
the filament comprises a tear-drop shape.
43. The article according to claim 31, wherein the cross-section of
the filament comprises a multi-lobe shape.
44. The article according to claim 31, wherein the cross-section of
the filament comprises a crescent shape.
45. The article according to claim 31, wherein the filament
comprises a polymer material.
46. The article according to claim 45, wherein the polymer material
of the filament comprises a polyester material.
47. The article according to claim 31, wherein said base substrate
comprises a knitted material.
48. The article according to claim 31, wherein said base substrate
comprises a woven material.
49. The article according to claim 31, wherein said base substrate
comprises a nonwoven material.
50. The article according to claim 31, wherein said base substrate
comprises a foam material.
51. The article according to claim 50, wherein the foam material
comprises a closed cell foam.
52. The article according to claim 50, wherein the foam material
comprises an open cell foam.
53. The article according to claim 31, wherein said base substrate
comprises a film.
54. The article according to claim 31, wherein the yarn forming
said loops comprise a mono-filament yarn.
55. The article according to claim 31, wherein the yarn forming
said loops comprise a multi-filament yarn.
56. The article according to claim 55, wherein the multi-filament
yarn comprises a plurality of filaments having the same
cross-sectional shape.
57. The article according to claim 55, wherein the multi-filament
yarn comprises a plurality of filaments having at least two
different cross-sectional shapes.
58. An article comprising: a base substrate; and a plurality of
loops extending from said base substrate, said loops comprising a
yarn having at least one filament, wherein the filament includes a
cross-section with a portion of the cross-section being concave,
and wherein the yarn has a total denier of less than 1000.
59. The article according to claim 58, wherein said loops comprise
a yarn having a denier per yarn of less than about 500.
60. The article according to claim 58, wherein the filament is at
least about 10 denier per filament.
61. The article according to claim 58, wherein the filament is at
least about 20 denier per filament.
62. The article according to claim 58, wherein the height of said
loop extending from said base substrate is between about 0.1
millimeters and about 5 millimeters.
63. The article according to claim 58, wherein the width of said
loop is between about 0.1 millimeters and about 5 millimeters.
64. The article according to claim 58, wherein the height of said
loop extending from said base substrate is between about 0.3
millimeters and about 3 millimeters.
65. The article according to claim 58, wherein the width of said
loop is between about 0.3 millimeters and about 3 millimeters.
66. The article according to claim 58, wherein the height of said
loop extending from said base substrate is about 1.0
millimeters.
67. The article according to claim 58, wherein the width of said
loop is about 0.8 millimeter.
68. The article according to claim 58, wherein the cross-section of
the filament comprises a tri-lobe shape.
69. The article according to claim 58, wherein the cross-section of
the filament comprises a crescent shape.
70. The article according to claim 58, wherein the filament
comprises a polymer material.
71. The article according to claim 70, wherein the polymer material
of the filament comprises a polyester material.
72. The article according to claim 58, wherein said base substrate
comprises a knitted material.
73. The article according to claim 58, wherein said base substrate
comprises a woven material.
74. The article according to claim 58, wherein said base substrate
comprises a nonwoven material.
75. The article according to claim 58, wherein said base substrate
comprises a foam material.
76. The article according to claim 75, wherein the foam material
comprises a closed cell foam.
77. The article according to claim 75, wherein the foam material
comprises an open cell foam.
78. The article according to claim 58, wherein said base substrate
comprises a film.
79. The article according to claim 58, wherein the yarn forming
said loops comprise a mono-filament yarn.
80. The article according to claim 58, wherein the yarn forming
said loops comprise a multi-filament yarn.
81. The article according to claim 80, wherein the multi-filament
yarn comprises a plurality of filaments having the same
cross-sectional shape.
82. The article according to claim 80, wherein the multi-filament
yarn comprises a plurality of filaments having at lease two
different cross-sectional shapes.
83. A method of forming a textile, comprising the steps of: a)
acquiring a sheet of polymer material; b) slitting the sheet of
polymer material into strips of polymer material; and c) forming a
base substrate and attaching the strips of polymer material to the
base substrate extending as loops from the base substrate.
84. The method according to claim 83, wherein the step of slitting
the sheet of polymer material includes engaging the sheet of
polymer with a row of knives.
85. The method according to claim 83 wherein the step of forming
the base substrate and attaching the strips of polymer comprises
the steps of: forming the base substrate and attaching the strips
of polymer to the base substrate around a sacrificial yarn; and,
removing the sacrificial yarn from between the strips of polymer
and the base substrate, thereby forming the loops.
86. The method according to claim 85, wherein the step of removing
the sacrificial yarn comprises dissolving the sacrificial yarn.
Description
BACKGROUND
[0001] The present invention generally relates to textiles having
loops extending outwardly from a base material.
[0002] Loop textiles have many applications. As an example, terry
cloth loop textiles have been used for cleaning purposes. However,
the terry cloth loops do not always provide a surface sufficient
for scrubbing a surface. Therefore, there is a need for loop
textiles having different characteristics for engaging another
item.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a cross-sectional view of an embodiment of the
present invention, illustrated as a loop textile.
[0004] FIGS. 2A-F are enlarged cross-sectional views of a filament
from a loop of the textile in FIG. 1.
[0005] FIG. 3 is a block diagram, illustrating one embodiment of
the method of forming the textile in FIG. 1.
DETAILED DESCRIPTION
[0006] Referring now to FIG. 1, there is shown a cross-sectional
view of an embodiment of the present invention, illustrated as the
textile 100. The textile 100 generally includes a base substrate
110 with a first surface 111 and a second surface 112, and a
plurality of loops 120 extending from the first surface 111 of the
base substrate 110.
[0007] As illustrated in FIG. 1, the base substrate 110 is a
knitted cloth formed from a plurality of substrate yarns 113.
Although the base substrate 110 is illustrated in FIG. 1 as a
knitted cloth, the base substrate 110 can be any material that
provides a flexible cloth-like base from which the loops 120 can
extend. For example, the base substrate can also be woven,
non-woven, foam (open or closed cell), film, or any other similar
web-like material. In one embodiment, the base substrate 110 is
absorbent. In another embodiment, the base substrate 110 can retain
small particles.
[0008] The loops 120 are a yarn that originate and extend outwardly
from the first surface 111 of the base substrate 110, and return
into the first surface 111 of the base substrate 110. The loops 120
have a height and width that is generally sufficient to receive
material within the loop 120 when the textile 100 passes over
another surface. In one embodiment, the height of the loop 120 is
between about 0.1 millimeter and about 5 millimeters, and the width
of the loop 120 is between about 0.1 millimeters and about 5
millimeters at the widest point. In another embodiment, the height
of the loop 120 is between about 0.3 millimeter and about 3
millimeters, and the width of the loop 120 is between about 0.3
millimeters and about 3 millimeters at the widest point. In a
particular embodiment, the loops 120 extend about 1.0 millimeters
from the base substrate 110, are about 0.8 millimeter wide at the
widest point.
[0009] As illustrated in FIG. 1, the loop 120 is a mono-filament
yarn. However, it is contemplated that the yarn forming the loops
120 can be either a mono-filament yarn or a multiple filament yarn.
In one embodiment, the yarn forming the loops 120 have at least one
filament with a denier per filament of at least about 10. In
another embodiment the yarn forming the loops 120 have at least one
filament with a denier per filament of at least about 20. In one
embodiment the yarn forming the loops 120 have a denier per yarn of
no greater than about 500 in one embodiment, and about 1000 in
another embodiment. In one embodiment, the yarn forming the loops
120 are stiffer than the material of the base substrate 110.
[0010] The loops 120 can be positioned on the base substrate 110 in
a regular pattern, a random pattern, overlapping, separated,
freestanding, or in any other desired configuration. In one
embodiment, the loops 120 are positioned on the base substrate in a
rectangular grid with about six rows of loops per centimeter in one
direction (the wide direction of the loops), and about seven and
one-half loops per centimeter in the other direction. It is also
contemplated that the plurality of loops in the present invention
can be combined with other material, such as loops of material
other than the loops described herein.
[0011] Referring now to FIGS. 2A-F, there are shown enlarged
cross-section of various embodiments of filaments that can be used
in the yarn of the loops 120 from FIG. 1. In FIG. 2A is illustrated
a filament having an elliptical cross-section. In FIG. 2B is
illustrated a filament having a rectangular cross-section. In FIG.
2C is illustrated a filament having a square cross-section. In FIG.
2D is illustrated a filament having a tear drop shaped
cross-section. In FIG. 2E is illustrated a filament having a
crescent shaped cross-section. In FIG. 2F is illustrated a filament
having a multi-lobe cross-section, such as a tri-lobe
cross-section.
[0012] In one embodiment, the cross-section of the filament(s)
forming the loop 120 have an aspect ratio of greater than about
1.2, as illustrated in FIGS. 2A-F. In another embodiment, the
cross-section of the filament(s) forming the loop 120 have an
aspect ratio of greater than about 2. As used herein an aspect
ratio shall mean the width of the cross-section at its widest point
divided by the width of the cross-section at its narrowest point.
In another embodiment, the cross-section of the filament(s) forming
the loop 120 have at least one corner edge, as illustrated in FIGS.
2 B-F. In yet another embodiment, the cross-section of the
filament(s) forming the loop 120 have a cross-section with at least
a portion of the cross-section being concave, as illustrated in
FIGS. 2E-F. As used herein, concave shall mean a shape that the
outer perimeter extends within a straight line drawn between any
two points on the outer perimeter.
[0013] In an embodiment where the loops 120 are formed of
mono-filament yarns, the cross sections of the filaments can either
be all one type of cross-section, or multiple cross-sections can be
used for the filaments forming the various loops 120. In an
embodiment where the loops are formed of multiple filament yarns,
the cross sections of the filaments forming the yarns can either be
all of one type of cross-section (homogeneous), or multiple types
of cross-sections (heterogeneous). Additionally, the various loops
120 can be yarns of different filaments, including any combination
of homogenous yarns and/or heterogeneous yarns. Furthermore, the
various loops 120 can be combinations of any of the mono-filament
yarns and multiple filament yarns.
[0014] Referring now to FIG. 3, there is shown a block diagram of a
method 200 of forming one embodiment of the textile according to
FIG. 1. The method 200 illustrated in FIG. 3 generally includes the
steps of acquiring a sheet of polymer material 210, slitting the
sheet of polymer material into strips 220, and forming a base
substrate and attaching the strips of polymer to the base substrate
as loops extending from the base material 230.
[0015] In step 210, the acquired sheet of polymer material can be a
polymer that is extruded, cast, blown, or that is formed in any
other manner that produces a sheet of polymer. The polymer can be
polyethylene, polyester, polypropylene, or the like. The thickness
of the sheet can be from about 0.0005 inches to about 0.005 inches.
In one embodiment, the film is about 0.0015 inches thick.
[0016] In step 220, the sheet of polymer material is slit into
individual filaments. In one embodiment, a long sheet of polymer
material is unrolled and engages a row of knives that slit the
sheet of polymer from its original width to many strips of the
polymer material, the number of strips determined by the number of
knives. The width of the filaments can be from about 0.002 inches
to about 0.25 inches. In one embodiment, the individual filaments
are strips of polymer that are about 0.0145 inches wide.
[0017] In step 230, the forming a base substrate and attaching the
strips of polymer can be performed by double knitting the base
substrate, tucking the strips of polymer into the base substrate,
and knitting the polymer strips into the base substrate as loops.
In one embodiment, the polymer strips are attached as loops to the
base substrate by attaching a first section of a strip of polymer
to the base substrate 231, bringing the strip of polymer around a
sacrificial yarn, attaching a second section of the strip of
polymer to the base substrate on the opposite side of the
sacrificial yarn from the first section of the strip of polymer
232, and removing the sacrificial yarn from between the strip of
polymer and the base substrate to form a loop of the strip of
polymer 233. In a further embodiment, the step of removing the
sacrificial yarn is performed by dissolving the sacrificial
yarn.
[0018] The present invention can also be better understood by
reference to the following example. A polymer sheet was acquired of
a polyester film being about 0.0015 inches thick. The polymer sheet
was slit into filament strips of about 0.0145 inches wide. A base
substrate was formed from a substrate yarn of textured filament
polyester yarn, having 34 filaments per yarn at a yarn denier of
150 (such as Dacron 56T by DuPont). The filament polymer strips
were attached to the base substrate by tucking the filament polymer
strips into the base substrate as it was being formed, and knitting
the filament polymer strips into the base substrate around a one
ply, 40 denier per filament, 12 filament sacrificial water-soluble
poly(vinyl alcohol) yarn (such as Solvron by Nitivy). The
sacrificial yarn was removed by immersing the textile into a hot
water scour of 160F. After formation of the loops by dissolving the
sacrificial yarn, the textile was dyed, slit to proper width,
dried, and cut to the appropriate size.
* * * * *