U.S. patent application number 10/304176 was filed with the patent office on 2004-05-27 for process for face finishing fabrics, fabrics having good strength and aesthetic characteristics, and items of napery having good pick and snag resistance.
Invention is credited to Greer, James T., Holloman, Talmage H., Love, Franklin S. III, McLendon, Susan K., Stavrakas, Karen H., Waldrop, David E..
Application Number | 20040098848 10/304176 |
Document ID | / |
Family ID | 32325148 |
Filed Date | 2004-05-27 |
United States Patent
Application |
20040098848 |
Kind Code |
A1 |
Love, Franklin S. III ; et
al. |
May 27, 2004 |
Process for face finishing fabrics, fabrics having good strength
and aesthetic characteristics, and items of napery having good pick
and snag resistance
Abstract
A process for face finishing fabrics, and in particular fabrics
containing filaments, to provide them with good aesthetic
characteristics is described. In addition, fabrics made from
filaments having aesthetic characteristics and surface effects
similar to those of fabrics made from spun yarns are described.
Also, items of napery made from filaments and having good surface
effects and low pick and snag performance are described. The
process involves pre-abrading a fabric, such as one made from
filaments, and then subjecting it to a high energy fluid treatment
process.
Inventors: |
Love, Franklin S. III;
(Columbus, NC) ; McLendon, Susan K.;
(Simpsonville, SC) ; Stavrakas, Karen H.;
(Greenville, SC) ; Greer, James T.; (Moore,
SC) ; Holloman, Talmage H.; (Inman, SC) ;
Waldrop, David E.; (Easley, SC) |
Correspondence
Address: |
Sara M. Current
Legal Department, M-495
PO Box 1926
Spartanburg
SC
29304
US
|
Family ID: |
32325148 |
Appl. No.: |
10/304176 |
Filed: |
November 26, 2002 |
Current U.S.
Class: |
28/167 ; 26/28;
28/104 |
Current CPC
Class: |
D06C 27/00 20130101 |
Class at
Publication: |
028/167 ;
028/104; 026/028 |
International
Class: |
D06C 027/00; D06C
011/00 |
Claims
We claim:
1. A process for enhancing the surface of a fabric comprising the
steps of: providing a textile fabric formed from a plurality of
fibers; pre-abrading said textile fabric and treating said textile
fabric with a high energy fluid, to thereby form a surface effect
on the textile fabric.
2. A process according to claim 1, wherein said fabric contains
filaments.
3. A process according to claim 1, wherein said steps of
pre-abrading and treating result in cut fiber ends, and said cut
fiber ends have a length of about 1.5 float lengths or less.
4. A process according to claim 1, wherein said step of
pre-abrading comprises a process selected from the group consisting
of sanding, brushing, napping, wet sueding, and dry sueding.
5. A process according to claim 1, wherein said step of treating
the fabric with a high energy fluid comprises a process selected
from the group consisting of high pressure gas treatment, and high
pressure liquid treatment.
6. A process according to claim 1, wherein said step of
pre-abrading is performed on only one surface of the fabric.
7. A process according to claim 1, wherein said step of treating
the fabric with a high energy fluid is performed on only one
surface of the fabric.
8. A process according to claim 1, wherein said step of treating
the fabric with a high energy fluid is performed by way of a
plurality of treatment stages.
9. A process according to claim 1, wherein said step of treating
the fabric with a high energy fluid is performed by way of a single
treatment stage.
10. A process according to claim 1, wherein said step of treating
the fabric with a high energy fluid comprises a high pressure
hydraulic treatment.
11. A fabric made by the process of claim 1.
12. A process according to claim 1, wherein said step of treating
the fabric with a high energy fluid is performed to apply at least
about 0.0295 horsepower-hr/lb of energy to the fabric.
13. A process for enhancing the aesthetic characteristics of a
filament containing textile fabric comprising the steps of:
providing a woven textile fabric comprising filaments in each of
the warp and filling directions; pre-abrading said textile fabric
to raise some fibers from each of the warp and filling; and
treating the fabric with a high energy fluid, such that a surface
effect is formed on at least one surface of said fabric and fibers
from adjacent yarns are entangled with each other.
14. A process according to claim 13, wherein the surface effect is
formed from short fibers having a length of about 1.5 float lengths
or less.
15. A fabric made by the process of claim 13.
16. A process according to claim 13, wherein said step of treating
the fabric with high energy fluid is performed to apply at least
about 0.0295 horsepower-hr/lb of energy to the fabric.
17. A fabric comprising a plurality of associated yarns comprising
a plurality of filaments, wherein said fabric comprises a surface
effect on at least one fabric surface, said surface effect
comprising a plurality of cut fiber ends, and wherein fiber ends
from at least some of said yarns are entangled with fiber ends of
associated yarns.
18. A fabric according to claim 17, wherein said fabric is selected
from the group consisting of woven, knit and nonwoven fabrics.
19. A fabric according to claim 17, wherein said fabric consists
essentially of filaments.
20. A fabric according to claim 17, wherein said fabric comprises a
woven fabric consisting essentially of filaments.
21. A fabric according to claim 20, wherein said fabric is in the
form of an article of napery.
22. A fabric according to claim 20, wherein said fabric is in a
plain weave construction.
23. A fabric according to claim 20, wherein said fabric has a Pick
and Snag rating of greater than 3 after one wash when tested
according to ASTM D5362-97a.
24. A fabric according to claim 20, wherein said fabric has a Pick
and Snag rating of greater than 2 after 50 washes when tested
according to ASTM D5362-97a.
25. A fabric according to claim 20, wherein said fabric has a Pick
and Snag rating of about 3 or greater after 50 washes when tested
according to ASTM D5362-97a.
26. A fabric according to claim 20, wherein said fabric has a Pick
and Snag rating of greater than 3.5 after 50 washes when tested
according to ASTM D5362-97a.
27. A fabric according to claim 20, wherein said fabric has a Pick
and Snag rating of greater than 1 after 125 washes when tested
according to ASTM D5362-97a.
28. A fabric according to claim 20, wherein said fabric has a Pick
and Snag rating of greater than 2 after 125 washes when tested
according to ASTM D5362-97a.
29. A fabric according to claim 20, wherein said fabric has a Pick
and Snag rating of greater than 3 after 125 washes when tested
according to ASTM D5362-97a.
30. A fabric according to claim 17, wherein said fabric is a woven
fabric and said fiber ends have a length of about 1.5 float lengths
or less.
31. A fabric according to claim 17, wherein said fabric has a
Kawabata System COMP05 value of about 45% or greater.
32. A fabric according to claim 31, wherein said fabric has a
Kawabata System COMP value of about 50% or greater.
33. A fabric according to claim 17, wherein said fabric has a
Kawabata System MIU value of about 0.15 or greater in each of the
lengthwise and crosswise directions.
34. A fabric according to claim 33, wherein said fabric has a
Kawabata System MIU value of about 0.21 or greater in each of the
lengthwise and crosswise directions.
35. A fabric comprising a plurality of associated yarns comprising
a plurality of filaments, said fabric defining first and second
fabric surfaces, wherein at least some of the filaments positioned
along said first fabric surface fabric define a plurality of cut
fiber ends, and at least some of said cut fiber ends extend through
the dimension of the fabric and outwardly from said second fabric
surface.
36. A fabric according to claim 35, wherein said fabric is a woven
fabric and said cut fiber ends extend outwardly from said first and
second fabric surfaces a distance of 1.5 float lengths or less.
37. A fabric comprising spun yarns, said fabric having first and
second exterior fabric surfaces defining a fabric interior
therebetween, wherein portions of said spun yarns adjacent said
first exterior surface have a greater number of cut fiber ends than
portions of said spun yarns adjacent the fabric interior, and
wherein at least some of said cut fiber ends originating from the
spun yarns at the first exterior surface of the fabric extend
through the interior of the fabric to the second exterior fabric
surface.
38. The fabric according to claim 37, wherein said fabric is a
woven fabric, and said cut fiber ends extend outwardly from said
first and second exterior fabric surfaces a distance of 1.5 float
lengths or less.
39. A napery article comprising substantially all filament fibers,
wherein said fabric has a Pick and Snag Rating of greater than 3
when tested according to ASTM D5362-97a, a filling tear strength of
about 2.5 or greater when tested according to ASTM D2261-96, and a
Kawabata System Comp05 value of about 45% or greater.
40. A napery article according to claim 39, wherein said fabric
comprises substantially all polyester.
41. A napery article comprising substantially all filament fibers,
wherein said fabric has a Pick and Snag Rating of greater than 3
when tested according to ASTM D5362-97a, a filling tear strength of
about 2.5 or greater when tested according to ASTM D2261-96, and a
Kawabata System MIU value of about 0.15 or greater in each of the
lengthwise and crosswise directions.
42. A napery article according to claim 41, wherein said fabric
comprises substantially all polyester.
43. A napery article comprising substantially all filament fibers
woven in a plain weave construction, wherein said fabric has a
filling tear strength of about 2.5 or greater when tested according
to ASTM D2261-96, and a Kawabata System Comp05 value of about 45%
or greater.
44. A napery article according to claim 43, wherein said fabric
comprises substantially all polyester.
45. A napery article comprising substantially all filament fibers
woven in a plain weave construction, wherein said fabric has a
filling tear strength of about 2.5 or greater when tested according
to ASTM D2261-96, and a Kawabata System MIU value of about 0.15 or
greater in each of the warp and filling directions.
46. A napery article according to claim 45, wherein said fabric
comprises substantially all polyester.
Description
BACKGROUND OF THE INVENTION
[0001] Conventional fabric fluid treatment processes designed to
enhance the surface characteristics of fabrics have been limited to
use on fabrics including spun yarns, in order that sufficient fiber
free ends are available for the fluid treatment process to raise
and entangle, and to form the surface effect. Conventionally, fluid
treatment processes have not been considered to be effective on
fabrics made primarily from filament fibers, such as all filament
fabrics. One attempt to use a hydraulic treatment process to
enhance an all-filament fabric is described in U.S. Pat. No.
5,806,155 to Malaney et al. That patent describes the use of a
hydraulic treatment process to "uniformly and continuously" impact
an all-filament woven fabric at a particular level of energy in
order to achieve controlled porosity and uniform spacing of the
yarns. However, as acknowledged by Malaney in that reference, there
are no free fiber ends in the fabric to be entangled or which can
be used to form a surface effect on the fabric. (For purposes of
this invention, the term "surface effect" is intended to describe a
nap or pile of fibers on the surface of the fabric, which provide
it with a variety of characteristics, e.g. softness, increased
compression, etc.)
[0002] Spun yarns are commonly used in the production of fabrics
for a variety of end uses, in particular, where aesthetics such as
a soft hand are desired. As will be readily appreciated by those of
ordinary skill in the art, spun yarns are those made from a
plurality of relatively short fibers (i.e. staple fibers) that are
formed into a yarn that is typically held together by twist. Some
disadvantages that are commonly associated with spun yarns are that
they are often not as strong as their filament counterparts and
they can tend to degrade during use and laundering, leading to the
production of lint, fabric weight loss, and loss of fabric
strength. In addition, fabrics made from spun yarns tend to retain
soil to a greater extent than fabrics made from filaments.
[0003] Fabrics made from filaments thus are generally considered to
have greater strength and soil release performance than those made
from spun yarns, though they generally are not considered to be as
soft or aesthetically pleasing as the fabrics made from spun yarns.
Therefore, yarns made from filaments are often put through a
texturing process designed to bulk out the filaments and make them
more compressible and pleasant to the touch. However, fabrics made
from the textured filaments are still considered to have only
limited to no surface effect, and considerably less surface effect
than a comparable fabric made from spun yarns.
[0004] One market that has capitalized on the features of filaments
is the napery market, and in particular, the rental laundry market.
The rental laundry market demands that the fabrics used in the
manufacture of its tablecloths and napkins be highly durable, in
order that the items can be re-used and laundered a large number of
times. In addition, such items need to have good soil release, and
need to have a good feel or hand, particularly when they will be
used as napkins, since they will contact the user's face.
[0005] As noted above, filaments are considered to provide greater
durability and soil release than spun yarns. As also noted
previously, the fabrics made from filaments have a rough feel and
limited to no surface effect. In an attempt to overcome this
disadvantage, fabrics made from filaments are typically sanded or
otherwise abraded to produce some cut fibers at the fabric surface.
However, to achieve an amount of abrasion sufficient to alter the
surface characteristics of the fabric, it is typically required
that the fabric construction present sufficient available fiber
lengths to the abrasion device, in order that an acceptable hand
can be achieved at an acceptable level of strength. (See FIG. 1,
which illustrates the effect that abrasion intensity as applied to
a plain weave fabric has on fabric tear strength.)
[0006] In order to present yarn floats that are sufficiently long
to receive an effective amount of abrasion by the abrading process,
it is customary to provide the fabrics in a 2.times.1 weave
construction. (As will be readily appreciated by those of ordinary
skill in the art, this construction provides a plurality of
staggered yarn floats, where a yarn extending in one direction
crosses over two or more yarns extending in the other direction. In
this way, the float can be sufficiently acted upon by the abrasive
action.) Not only does this construction provide greater fiber
availability for the abrasion process, but this weave construction
is typically considered to have better tear strength as compared
with a plain weave construction made from the same yarns.
[0007] One problem posed by this construction is that the longer
floats have a tendency to pick and snag. When this occurs,
filaments or even a whole yarn are pulled outwardly from the
fabric, resulting in an unsightly looking defect in the product.
These picks and snags can occur routinely from fabric use or from
the laundering process, and are a common cause of rental napery
products being withdrawn from use. Despite the above-noted
disadvantages associated with the 2.times.1 construction, prior to
the present invention, it had been considered to be the only
acceptable construction for a filament napery fabric with
acceptable surface effects.
SUMMARY
[0008] The instant invention is directed to a process for making
fabrics made from filaments have aesthetic characteristics
simulating those of fabrics made from spun yarns. In addition, the
invention is directed to fabrics having spun-like aesthetic
characteristics made from filaments. Furthermore, the invention
enables the achievement of fabrics having a durable soft hand, good
fabric durability and strength, good soil release, good color
retention, improved moisture transport and low pill characteristics
as compared with similar fabrics made from spun yarns. In addition,
the invention includes fabrics suitable for use in the rental
napery market, which have a reduced tendency to pick and snag
relative to other napery fabrics made from filaments.
[0009] The invention involves providing a fabric containing
filaments, and subjecting the fabric to a pre-abrasion step. For
example, the fabric can be sanded, brushed, napped, etc., with the
goal being to abrade some of the filaments and form some cut fiber
ends along the yarns. (For purposes of this disclosure, the term
"cut fiber ends" is intended to encompass ends that are severed all
the way through, as well as those formed through fiber
fibrillation, which is a slicing or peeling of a portion of the
fiber.)
[0010] The fabric is then subjected to a high energy fluid
treatment process, which serves to act on the pre-abraded fabric
and create a surface effect on at least one surface of the fabric
and/or push cut fiber ends from one surface of the fabric through
the dimension of the fabric toward or through to the other fabric
surface. For example, the fabric can be treated with high pressure
water, gas, or the like. (For purposes of this application, "high
energy" is intended to encompass fluids at sufficient pressures
and/or velocities to push cut fiber ends through the dimension of
the fabric (i.e. invert the pile) and/or entangle fibers, as
opposed to simply slightly displacing them, and to push fibers
through and/or outwardly from the dimension of the fabric.) Where
an amount of energy is described herein as being applied to a
fabric, it is understood that those of ordinary skill in the art
will recognize that the speed of the fabric through the treatment
zone, the dimension of the treatment zone, the pressure and
velocity of the fluid as it reaches the fabric, the fluid density
and mass, the mass of the fabric presented to the fluid, and the
time the fabric is exposed will be coordinated to achieve the
desired level of energy application. In addition, the total energy
may be applied to the fabric in one stage, through passage through
a series of fluid treatment stages.
[0011] In the case of multiple treatment stages, they can be
achieved by way of plural treatment stages in a single apparatus,
or from multiple passes through a single fluid treatment apparatus.
Typically, it would be expected that an energy of about 0.0295
horsepower-hr/lb of fabric would perform well in effectively
entangling the fibers and raising the fibers to form the surface
effect, although other energy levels are contemplated within the
scope of the invention, depending on the treatment process
utilized, the fabric treated, and the amount of surface effect
desired.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a graphical illustration of the effect that
abrasion intensity has on the tear strength of a plain weave
fabric;
[0013] FIG. 2 is a schematic illustration of a process according to
the instant invention;
[0014] FIG. 3A is a photomicrograph (30.times. magnification, no
tilt) of the fabric described in Example A, in its greige
state;
[0015] FIG. 3B is a photomicrograph (30.times. magnification, no
tilt) of the fabric shown in FIG. 3A, after it has been abraded in
the manner described below in Example A;
[0016] FIG. 3C is a photomicrograph (30.times. magnification, no
tilt) of the fabric shown in FIG. 3A, after it has been abraded and
fluid treated in the manner described below in Example A;
[0017] FIG. 4A is a photomicrograph (30.times. magnification,
45.degree. tilt) of the fabric described in Example 1, in its
greige state;
[0018] FIG. 4B is a photomicrograph (30.times. magnification,
45.degree. tilt) of the fabric shown in FIG. 4A, after it has been
abraded in the manner described below in Example A;
[0019] FIG. 4C is a photomicrograph (30.times. magnification,
45.degree. tilt) of the fabric shown in FIG. 4A, after it has been
abraded and fluid treated in the manner described below in Example
A;
[0020] FIG. 5A is a photomicrograph (30.times. magnification,
75.degree. tilt) of the fabric described in Example A, in its
greige state;
[0021] FIG. 5B is a photomicrograph (30.times. magnification,
75.degree. tilt) of the fabric shown in FIG. 5A, after it has been
abraded in the manner described below in Example A;
[0022] FIG. 5C is a photomicrograph (30.times. magnification,
75.degree. tilt) of the fabric shown in FIG. 5A, after it has been
abraded and fluid treated in the manner described below in Example
A;
[0023] FIG. 6A is a cross-sectional photomicrograph (30.times.
magnification) of the fabric described in Example A in its greige
state;
[0024] FIG. 6B is a cross-sectional photomicrograph (30.times.
magnification) of the fabric described in Example A, after it has
been abraded;
[0025] FIG. 6C is a cross-sectional photomicrograph (30.times.
magnification) of the fabric described in Example A after it has
been abraded and fluid treated;
[0026] FIG. 7 is a schematic illustration of an apparatus that can
be used to pre-abrade the fabric according to the instant
invention;
[0027] FIG. 8A is an illustration of a cross-sectional view of a
fabric which has been abraded on one side only;
[0028] FIG. 8B is an illustration of the fabric of FIG. 8A after it
has been subjected to a fluid treatment step in accordance with the
instant invention;
[0029] FIG. 8C is an illustration of a fabric made from spun yarns
that has been abraded on one side only and subjected to a fluid
treatment step in the manner set forth in the invention; and
[0030] FIG. 9 is a bar chart illustration of the total picks and
snag test results for the Example A, B and C fabrics.
DETAILED DESCRIPTION
[0031] In the following detailed description of the invention,
specific preferred embodiments of the invention are described to
enable a full and complete understanding of the invention. It will
be recognized that it is not intended to limit the invention to the
particular preferred embodiment described, and although specific
terms are employed in describing the invention, such terms are used
in a descriptive sense for the purpose of illustration and not for
the purpose of limitation.
[0032] The instant invention is directed to a process for enhancing
the hand and aesthetic characteristics of fabrics. In particular,
the process has been found to be particularly suitable in the
enhancement of filament-containing fabrics. In one aspect of the
invention, it has been found that fabrics made substantially or
substantially entirely from filaments can be made to feel and
appear substantially like fabrics made from spun yarns. This can be
particularly desirable because fabrics having comparable levels of
feel as those made from spun yarns can be achieved at greater
levels of strength, durability, soil release, and/or levels of
manufacturing ease and efficiency.
[0033] The fabric can be produced in any known manner, including
but not limited to weaving, knitting, and nonwoven manufacturing
processes. As will be appreciated by those of ordinary skill in the
art, such fabrics include a plurality of fibers and/or yarns that
are interwoven, interknit, or otherwise associated with each other
to form a coherent stable structure.
[0034] The invention contemplates the use of any type of fibers,
including but not limited to synthetic and non-synthetic fibers
(e.g. polyester, nylon, rayon, silk, cotton, polylactide based
fibers, PTT fibers, wool, aramids, etc.), single or multi-plied
yarns, or the like.
[0035] The invention involves pre-abrading a fabric, then treating
it with a high energy fluid. The pre-abrasion can be performed in
any of a variety of ways. For example, the pre-abrading can be
performed by processes including, but not limited to, sanding,
brushing, napping, wet sueding, dry sueding, or processing by the
sanding methods and/or apparatus described in commonly-assigned
U.S. Pat. No. 6,233,795 to Dischler, 6,260,247 to Dischler et al.,
6,269,525 to Dischler et al., 6,345,421 to Dischler et al.,
4,468,844 to Otto, 4,512,065 to Otto, 5,943,745 to Dischler,
6,242,370 to Dischler, 5,815,896 to Dischler, and 5,752,300 to
Dischler, the disclosures of which are incorporated herein by
reference. For purposes of this disclosure, the term "sanding" is
intended in its broadest sense to encompass all types of grits
(e.g. sandpaper, sanding films, diamond plated rolls,
three-dimensional abrasion such as by using Scotchbrite.RTM. grit
available from 3M Corporation of St. Paul, Minn., etc.), and grit
supports.
[0036] The fabric can be pre-abraded on one or both surfaces,
according to the desired amount of surface effect. For example, in
one aspect of the invention illustrated in FIGS. 8A and 8B, the
fabric is pre-abraded on one surface (FIG. 8A), with the fluid
treatment serving to produce a surface effect on each of the fabric
surfaces, by forcing some of the cut fiber ends of the abraded
fibers through the fabric to the opposite fabric surface (FIG. 8B).
Alternatively, both surfaces of the fabric can be pre-abraded
within the scope of the instant invention. FIGS. 8A and B
illustrate a filament fabric, while FIG. 8C illustrates a fabric
made from spun yarns.
[0037] The high energy fluid treatment can be of any variety that
functions to entangle fibers within the fabric, including treatment
with high pressure gas, treatment with high pressure liquid, or the
like. For example, it has been found that a high pressure water
treatment of the variety described in commonly-assigned co-pending
U.S. patent application Ser. No. 09/344,596 to Emery et al, filed
Jun. 25, 1999 works well in the invention. The disclosure of U.S.
patent application Ser. No. 09/344,596 to Emery et al., filed Jun.
25, 1999, is incorporated herein by reference. However, other types
of fluid treatment apparatus could be used within the scope of the
invention, including but not limited to those described in U.S.
Pat. No. 5,806,155 to Malaney et al.; U.S. Pat. No. 6,253,429 to
Zolin; U.S. Pat. No. 5,632,072 to Simon et al.; and U.S. Pat. No.
6,343,410 to Greenway et al.; U.S. Pat. No. 5,791,028 to Zolin;
U.S. Pat. No. 6,442,810 to Greenway et al.; U.S. Pat. No. 6,442,809
to Greenway et al.; U.S. Pat. No. 5,136,761 to Sternlieb et al.;
U.S. Pat. No. 4,995,151 to Siegel et al.; U.S. Pat. No. 4,967,456
to Sternlieb et al., the disclosures of which are incorporated
herein by reference. The high energy fluid treatment can be
performed on both surfaces or on one surface only. As noted above,
in some embodiments of the invention (such as when using the fluid
treatment apparatus described above in the '596 application to
Emery et al), a surface effect may be achieved on both surfaces of
the fabric despite fluid treatment being performed only on a single
side of the fabric.
[0038] As noted previously, the amount of energy applied can be
selected to optimize the surface effect on the particular fabric
being treated. In addition, the parameters of the particular
treatment apparatus can be selected without undue experimentation
to achieve the desired level of treatment, so that the desired
level of surface effect is achieved for the particular fabric. It
is expected that by treating a fabric with at least about 0.0295
hp-hr/lb of energy, a good surface effect could be achieved for
many textile fabrics. In some embodiments of the invention, it has
been found that an energy application of about 0.0295-0.118
hp-hr/lb achieves a good fabric.
[0039] It has surprisingly been found that by pre-abrading a fabric
and in particular, a filament-containing fabric, the high energy
fluid is able to dramatically change the surface of the fabric far
beyond the effects of the abrasion alone. This unique combination
of pre-abrasion and fluid treatment has been found to give
filament-containing fabrics unique surface effects similar to those
of fabrics made from spun yarns. In particular, while abraded
fabrics have a flat and rough feel, the fabrics of the instant
invention have a number of loopy filament ends that are exposed to
the surface, which form a cushioned surface effect. In other words,
fibers from both the warp and filling are affected (in contrast to
many other processes that affect only one set of yarns) and a
plurality of short round loops with free ends are produced, with
the fibers being entangled with those from other adjacent yarns, to
form a dense cover of fibers.
[0040] In addition, the cut fiber ends had a length of about 1-11/2
floats, which resulted in a unique short, soft surface effect, with
the fibers being entangled with other adjacent fibers, and
throughout the thickness dimension of the fabric. In contrast,
surface effects produced from conventional processes such as
brushing result in long pulled fibers that do not form a cohesive
entangled surface effect. This short fiber feature is of particular
advantage because long pulled fibers have a tendency to exacerbate
fabric pilling. Therefore, in one aspect of the invention, it is
desirable that the pre-abrasion and fluid treatment processes be
performed to produce cut fiber ends having a length of about 1.5
float lengths or less.
[0041] Intermediate steps such as dyeing, chemical treatment, etc.
can be performed where desired, either before pre-abrasion, after
pre-abrasion but before fluid treatment, or after fluid treatment.
In addition, the pre-abrasion and fluid treatment operations can be
performed in-line, or as separate operations. Following fluid
treatment, the fabric can be finished in a conventional manner.
Conventional chemistries such as soil release chemicals, wicking
agents, handbuilders, anti-stats, etc. can also be added at any
desired point in the process.
[0042] The fabrics produced by the process of the invention have a
variety of unique combinations. Of particular significance is the
fact that fabrics made from filaments can be made to look and feel
like fabrics made from spun yarns. In this way, a unique fabric
which has the desirable properties associated with filaments (e.g.
strength, low linting, good soil release and the like) can be
achieved but with the aesthetic characteristics associated with
fabrics made from spun yarns.
EXAMPLES
[0043] The examples below were directed to napery articles,
although it is to be noted that these were for example only, and
that the fabrics of the invention are believed to have a broader
utility than the napery market alone. In addition, where the term
"napery article" appears herein, it is intended to encompass both
the articles in the form in which they are provided to the end
user, as well as fabrics that are useful in the production of
napery (e.g. napkins, tablecloths, table skirts, etc.)
Example A
[0044] A 100% polyester filament plain weave fabric was provided.
The fabric had 1/300/136 false twist texture yarns in the warp
direction, and 3/150/68 false twist textured yarns in the filling
direction, and it was woven with 60 ends per inch and 46 picks per
inch. The fabric was prepared and dried in a conventional manner.
Samples were taken here, and photomicrographs were taken as
described above.
[0045] The fabric was then sanded using an apparatus of the variety
described commonly-assigned U.S. Pat. No. 6,233,795, the disclosure
of which is incorporated herein by reference, with the machine
set-up illustrated in FIG. 6 above. The fabric F was fed to the
abrasive rolls in a face-up configuration at an initial tension at
R1 of 110 psi and a speed of 20 yards per minute. The fabric F was
treated on its face in Section A by treatment rolls A1, A2, A3, and
A4. The tension at R2 was 300 psi. The abrasive rolls A1, A2, A3,
A4, B1, B2, B3, and B4 were 400 grit diamond plated rolls of the
variety described in the above-referenced patent. The abrasive
rolls were turned in a clockwise or counterclockwise direction at a
designated percentage of machine speed. A1 rotated counterclockwise
at a roll ratio of 1800, A2 rotated clockwise at a roll ratio of
1780, A3 rotated counterclockwise at a roll ratio of 1800, A4
rotated clockwise at a roll ratio of 1780. The back of the fabric
was treated in Section B. B1 rotated clockwise at a roll ratio of
2000, B2 rotated counterclockwise at a roll ratio of 1980, B3
rotated clockwise at a roll ratio of 2000, and B4 rotated
counterclockwise at a roll ratio of 1980. The tension at R3 was 150
psi. Samples of the fabric were taken here, and photomicrographs
were taken as described above.
[0046] The fabric was fed through a pad containing 1% owf of a high
molecular weight ethoxylated polyester, of the variety known in the
art to promote soil release of fabrics. The fabric was then
processed in a fluid treatment apparatus of the variety described
in commonly-assigned U.S. patent application Ser. No. 09/344,596 to
Emery et al.
[0047] The fabric, which was 98 inches wide and had a weight of
about 6 oz/sq yd, was pulled through the pad and hydraulically
processed at a speed of 80 yds/min. The first treatment zone
hydraulically treated the front side of the fabric at an energy
level of 0.037 hp-hr/lb, and the opposite side of the fabric was
then treated at an energy level of 0.022 hp-hr/lb, for a total
treatment of 0.059 hp-hr/lb.
[0048] The fabric was dried and taken up in a conventional manner.
Samples were taken here, and photomicrographs were taken as
described above. The fabric had a finished weight of 6 oz/sq
yd.
Example B
[0049] A commercially available abraded filament napery fabric of
the variety sold by Milliken & Company of Spartanburg, S.C. was
obtained. The fabric was an all filament polyester product, which
was woven in a 2.times.1 weave construction. The fabric had a
weight of about 6 oz/sq yd.
Example C
[0050] A commercially available napery fabric was obtained. The
fabric was 100% polyester, and was made entirely from spun yarns,
and had a weight of about 5.8 oz/sq yd.
[0051] Industrial Wash Process
[0052] Unless otherwise stated, the washes referred to herein were
performed according to the following wash process:
[0053] The fabric was loaded into an open pocket industrial washer.
The equipment was verified to be free of burrs and sharp edges, to
have properly functioning water level, temperature controls, and
chemical delivery systems.
[0054] Wash Cycle
1 Temperature Time Cycle Water Level .degree. F. (Min.)
Chemicals/100 lbs. Flush High 120 3 Break Low 160 12 24 oz. Alkali
30 oz. Surfactant Carry-over Low 160 6 Rinse High 145 2 Rinse High
130 2 Rinse High 115 2 Sour Low 90-100 8 2 oz. sour Extract 5
[0055] The extraction time should be sufficient to permit the
fabric to be ironed without tumble drying. Fabrics used for the
pick and snag testing were pressed on a commercial flatwork ironer
in a conventional manner. Fabrics used for the other tests
(strength, Kawabata, pilling) were tumbled dry in a conventional
manner following washing, but were not ironed.
[0056] Pick and Snag Testing
[0057] Picking and snagging of the fabrics described above in
Examples A and B were tested according to ASTM D5362-97a (option
B). Fabrics were tested after one wash, after 50 washes, and after
125 washes. For Snag Rating, a 5 indicates no snagging or
insignificant snagging, a 4 represents slight snagging, a 3
represents moderate snagging, a 2 represents severe snagging, and a
1 represents very severe snagging. For the Average Picks and Snags,
samples of each fabric were put through the pick and snag tester in
accordance with the above test method, and the number of picks and
snags were counted (also in the manner described in the test
method) in a three inch square area. Eight samples were taken from
each side of the fabric, and the results were averaged and
recorded. The results are listed below in Table 1.
2 TABLE 1 Example A fabric Example B fabric Snag Rating after 1 4 3
wash Snag rating after 50 3.88 2 washes Snag rating after 125 3.63
.38 washes Average Picks & Snags 3.25 5.25 per bag at 200
revolutions after 1 wash Average Picks & Snags 4.5 10 per bag
at 200 revolutions after 50 washes Average Picks & Snags 4.88
17.5 per bag at 200 revolutions after 125 washes
[0058] Kawabata Testing
[0059] A variety of characteristics were measured using the
Kawabata Evaluation System ("Kawabata System"). The Kawabata System
was developed by Dr. Sueo Kawabata, Professor of Polymer Chemistry
at Kyoto University in Japan, as a scientific means to measure, in
an objective and reproducible way, the "hand" of textile fabrics.
This is achieved by measuring basic mechanical properties that have
been correlated with aesthetic properties relating to hand (e.g.
smoothness, fullness, stiffness, softness, flexibility, and
crispness), using a set of four highly specialized measuring
devices that were developed specifically for use with the Kawabata
System. These devices are as follows:
[0060] Kawabata Tensile and Shear Tester (KES FB1)
[0061] Kawabata Pure Bending Tester (KES FB2)
[0062] Kawabata Compression Tester (KES FB3)
[0063] Kawabata Surface Tester (KES FB4)
[0064] KES FB1 through 3 are manufactured by the Kato Iron Works
Col, Ltd., Div. Of Instrumentation, Kyoto, Japan. KES FB4 (Kawabata
Surface Tester) is manufactured by the Kato Tekko Co., Ltd., Div.
Of Instrumentation, Kyoto, Japan. In each case, the measurements
were performed according to the standard Kawabata Test Procedures,
with four 8-inch.times.8-inch samples of each type of fabric being
tested, and the results averaged. Care was taken to avoid folding,
wrinkling, stressing, or otherwise handling the samples in a way
that would deform the sample. The fabrics were tested in their
as-manufactured form (i.e. they had not undergone subsequent
launderings.) The die used to cut each sample was aligned with the
yarns in the fabric to improve the accuracy of the
measurements.
[0065] Shear Measurements
[0066] The testing equipment was set up according to the
instructions in the Kawabata manual. The Kawabata shear tester (KES
FB1) was allowed to warm up for at least 15 minutes before being
calibrated. The tester was set up as follows:
[0067] Sensitivity: 2 and X5
[0068] Sample width: 20 cm
[0069] Shear weight: 195 g
[0070] Tensile Rate: 0.2 mm/s
[0071] Elongation Sensitivity: 25 mm
[0072] The shear test measures the resistive forces when the fabric
is given a constant tensile force and is subjected to a shear
deformation in the direction perpendicular to the constant tensile
force.
[0073] Mean Shear Stiffness (G) [gf/(cm-deg)]. Mean shear stiffness
was measured in each of the warp and filling directions. A lower
value for shear stiffness is indicative of a more supple hand.
[0074] Four samples were taken in each of the warp and filling
directions, averaged for each, and are listed below.
[0075] Bending Measurements
[0076] Bending Stiffness (B)--_A lower value means a fabric is less
stiff. Four samples were taken in each of the warp and filling
directions, averaged for each, and are listed below.
[0077] Compression Analysis
[0078] The testing equipment was set up according to the
instructions in the Kawabata manual. The Kawabata Compression
Tester (KES FB3) was allowed to warm up for at least 15 minutes
before being calibrated. The tester was set up as follows:
[0079] Sensitivity: 2 and X5
[0080] Stroke: 5 mm
[0081] Compression Rate: 1 mm/50 s
[0082] Sample Size: 20.times.20 cm
[0083] The compression test measured the resistive forces
experienced by a plunger having a certain surface area as it moves
alternately toward and away from a fabric sample in a direction
perpendicular to the fabric. The test ultimately measures the work
done in compressing the fabric (forward direction) to a preset
maximum force and the work done while decompressing the fabric
(reverse direction).
[0084] Percent compressibility at 0.5 grams (COMP05) (%) The higher
the measurement, the more compressible the fabric.
[0085] Maximum Thickness (TMAX)--Thickness [mm] at maximum pressure
(nominal is 50 gf/cm.sup.2). A higher TMAX indicates a loftier
fabric.
[0086] Minimum Thickness (TMIN) Thickness at 0.5 g/sq cm. More is
generally considered to be better. A higher TMIN indicates a
loftier fabric.
[0087] Minimum Density--Density at TMIN (DMIN). Less is generally
considered to be better) T.sub.min[g/cm.sup.3]
[0088] Maximum Density--Density at TMAX
(DMAX)--T.sub.max[g/cm.sup.3] A lower value is generally considered
to be better.
[0089] Compressional Work per Unit Area (WC) Energy to compress
fabric to 50 gf/cm.sup.2[gf-cm/cm.sup.2]. More is generally
considered to be better.
[0090] Decompressional Work per Unit Area (WC') This is an
indication of the resilience of the fabric. A larger number
indicates more resilience (i.e. a springier hand), which is
generally considered to be better.
[0091] Surface Analysis
[0092] The testing equipment was set up according to the
instructions in the Kawabata Manual. The Kawabata Surface Tester
(KES FB4) was allowed to warm up for at least 15 minutes before
being calibrated. The tester was set up as follows:
[0093] Sensitivity 1: 2 and X5
[0094] Sensitivity 2: 2 and X5
[0095] Tension Weight: 480 g
[0096] Surface Roughness Weight: 10 g
[0097] Sample Size: 20.times.20 cm
[0098] The surface test measures frictional properties and
geometric roughness properties of the surface of the fabric.
[0099] Coefficient of Friction--(MIU) Mean coefficient of friction
[dimensionless]. This was tested in each of the warp and filling
directions. A higher value indicates that the surface consists of
more fiber ends and loops, which gives the fabric a soft, fuzzy
hand. Four samples were taken in each of the warp and filling
directions, averaged, and are listed below.
[0100] Surface roughness (SMD) Mean deviation of the displacement
of contactor normal to surface [microns]. Indicative of how rough
the surface of the fabric is. A lower value indicates that a fabric
surface has more fiber ends and loops that give a fabric a softer,
more comfortable hand. Four samples were taken in each of the warp
and filling directions, and are listed below.
[0101] Prior to Kawabata Testing, all of the fabrics were home
laundered one time and tumble dried to remove any handbuilders,
etc. that may have been on the fabrics. The results of the Kawabata
Tests are listed below in Table 2.
3 TABLE 2 Measurement Example A Example B Example C DMAX 0.346
0.344 0.462 DMIN 0.158 0.160 0.230 COMP05 54.001 53.570 50.212 MIU
(Filling) 0.233 0.264 0.175 MIU (Warp) 0.231 0.234 0.191 B
(Filling) 0.11 0.45 0.16 B (Warp) 0.250 0.102 0.413 TMIN 1.168
1.297 0.809 TMAX 0.537 0.603 0.403 WC 0.563 .640 .279 WC' 0.248
0.293 0.138 SMD (Filling) 5.136 5.961 6.945 SMD (Warp) 7.921 11.243
10.496 G (Filling) 1.041 0.827 2.136 G (Warp) 1.113 0.897 2.318
[0102] Pilling Testing
[0103] Fabric pilling was tested according to ASTM D-3512-99a at 60
minutes, after 5 Industrial Launderings and ironings. The results
are listed below in Table 3.
4 TABLE 3 Fabric Pilling Rating Example A 3.5 Example B 4.5 Example
C 2.5
[0104] Fabric Strength
[0105] Tear strength in the filling direction was tested in
accordance with ASTM D2261-96. The results are listed below in
Table 4.
5 TABLE 4 Test Example A Example B Example C Tear-Filling (lbs)
6.00 5.00 11.50
[0106] As will be readily appreciated by those of ordinary skill in
the art, the fabrics of the invention have utility in a broad range
of end uses where a surface effect is desired, including but not
limited to napery, home furnishings, apparel of all types,
industrial products, upholstery, shower curtains, draperies,
shades, aprons, linings, bedding, casket linings, flags, labels,
bandages, ribbons, etc.
[0107] In the specification there has been set forth a preferred
embodiment of the invention, and although specific terms are
employed, they are used in a generic and descriptive sense only and
not for purpose of limitation, the scope of the invention being
defined in the claims.
* * * * *