U.S. patent application number 12/449990 was filed with the patent office on 2010-07-15 for composite fabric and a method and apparatus for manufacturing the same.
This patent application is currently assigned to Arvind Limited. Invention is credited to Sachin Kulkarni.
Application Number | 20100178829 12/449990 |
Document ID | / |
Family ID | 39738905 |
Filed Date | 2010-07-15 |
United States Patent
Application |
20100178829 |
Kind Code |
A1 |
Kulkarni; Sachin |
July 15, 2010 |
COMPOSITE FABRIC AND A METHOD AND APPARATUS FOR MANUFACTURING THE
SAME
Abstract
This invention relates generally to a composite fabric and a
method and apparatus for manufacturing a composite fabric,
especially suitable for apparel application, upholstery, bed and
bath applications. In an embodiment, a composite fabric comprises a
base fabric made by weaving or knitting. A plurality of gaps is
disposed in-between the fibers of the yarns of the base fabric. A
plurality of functional fibers is entangled in the gaps followed by
swelling of the fibers, with predetermined retention to the yarns
of the base fabric.
Inventors: |
Kulkarni; Sachin;
(Ahmedabad, IN) |
Correspondence
Address: |
THE NATH LAW GROUP
112 South West Street
Alexandria
VA
22314
US
|
Assignee: |
Arvind Limited
Ahmedabad
IN
|
Family ID: |
39738905 |
Appl. No.: |
12/449990 |
Filed: |
December 18, 2007 |
PCT Filed: |
December 18, 2007 |
PCT NO: |
PCT/IN2007/000605 |
371 Date: |
February 23, 2010 |
Current U.S.
Class: |
442/301 ; 28/104;
442/181; 442/304 |
Current CPC
Class: |
B32B 5/26 20130101; B32B
2307/734 20130101; Y10T 442/40 20150401; B32B 2262/0261 20130101;
B32B 2307/7145 20130101; B32B 5/024 20130101; B32B 2601/00
20130101; B32B 2262/062 20130101; B32B 2262/0276 20130101; B32B
2262/08 20130101; Y10T 442/3976 20150401; D04H 13/00 20130101; B32B
2262/065 20130101; D04H 1/498 20130101; B32B 5/026 20130101; D04H
18/04 20130101; Y10T 442/30 20150401; B32B 2437/00 20130101 |
Class at
Publication: |
442/301 ;
442/181; 442/304; 28/104 |
International
Class: |
D03D 15/00 20060101
D03D015/00; D03D 25/00 20060101 D03D025/00; D04B 1/00 20060101
D04B001/00; D04H 1/46 20060101 D04H001/46 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 7, 2007 |
IN |
433/MUM/2007 |
Mar 29, 2007 |
IN |
598/MUM/2007 |
Claims
1. A composite fabric, comprising: (i) a base fabric made by
weaving or knitting; (ii) a plurality of gaps disposed in-between
the fibers of the yarns of the base fabric wherein a plurality of
functional fibers are entangled in the gap with predetermined
retention to the yarns of the base fabric.
2. A composite fabric according to claim 1 further comprising a
plurality of functional fibers locked in-between the yarns of the
base fabric.
3. A composite fabric according to claim 2 further comprising a
plurality of functional fibers in mutually entangled
configuration.
4. A composite fabric according to claim 1 wherein the entangled
functional fibers and the fibers of the yarns of the base fabric
are permanently swollen.
5. A composite fabric according to claim 1 wherein the base fabric
comprises at least one of a natural or a synthetic fiber.
6. A composite fabric according to claim 1 wherein the functional
fiber is selected based on required properties and application of
the composite fabric product.
7. A composite fabric according to claim 6 wherein the functional
fiber includes at least one among the group consisting of phase
change fiber, anti-microbial fiber, eco-friendly fiber, regenerated
fiber, cotton, bamboo, nylon, silk, polyester and wool.
8. A composite fabric according to claim 6 wherein the fabric
product is at least one among an apparel, upholstery, bed and bath
fabric product.
9. A composite fabric manufacturing apparatus, comprising: (i) at
least one first entanglement unit for stabilizing a base fabric;
(ii) at least one second entanglement unit for entangling a
plurality of functional fibers into the yarns of the base fabric,
wherein the entanglement units are configured having a plurality of
injectors and perforated drums operating at predetermined operating
parameters so as to lock the functional fibers into the yarns of
the base fabric.
10. An apparatus according to claim 9 wherein the drums are covered
with sleeves having openness in the range of about 20% to 80%.
11. An apparatus according to claim 9 further comprises a means for
maintaining the dimensional stability of the stabilized base
fabric.
12. An apparatus according to claim 9 further comprises a means for
squeezing the composite fabric.
13. An apparatus according to claim 9 further comprises a unwinding
unit configured having a means for continuous monitoring and
control of the original dimensions of the base fabric.
14. A composite fabric manufacturing method, comprising: (i)
stabilizing and forming gaps in-between fibers in the yarns of a
base fabric, using a fluid jet of predetermined first pressure;
(ii) entangling a plurality of functional fibers in the gaps using
fluid jet of predetermined second pressure wherein the functional
fibers are coupled to the yarns of the base fabric with
predetermined retention.
15. A method according to claim 14 wherein the fluid jet comprises
water.
16. A method according to claim 14 wherein the first pressure is in
the range of about 20 bar to 250 bar.
17. A method according to claim 14 wherein the second pressure is
in the range of about 60 bar to 400 bar.
18. A method according to claim 14 wherein the length of the fluid
jet is in the range of about 6 mm to 12 mm.
19. A method according to claim 14 wherein the jet size is in the
range of about 0.07 mm to 0.3 mm.
20. A method according to claim 14 wherein the yarns are spun with
substantially low twist levels and/or with substantially shorter
and coarser fibers.
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to a composite fabric and a
method and apparatus for manufacturing a composite fabric,
especially suitable for apparel application, upholstery, bed and
bath applications.
PRIOR ART
[0002] Conventional textile fabrics are produced mainly through
weaving and knitting technology. This value chain starts from fiber
selection and development/modification so as to bring them to a
spinnable form. This is followed by spinning of the yarns. Many
spinning technologies are known in the art. However, ring spinning
is the most versatile and dominant one. Compact spinning is the
latest advancement in this ring spinning technology. Spinning is
followed by weaving or knitting process wherein yarns are
interlaced or intermeshed together to form a fabric.
[0003] Woven fabrics are interlaced structures involving two series
of threads i.e. warp and weft at right angles to each other. The
fabric properties are governed by its constructional parameters
like yarn count, thread density, yarn crimp, weave and area density
which is a function of all other parameters. Fabrics are woven with
variety of structures like plain, twills, ribs and combinations
thereof. Woven fabrics find a wide range of applications as
apparels like denims, bottom weights, shirting, ladies dress
material etc. Compared to knitted fabrics, woven fabrics are well
known for their graceful appearance, crease recovery and drape. But
the properties like thermal insulation, water vapor permeability
& air permeability are poor in these constructions because of
compact structures resulting from the pressure of interlacing at
the cross over points. In order to make these fabrics more
functional with respect to insulation properties and water vapor
transmission, wrinkle free, etc structural modifications need be
done in combination with suitable additional
materials/chemicals.
[0004] On the contrary, knitted fabrics are intermeshed structures,
which are developed from a single source of yarn. They can be weft
knitted or warp knitted. Since there is no axial alignment of
threads in knitted fabrics they lack the gracefulness as in case of
woven fabrics. Thus, the drape is poor and these fabrics are soft
to handle. Most of these fabrics in use are weft knitted and
preferred for next-to-skin inner garments or as casual wear. The
crease recovery of these fabrics is also poor.
[0005] Thus, in order to improve aesthetics of these constructions
without affecting their basic functionality, reinforcement may be
provided which is loose in construction and has open fiber
configuration. Knitted fabrics can find wide spread applicability
with all desirable functional properties and dimensional stability
as a formal wear.
[0006] Additional function can be introduced in a basic fabric
through the structural modifications or through chemical finishes.
While modifying the parent woven and knitted fabric structures, it
should always be borne in mind that the basic properties should not
be affected. The structure-property inter-relationships are so
intense in textile materials, that one property cannot be altered
in isolation from all other properties. Further, route of chemical
finishes has a limitation of life of finish and also the fabric
doesn't remain eco-friendly
[0007] Thus, the most appropriate approach is to achieve
optimization with respect to all functional properties at the same
time taking into consideration the economic aspects of production.
A composite textile fabric is the best solution. While the
composite structure results in better functionality, composite
structures can be made out of combination of woven and/or knitted
and for nonwoven fabrics or layers.
[0008] Nonwoven is a latest technology of forming fabric directly
from fibers and/or filaments. It involves first step of preparation
of web of fibers and/or filaments followed by the bonding of the
fibers so as to form a fabric. Chemical bonding and thermal bonding
are the known methods. Fabrics made through these processes are
very stiff and lag in handle and feel and not suitable for any
application next to human skin.
[0009] Known composite fabrics include at least one layer of a
non-woven fabric added on as a fused or interlined layer on a base
fabric made of a woven or knitted material. Some composite fabrics
include a sandwiched non-woven layer in-between two woven, knitted
or any other synthetic layers. However, both need to be produced
separately in the beginning and then should be bonded together in a
separate process either by using chemicals or by means of heat or
by stitching. Also these layers always tend to behave as separate
entities and the characteristics of the two layers may not be
complementing each other. Additionally it is a long and expensive
process to produce a composite fabric.
[0010] Thus, there exists a need for a composite fabric wherein (i)
the fabric is soft and lofty and suitable apparel textile (ii) air
permeability is excellent and controllable (iii) the fabric could
be made using fibers which otherwise could not be made through
conventional textile processes (iv) the fabric has improved tensile
strength and bursting strength (v) throughput of the textile
machine is improved (vi) obtains reduced value chain.
[0011] Further, conventional composite fabrics, methods and systems
for manufacture of the same do not provide a fabric (i) wherein
induced stresses in the fabric are substantially minimized without
repositioning of the yarns and/or reduction in dimensions of the
finished fabric (ii) hygienic and eco-friendly method of
manufacturing a composite fabric (iii) a composite fabric whose
strength and properties can be adjusted during manufacture so as to
suit desired application (iv) a significantly wider range of
application as against traditional textiles.
SUMMARY
[0012] In an embodiment, a composite fabric comprises a base fabric
made by weaving or knitting. A plurality of gaps is disposed
in-between the fibers of the yarns of the base fabric. A plurality
of functional fibers is entangled in the gap, with predetermined
retention to the yarns of the base fabric.
[0013] In an embodiment, a composite fabric manufacturing apparatus
comprises at least one first entanglement unit for stabilizing a
base fabric. At least one second entanglement unit is provided for
entangling a plurality of functional fibers into the yarns of the
base fabric. The entanglement units are configured having a
plurality of injectors and perforated drums operating at
predetermined operating parameters so as to lock the functional
fibers into the yarns of the base fabric.
[0014] In an embodiment, a composite fabric manufacturing method
comprises stabilizing and forming gaps in-between fibers in the
yarns of a base fabric using a fluid jet of predetermined first
pressure. A plurality of functional fibers is entangled in the gaps
using fluid jet of predetermined second pressure wherein the
functional fibers are coupled to the yarns of the base fabric with
predetermined retention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 shows a cross-section of a composite fabric according
to an embodiment of this invention.
[0016] FIG. 2 shows an embodiment of an apparatus for manufacturing
a composite fabric according to this invention.
[0017] FIG. 3 shows a flowchart of a method for manufacturing a
composite fabric according to an embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Various embodiments of this invention provide a composite
fabric. Further embodiments of this invention provide a method and
apparatus for manufacturing a composite fabric. However, the
embodiments are not limited and may be used in connection with
various applications that will be described in later part of this
specification.
[0019] FIG. 1 shows a cross-section of an embodiment of a composite
fabric according to this invention, wherein the composite fabric
(5) comprises a base fabric (1) made by weaving or knitting. A
plurality of functional fibers (7) is coupled with predetermined
retention to the base fabric (1). A plurality of gaps are disposed
in-between the fibers of the yarns (3) of the base fabric (1). A
plurality of functional fibers (7) is locked (entangled) into the
gaps in-between the fibers of the yarns (3). A plurality of the
functional fibers (7) is locked in-between the yarns (3) and the
functional fibers (7) are also mutually entangled.
[0020] In an example, the base fabric (1) may comprise a natural
fiber such as, a cotton fiber, vegetable fiber, etc. However, the
base fabric (1) may also include a synthetic fiber. Examples of
functional fibers (7) may include outlast fiber (phase change
fiber), lyocell (anti-microbial fiber), organic cotton
(eco-friendly fiber), Cotton, bamboo (anti-microbial), regenerated
fiber (viscose), nylon, silk, polyester, wool or any other
functional fiber depending on the required properties and
application of the composite fabric product.
[0021] FIG. 2 shows an embodiment of an apparatus for manufacturing
a composite fabric according to this invention, wherein the
apparatus comprises a preparatory unit (80) for opening a bale of
functional fibers (7) (not shown in FIG. 2) and feeding it on to a
carding unit (90). The carding unit (90) converts the functional
fibers (7) into the form of a web (110) and feeds on to a belt
(120) that transports the web (110) to an entanglement unit (140).
The web (110) obtained has predetermined properties such as,
uniformity, linear density for example, in the range of 8
gm/m.sup.2 to 130 gm/m.sup.2, fiber orientation for example,
completely random orientation up to 5:1 direction. It should be
noted that the properties of the web (110) are controlled so as to
obtain composite fabric properties like tensile strength,
stiffness, recovery from the wrinkles, etc. The base fabric (1) is
unwound by a fabric un-winder (10). The fabric unwinder (10)
delivers the base fabric (1) under predetermined tension to an
entanglement unit (130) maintaining the base fabric width. The
tension in the base fabric (1) may be set in the range of 0 to 250
gms.
[0022] In an embodiment, an entanglement unit (130) comprises at
least one perforated drum (D1) with or without sleeve and at least
a pair of injectors (132). This entanglement unit (130) stabilizes
the base fabric (1) and delivers the base fabric (1) to the next
entanglement unit (140). A compaction belt (150) is provided to
combine and compact the stabilized base fabric (1) and the web
(110) from the carding unit (90). This is followed by entanglement
of the functional fibers from the web (110) into the base fabric
(1) thus forming a composite fabric (5). This entanglement is done
using a plurality of drums (D2-D4) and injectors (142, 152, 162) at
predetermined operating parameters. This is followed by a squeezing
unit (160) that squeezes and removes excess water from the
composite fabric (5) thus formed and delivers the composite fabric
to a drying unit (170). The drying unit (170) comprises a plurality
of steam heated drying cans and/or air-heated drums. Thus dried
composite fabric (5) is wound on to a composite fabric winder
(190).
[0023] FIG. 3 shows an embodiment wherein a composite fabric
manufacturing method comprises preparing a web (110) of functional
fibers using the preparatory unit (80) and the carding unit (90).
The base fabric (1) selected is in unfinished grey or semi-finished
or finished form. A fluid jet for example, water jet at
predetermined pressure (example 20 bar up to 250 bar) is used for
pre-wetting and entanglement of yarns in the base fabric (1)
preferably at the cross over (intermeshing/interlacement) points
and also reorganize the fibers in the yarns of the base fabric (1)
to relax the prevailing stresses in the base fabric (1) thereby
making the base fabric (1) stable.
[0024] Furthermore, in an embodiment of the method of manufacturing
a composite fabric, the repositioning/reorganizing of the fibers
simultaneously opens out the yarn structure in the base fabric (1).
The opening out of the yarn structure in the base fabric (1)
increases the surface area to generate additional space among the
fibers to accommodate functional fibers (7) for entanglement.
[0025] In some embodiments, the fibers in the yarns of base fabric
(1) may be treated with chemicals such as, caustic soda, ammonia,
etc so as to facilitate availability of extra space for the
functional fibers (7) to reside into. The base fabric (1) with
yarns made out of partly or fully with the synthetic fibers may be
heat set to stabilize and some times initiate the preliminary
yarn-to-yarn and fiber-to-fiber bonding.
[0026] In some embodiments, fibers, yarns and/or the base fabric
(1) itself may be treated with chemical adhesives, binders, etc so
as to activate the surfaces thereby facilitating improved
entanglement strength.
[0027] In some embodiment, fibers, yarns and base fabric (1) may be
treated with plasma so as to activate the surfaces thereby
facilitating improved entanglement strength.
[0028] In general, the base fabric (1) is constructed lightly
facilitating achievement of required properties in the composite
fabric (5).
[0029] In an embodiment, the yarns (3) of the base fabric (1) are
spun with low twist levels (3% to 6%) and/or with much shorter and
coarser fibers. This enables more yarn diameter and more free space
among the fibers of the yarns (3). This also helps in fiber
movement and creation of additional space during entanglement and
stabilization of the base fabric (1). This helps in entangling more
proportion of functional fibers (7) into the gaps among the fibers
in the yarns of the base fabric (1).
[0030] Thus stabilized base fabric (1) is laid with functional
fibers (7) from the web (110) followed by compacting.
[0031] A series of fluid jets at predetermined pressure (example 60
bar up to 400 bar) is used for entanglement of functional fibers
(7) from the web (110) with the base fabric (1). In the process,
functional fibers (7) are systematically separated out from the web
followed by pushing them preferably in a single fiber form into the
gaps created among the fibers in the yarn. For those functional
fibers (7), which do not get this opportunity, are assembled in a
proper format followed by their entanglement with the already
entangled functional fibers (7) and at the end amongst themselves.
For example, the number of fluid jets is at least two. This step is
followed to lock the functional fibers 7 into the gaps in-between
the fibers of the yarns (3). A plurality of the functional fibers 7
is locked in-between the yarns and the functional fibers 7 are also
mutually entangled.
[0032] The high-pressure fluid jet is impacted on the base fabric
(1) such that the fluid jet penetrates into the fibers of the yarn
(3). The penetrated fluid jet further gets reflected at
substantially in all directions from the surface of the sleeve or
the surface of the perforated drum (D1) through the fibers in the
yarn (3). The fibers in the yarn (3) get reoriented/reorganized
wherein during such repositioning/reorganization of the fibers, the
fibers absorb the energy from the fluid jet and thereby get
relieved of their stresses and also reach to the minimum energy
position.
[0033] The wet base fabric (1) delivered by the entanglement unit
(140) is uniformly squeezed so as to remove excess water and at the
same time facilitate further pushing of partially pushed-in
functional fibers (7) into the spaces still available in the yarns
and in the base fabric (1). In case of surface activated base
fabric (1), the squeezing helps in creating uniform bonding thereby
improving entanglement strength. The squeezing helps in reducing
the overall weight of the composite fabric being offered for the
drying under a predetermined tension. This weight reduction and
reduction of mobilizing agent like water enables the reduction of
the possibilities of weakening of entanglement points before they
are frozen during drying.
[0034] A plurality of functional fibers is entangled to the base
fabric (1) from at least one side of the base fabric (1).
[0035] In an embodiment, the perforated drums (D1-D4) are covered
with sleeves with predetermined openness (example 20% up to 80%).
This is one of the factors to control the entanglement
strength.
[0036] The length of the fluid jet (example 6 mm up to 12 mm)
decides the entanglement strength. For example, lower the length of
the fluid jet, the entanglement strength initially increases
followed by more scattering of the functional fibers (7) due to
severe reflection from the surface of the drum and the sleeve, with
further reduction thereby resulting into reduction of the
entanglement strength.
[0037] A vacuum slot (6 mm up to 14 mm) in the perforated drum (D1)
decides the amount of reflection of the fluid jet from the surface
of the sleeve or the perforated drum (D1) and thereby the
entanglement strength.
[0038] In an embodiment, the number of jets per inch is in the
range of 10 up to 120. The jet size is in the range of 0.07 mm up
to 0.3 mm. The number of rows of jets is in the range from 1 up to
3. These parameters decide the way of entanglement and the
entanglement strength.
[0039] In an embodiment, the through-put rate of 10 m/min up to 100
m/min decides the residence time of entanglement zone on the
composite fabric (5) and thereby the entanglement strength.
[0040] In an embodiment, the number of passes through the
entanglement unit (140) also decides the entanglement strength. For
example, increased number of passes will result in improved
entanglement strength to an optimum. Further additional passes
start deteriorating the entanglement strength and also composite
fabric (5) becomes more stiff comparable to paper material.
[0041] In an embodiment, in the entanglement unit (140), on drum
(D4) another side of the composite fabric (5) is treated by at
least a pair of high-pressure fluid jets (example 20 bar to 120
bar) and preset parameters (0.07 mm to 0.12 mm jet size, 40 to 80
holes/inch, etc) to a necessary level thereby achieving the
necessary surface effects require for apparel, upholstery, bed and
bath applications.
[0042] In an embodiment, on the drum (D4), by selecting suitable
sleeve and fluid jets, various surface effects such as striking off
of loose hairs, loose color, embossing, aperturing effects may be
created on the composite fabric suitable for apparel, upholstery,
bed and bath applications.
[0043] In an embodiment, on drum (D4), by adjusting one of the
fluid jets, at an angle (example 20 deg to 35 deg) to the drum and
fabric surface thereby combing the yarn surfaces very effectively.
This arrangement may be used for creating the effects equivalent to
pitching or emery finishes on the composite fabric (5) surface
suitable for apparel application.
[0044] The composite fabric (5) made according to this invention
may be further processed using chemicals or heat so as to lock and
freeze the entanglement points to a necessary level thereby
achieving a balance between elastic and plastic movement.
[0045] Thus, according to the principles of this invention, the
composite fabric can be made at an affordable cost in the following
way.
[0046] Tear and Tensile strength of the base fabric (1) can be
improved substantially by virtue of realizing the strength of
fibers directly from the non-woven web combined with the base
fabric (1). The composite fabric (5) can be made isotropic or
anisotropic by controlling non-woven web geometry. Therefore, there
is no need to use expensive fibers.
[0047] Fabric body can be improved, for example, a 11-ounce fabric
can be made to feel like 14-ounce fabric. This can be achieved
through web geometry and level of entanglement with base fabric
(1).
[0048] Complete dimensions of the fabric can be retained to as
close as possible to the loom/manufacturing stage dimensions with
the achievement of best dimensional stability. Functional fibers
from the web (110) which are locked into the yarn structures of the
base fabric (1) will freeze the yarn positions as they are,
resulting into minimal shrinkage potential and best dimensional
stability.
[0049] Keeping the OE based fabrics, flatness and washdowns of ring
yarns based fabrics may be obtained. Also, economical stretches can
be developed through this route and flat washdowns can be
achieved.
[0050] Wherever possible by using heavier functional fiber webs
(110) of waste and/or blend of waste and virgin fibers, basic
fabric can be made lighter and/or thinner thereby saving overall
costs.
[0051] Also, there will be a great opportunity for bringing down
the raw material cost. The usage of expensive fibers can be
curtailed in the conventional fabric process and can be
supplemented by proper selection of fibers, web geometry,
hydro-entanglement energy and number of passes through the
hydro-entanglement process. This is a most economical way.
[0052] Conventionally, functions are introduced in the fabric by
way of chemical finishes that do not stay long. Expensive
functional fibers are blended with regular fibers. And one doesn't
have a direct control on fiber position in yarn structure.
Accordingly, there will not be a complete realization of benefits
of these functional fibers. Also, if the fibers are of different
origin, will call for dyeing of both which would be an expensive
proposal.
[0053] In an embodiment, according to this invention, in a
composite fabric, we can place only required quantity of fibers at
the right place and realize the complete benefits. Also, in case of
backside functional layer, the fibers selected need not be dyed or
else one can use predyed fibers and initiate the action. Since
these fibers are of only adequate quantity and are properly
entrapped into yarn structures, the fibers will stay long enough
and offer functions for a substantial long time. [0054] Functions
that can be inculcated are as follows: [0055] High absorbency for
comfort [0056] High wicking, transportation and release for high
comfort [0057] High wicking, transportation and slow release for
temperature regulation [0058] Entrap heat for warmth [0059] Wrinkle
free [0060] Wrinkle resistant [0061] Stretches [0062] Vegetable
fiber based functional fabrics [0063] Fluorescent/Reflective
exteriors [0064] Metal fiber based antibacterial, antimicrobial,
antifungal [0065] Protective/Filtration [0066] Stain, water, oil
Repellent/Resistant
[0067] According to the principles of this invention, the
applications of the composite fabric may include:
Denims
[0068] 1) Chamrey with 10 gsm web through Expresso.TM. for trouser
and five pocket jeans [0069] 2) OE to Ring through Expresso.TM.
technology with/without new AT rotors [0070] 3) Vegetable fiber
denims [0071] 4) Expresso.TM. denims [0072] 5) Unstable
construction with 200-gsm web [0073] 6) Truly Organic Denims [0074]
7) Rope to Sucker Muller for dark shades using Plasma activated
warp sheet [0075] 8) Plasma treated dull Polypropylene/Polyester
spun and/or filament based Indigo [0076] 9) Dyed Denims [0077] 10)
Electronics integrated--Denims
Khakhis
[0077] [0078] 1) 16*12 with DP 4 [0079] 2) PCM khakhis [0080] 3)
Truly organic Khakhis [0081] 4) Durable stain and water repellency
using film/membrane and staple fibers through combination of
Expresso.TM. and thermal/steam bonding technology [0082] 5) Durable
functionalities through functional fibers [0083] 6) Work wear and
protective wears [0084] 7) Vegetable fiber khakhis [0085] 8)
Expresso.TM. khakhis [0086] 9) Long life chemical finishes using
plasma activation technology.
Knits
[0086] [0087] 1. Cotton sports wear using cotton fiber web and
Expresso.TM. technology. [0088] 2. Knitted stretch Indigo denims
[0089] 3. PCM knits [0090] 4. Truly organic knits [0091] 5.
Multilayer undergarments using viscose/silk fiber web from bottom
side and Expresso.TM. technology. [0092] 6. OE to Ring knits [0093]
7. Durable Functionalities through functional fibers from bottom
side and Expresso.TM. technology. [0094] 8. Vegetable fiber knits
[0095] 9. Electronics integrated knits [0096] 10. Long life
chemical finishes using plasma activation technology [0097] 11.
Semi durable and durable knits using staple fiber web and
Expresso.TM. technology with or without chemicals
Shirts
[0097] [0098] 1. DP 4 [0099] 2. PCM shirts [0100] 3. Durable
functionalities through functional fibers and Expresso.TM.
technology. [0101] 4. OE to Ring shirts [0102] 5. Plasma activated
yarn dyed shirts. Plasma activation will help high exhaustion rates
and thereby reduction in dyes and chemical consumption. This will
reduce the loss of yarn strength. Overall this will result into
deeper and darker shades at lower cost. Possibly, one can also save
on fiber cost. [0103] 6. Long life chemical finishes using Plasma
activated shirting fabrics [0104] 7. Electronics integrated shirts
[0105] 8. Semi durable and durable shirts using staple fiber web
and Expresso technology with or without support of chemicals.
[0106] Furthermore, according to the principles of this invention,
the upholstery applications include: [0107] 1. Lightweight and fine
yarn based jacquard structured fabric stabilized with or without
web --Expresso.TM.. These fabrics in original form are highly
unstable and very delicate. These can be stabilized, strengthened
using Expresso.TM.. [0108] 2. Machine washable microweight
upholstery fabrics--using Expresso.TM. alone this can be achieved.
[0109] 3. Pre-washed and stabilized Indigo micoweight
upholstery--can be achieved by selecting proper combination of jet
strips, pressures. Effect is generated on fabric face side and
while going through this process whole fabric will get
dimensionally stable. [0110] 4. Stiffness without coating and
chemical finishes can be inculcated in the fabrics by using 10 GSM
webs with MD: CD of 10:1 and heavily entangling the two together.
This will add up the necessary stiffness and unidirectional drape.
[0111] 5. High durability and anti pilling--By simple Expresso.TM.
and with proper selection of entanglement parameters, the surfaces
of the fabric can be made very tough. [0112] 6. Fire resistant and
Fire proof upholstery--By selecting Aramid fies like NOMEX or
Asbestos based fibers and entangling the required web gsm on face
side of the fabric these properties can be achieved. Further, by
using embossing and aperturing technologies of Expresso.TM.,
surface looks can be engineered. [0113] 7. Water and stain
repellent--This can be achieved by entangling required gsm of web
of low melting temperature fibers like PP on back side in such a
way that intentionally few % of fibers are allowed to project thru
the fabric onto face side. Using these fibers the whole structure
can be thermally bonded with water repellent films like PE,
POLYESTER, NYLON etc to make the surface water and stain repellent.
[0114] 8. UV repellent Upholstery--By using UV repellent treated
polyester fibers on the face side, this fabric function can be
achieved. GSM of the web will be optimized between look and
function level. [0115] 9. Absorb light and convert it into heat
upholstery--This can be achieved through optically sensitive fibers
available in Japan. The web can be on face or back side of the
fabric. [0116] 10. Fragrance release upholstery--This can be
achieved thru temperature sensitive fragrance release chemicals
doped during extrusion of fibers. Using web of these fibers, this
function can be achieved. Further, it can be made sensitive to
temperature that is interactive. [0117] 11. Antistatic
Upholstery--By using a thin web of antistatic fibers on both face
and backside of the fabric, this effect can be achieved. [0118] 12.
Durable non woven upholstery--Embossed & or/apertured
cotton/blended nonwoven fabric by at least 15% followed by resin
spot bonding will meet this requirement. By using long staple
synthetic polyester/Nylon fibers and higher level of entanglement,
one can also generate durable non-woven upholstery. Also by
hydroentanglement of light bonded spunbond nonwoven fabric, one can
produce durable upholstery. [0119] 13. E-Upholstery--by embedding
various e-components while doing Espresso, one can generate a range
of smart upholstery. [0120] 14. Heat-proof table tops and
upholstery--this can be achieved by bonding asbestos/carbon/aramid
fibers on the top surface and soft bulky 100% cotton/blend layer at
bottom. [0121] 15. Wind proof curtains--this can be achieved by
controlling the porosity in the web through right selection of
fiber properties, web geometry and entanglement/aperturing
parameters of Espresso. It can be 100% non-woven or composite also.
[0122] 16. Highly Breathable upholstery--This can pass on the heat
and air very fast. This can be achieved by controlling the
parameters as described in point 15. [0123] 17. Mosquito repellent
upholstery--this can be achieved thru polyester/viscose fibers with
mosquito repellent finish. [0124] 18. Hygienic upholstery--this can
be achieved through Expresso.TM. process and also by using
antibacterial antimicrobial and antifungal finished fibers in the
web and the web can be bonded on the required side of composite
upholstery fabric. [0125] 19. Disposable table tops, sofa covers
and window laminates--these are functional one time usage
non-wovens. [0126] 20. Highly absorbent table-tops--these can be
produced using 3 layered composite durable/semi durable non-wovens
and woven/knitted and non-woven composites. [0127] 21. Anti-termite
dosing upholstery--this can be done using polyester/nylon fibers
with suitable finishes and may be activated thru e-controls or
temperature based or light based release mechanisms. [0128] 22.
Anti-mite upholstery--this can be done using split fibers and
multilayer non-wovens. [0129] 23. Anti-cockroach upholstery--this
can be achieved thru polyester/nylon fibers doped with suitable
finishes and the fibers can be on the operating surface of the
product. [0130] 24. Anti-spider upholstery--this can be achieved
thru polyester/nylon fibers with suitable finishes and fiber can be
on the operating side of the product. [0131] 25. Structured
upholstery--this can be through two routes, [0132] A. Non-woven on
the top and woven on bottom side--limit of imagination=limit of
options. Different embossing/aperturing tools can be used to
generate the effects. Further options can be thru differential
bonding levels at different locations resulting into "n" number of
effects. [0133] B. Woven fabric on top and non-woven on
bottom--using jacquard one can generate required designs. The
design and fabric structure will be consolidated by Espresso.
Fibers can be functional or aesthetic support through different web
geometries [0134] Different colored fibers [0135] Different
shrinkage behavior fibers [0136] Fibers piercing thru the fabric
onto face side [0137] Different levels of bondings=different
effects. [0138] C. This can be a woven fabric alone--use all
Espresso variables like [0139] Jet strips [0140] Pressures [0141]
Oscillating jets [0142] Block the jets at preferred locations
[0143] Different embossing sleeves.
[0144] Fibers and additives undoable through conventional processes
can be done using the principles of this invention and be made as
the integral part of the base fabric (1).
[0145] Further, aperturing, embossing tools of this non-woven
fabric can be used for enhancing further the base fabric using the
principles of this invention. For example, (i) wash and remove
Indigo/Sulphur from the selected areas on the fabric and generate
various patterns, logos, etc on face side of fabric (ii) Emboss the
patterns and generate different look, touch and feel of the fabric
(iii) offer pre-washed fabric wherein one can vary the level of
wash, uniformity of wash and also generate virtual optics during
wash. This can be achieved through proper selection of jet
pressures, throughput rates, and different embossing sleeves. If
the need be, fabric can be apertured in different patterns using
different aperturing sleeves.
[0146] However, one can take any fabric, define a function, get
right fiber and/or additives hydro-entangle the composites together
using right combination of parameters. In the apparel textiles,
upholstery, towels and wipes, conventional textile process doesn't
need much changes implying easy to get through. We can use all
types of staple fibers manmade, natural, etc. Also, one can use
powders/very small fibers like wood pulp, paper pulp, etc and find
out new applications. This is a 100% hygienic process since it uses
water in the form of high pressure jets to bond the composites.
Accordingly, products are hygienic.
[0147] The fear of pilling or poor abrasion resistance or peeling
off of layers does not exist, as there is no 100% non-woven fabric.
Fibers from the web (110) are pushed through and are entrapped into
yarn structure of the base fabric (1). Also, the right combination
of web GSM, Fiber type, web geometry, hydro-entanglement energy
levels, entanglement time and number of passes will result into
trouble free composite fabric (5).
[0148] Various applications of the composite fabric includes
durable stain and water repellent fabric using film/membrane and
staple fibers, work wear and protective wears, long life chemical
finishes using plasma activation technology, semi durable and
durable goods.
[0149] Thus, various specific embodiments of this invention provide
a method and a system for treating a fabric. Further embodiments of
this invention provide a method for manufacturing a composite
fabric and a composite fabric thereof.
[0150] Various modifications of this invention are possible.
However, it will be recognized by those skilled in the art that all
such modifications have been deemed to be covered by this invention
and are within the spirit and scope of the claims appended
hereto.
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