U.S. patent application number 15/843456 was filed with the patent office on 2018-06-21 for laser-treated fabric.
The applicant listed for this patent is The H.D. Lee Company. Invention is credited to Dhruv Agarwal, Amsarani Ramamoorthy.
Application Number | 20180171540 15/843456 |
Document ID | / |
Family ID | 60937922 |
Filed Date | 2018-06-21 |
United States Patent
Application |
20180171540 |
Kind Code |
A1 |
Agarwal; Dhruv ; et
al. |
June 21, 2018 |
Laser-Treated Fabric
Abstract
A laser-treated fabric including a body side and a face side has
a plurality of pores located on at least some fibers on at least
the body side of the fabric and at least one chemical additive
embedded within or anchored to the plurality of pores. The pores
have a pore size of from about 1 nm to about 20 .mu.m. Garments
including the laser-treated fabric are also described. The fabric
in the garment may be laser-treated such that the plurality of
pores are located in discrete regions of the fabric. Methods for
treating a fabric are also described. The chemical additive in the
laser-treated fabrics is more durable than in non-laser-treated
fabrics have a chemical additive applied on only the surface of the
fabric.
Inventors: |
Agarwal; Dhruv; (Greensboro,
NC) ; Ramamoorthy; Amsarani; (Greensboro,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The H.D. Lee Company |
Wilmington |
DE |
US |
|
|
Family ID: |
60937922 |
Appl. No.: |
15/843456 |
Filed: |
December 15, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62435015 |
Dec 15, 2016 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06M 11/46 20130101;
A41D 1/06 20130101; D06M 15/15 20130101; D06M 10/04 20130101; D06M
11/83 20130101; D06M 2400/02 20130101; A41D 1/02 20130101; D06M
23/08 20130101; D06M 11/50 20130101; A41B 1/08 20130101; D06M
10/005 20130101; D06M 2200/00 20130101 |
International
Class: |
D06M 10/00 20060101
D06M010/00; A41B 1/08 20060101 A41B001/08; A41D 1/02 20060101
A41D001/02; A41D 1/06 20060101 A41D001/06 |
Claims
1. A laser-treated fabric having a body side and a face side,
comprising: a plurality of pores located on at least some fibers on
at least the body side of the fabric; and at least one chemical
additive embedded within or anchored to the plurality of pores,
wherein the pores have a pore size of from about 1 nm to about 20
.mu.m.
2. The laser-treated fabric according to claim 1, wherein the
plurality of pores are formed by applying a laser treatment to at
least the body side of the fabric.
3. The laser-treated fabric according to claim 1, wherein at least
the body side of the fabric has an increased surface area as
compared to a substantially similar fabric that has not been
subjected to a laser treatment.
4. The laser-treated fabric according to claim 1, wherein at least
the body side of the fabric has an enhanced microclimate as
compared to a substantially similar fabric that has not been
subjected to a laser treatment.
5. The laser-treated fabric according to claim 1, wherein the
plurality of pores is located on both the body side and the face
side of the fabric.
6. The laser-treated fabric according to claim 5, wherein the
plurality of pores on both the body side and the face side of the
fabric are formed by applying a laser treatment to both the body
side and the face side of the fabric.
7. The laser-treated fabric according to claim 1, wherein the
fibers comprise natural fibers, synthetic fibers, or a combination
thereof.
8. The laser-treated fabric according to claim 7, wherein the
natural fibers comprise cotton, wool, leather, silk or a
combination thereof.
9. The laser-treated fabric according to claim 7, wherein the
synthetic fibers comprise viscose, polyester, nylon, polypropylene,
modacrylic, aramid, polybenzimidazole (PBI), polybenzoxazole (PBO),
melamine and combinations thereof.
10. The laser-treated fabric according to claim 1, wherein the at
least one chemical additive is cured.
11. The laser-treated fabric according to claim 1, wherein the at
least one chemical additive comprises silver, titanium dioxide,
zinc peroxide, aerogel, keratin or a combination thereof.
12. The laser-treated fabric according to claim 1, wherein the at
least one chemical additive is in the form of nanoparticles or
microparticles, and the nanoparticles or microparticles are
embedded within or anchored to the plurality of pores.
13. The laser-treated fabric according to claim 12, wherein the at
least one chemical additive comprises cellulose nano crystals
(CNC), cellulose nano filaments (CNF) or a combination thereof.
14. The laser-treated fabric according to claim 1, wherein the
fabric has improved properties as compared to a substantially
similar fabric that has not been subjected to a laser treatment,
wherein the improved properties include one or more of
antibacterial properties, odor control properties, ultraviolet (UV)
protection, moisture transport properties, antistatic properties,
thermal insulation properties, shrink resistance, abrasion
resistance, and stain repellant properties.
15. The laser-treated fabric according to claim 1, wherein the at
least one chemical additive in the fabric exhibits improved wash
fastness as compared to a chemical additive in a substantially
similar fabric that has not been subjected to a laser
treatment.
16. A garment comprising a laser-treated fabric, the laser-treated
fabric having a body side and a face side and comprising: a
plurality of pores located on at least some fibers on at least the
body side of the fabric; and at least one chemical additive
embedded within or anchored to the plurality of pores, wherein the
pores have a pore size of from about 1 nm to about 20 .mu.m.
17. The garment according to claim 16, wherein the fabric is
laser-treated such that the plurality of pores are located in
discrete regions of the fabric.
18. The garment according to claim 16, wherein the garment is a
shirt or a jacket and the discrete regions comprise one or more of
a shirt collar region, a shirt cuff region or a shirt armpit
region.
19. The garment according to claim 16, wherein the garment is pants
and the discrete regions comprise one or more of a knee region or a
crotch region.
20. A method for treating a fabric, the fabric having a body side
and a face side, the method comprising: applying a laser treatment
to at least the body side of the fabric to form a plurality of
pores on fibers of at least the body side of the fabric; and
applying at least one chemical additive to the fabric such that the
at least one chemical additive is embedded within or anchored to
the plurality of pores, wherein the pores have a pore size of from
about 1 nm to about 20 .mu.m.
Description
RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Patent Application No. 62/435,015 filed Dec. 15, 2016,
the disclosure of which is incorporated herein by this reference in
its entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to fabrics and garments, and
in particular to fabrics and garments that are laser-treated to
improve their properties.
BACKGROUND OF THE DISCLOSURE
[0003] The face side of fabric (i.e., the side facing away from the
wearer of a garment incorporating the fabric) has been treated with
a high wavelength laser to provide aesthetic features to the
fabric, including patterns and designs. For example, denim jeans
have been treated with a laser to give the jeans an aged or
"vintage" appearance. The laser treatments affect the fabric at the
fiber level.
[0004] In addition, many fabrics are treated with chemical
additives to provide the fabric with desirable properties or to
improve existing fabric properties. For example, it has been known
to coat fabrics with silver to provide antimicrobial resistance,
with titanium dioxide for ultraviolet protection, and with zinc
peroxide to provide antistatic properties. Chemical coatings have a
tendency to wash out of the fabric during laundering, however.
[0005] These and other shortcomings are addressed by aspects of the
present disclosure.
BRIEF DESCRIPTION OF THE FIGURES
[0006] In the drawings, which are not necessarily drawn to scale,
like numerals may describe similar components in different views.
Like numerals having different letter suffixes may represent
different instances of similar components. The drawings illustrate
generally, by way of example, but not by way of limitation, various
embodiments discussed in the present document.
[0007] FIG. 1 is a process diagram describing a method for
laser-treating a fabric according to aspects of the disclosure.
[0008] FIGS. 2A and 2B are scanning electron microscopy (SEM)
photographs of an untreated cotton weft fabric.
[0009] FIGS. 3A and 3B are SEM photographs of a laser-treated denim
fabric according to an aspect of the disclosure.
[0010] FIGS. 4A and 4B are SEM photographs of a laser-treated and
coated denim fabric according to an aspect of the disclosure.
[0011] FIGS. 5A and 5B are SEM photographs of a laser-treated
prewashed denim fabric according to an aspect of the
disclosure.
[0012] FIGS. 6A and 6B are SEM photographs of a laser-treated and
coated prewashed denim fabric according to an aspect of the
disclosure.
[0013] FIG. 7 is a SEM photograph of the fabric of FIG. 3A at a
magnification of 5000.times..
[0014] FIG. 8 is a SEM photograph of the fabric of FIG. 5A at a
magnification of 5000.times..
[0015] FIGS. 9A-9F are SEM photographs of exemplary sample fabrics
formed in accordance with aspects of the disclosure at a
magnification of 100.times..
[0016] FIGS. 10A-10D are SEM photographs comparing conventional
fabrics (FIGS. 10A-10C) to laser-cured fabrics according to aspects
of the disclosure (FIG. 10D) at a magnification of 100.times..
SUMMARY
[0017] Aspects of the disclosure relate to a laser-treated fabric
having a body side and a face side, comprising: a plurality of
pores located on at least some fibers on at least the body side of
the fabric; and at least one chemical additive embedded within or
anchored to the plurality of pores. The pores have a pore size of
from about 1 nm to about 20 .mu.m.
[0018] Further aspects of the disclosure relate to a garment
comprising a laser-treated fabric, the laser-treated fabric having
a body side and a face side and comprising: a plurality of pores
located on at least some fibers on at least the body side of the
fabric; and at least one chemical additive embedded within or
anchored to the plurality of pores. The pores have a pore size of
from about 1 nm to about 20 .mu.m.
[0019] Certain aspects of the disclosure relate to a method for
treating a fabric, the fabric having a body side and a face side,
the method comprising: applying a laser treatment to at least the
body side of the fabric to form a plurality of pores on fibers of
at least the body side of the fabric; and applying at least one
chemical additive to the fabric such that the at least one chemical
additive is embedded within or anchored to the plurality of pores.
The pores have a pore size of from about 1 nm to about 20
.mu.m.
DETAILED DESCRIPTION
[0020] The present disclosure can be understood more readily by
reference to the following detailed description of the disclosure
and the Examples included therein. In various aspects, the present
disclosure pertains to methods for treating a fabric. The fabric
has a body side and a face side. The method includes applying a
laser treatment to at least the body side of the fabric. The laser
treatment forms a plurality of pores on fibers of at least the body
side of the fabric. The method further includes applying at least
one chemical additive to the fabric such that the at least one
chemical additive is embedded within or anchored to the plurality
of pores. The pores have a pore size of from about 1 nm to about 20
.mu.m. In some aspects a curing treatment is optionally applied to
the fabric to cure the at least one chemical additive. Aspects of
the disclosure further relate to laser-treated fabrics and garments
including the laser-treated fabrics.
[0021] Before the present compounds, compositions, articles,
systems, devices, and/or methods are disclosed and described, it is
to be understood that they are not limited to specific synthetic
methods unless otherwise specified, or to particular reagents
unless otherwise specified, as such can, of course, vary. It is
also to be understood that the terminology used herein is for the
purpose of describing particular aspects only and is not intended
to be limiting.
[0022] Various combinations of elements of this disclosure are
encompassed by this disclosure, e.g., combinations of elements from
dependent claims that depend upon the same independent claim.
[0023] Moreover, it is to be understood that unless otherwise
expressly stated, it is in no way intended that any method set
forth herein be construed as requiring that its steps be performed
in a specific order. Accordingly, where a method claim does not
actually recite an order to be followed by its steps or it is not
otherwise specifically stated in the claims or descriptions that
the steps are to be limited to a specific order, it is no way
intended that an order be inferred, in any respect. This holds for
any possible non-express basis for interpretation, including:
matters of logic with respect to arrangement of steps or
operational flow; plain meaning derived from grammatical
organization or punctuation; and the number or type of embodiments
described in the specification.
[0024] All publications mentioned herein are incorporated herein by
reference to disclose and describe the methods and/or materials in
connection with which the publications are cited.
Definitions
[0025] It is also to be understood that the terminology used herein
is for the purpose of describing particular aspects only and is not
intended to be limiting. As used in the specification and in the
claims, the term "comprising" can include the embodiments
"consisting of" and "consisting essentially of" Unless defined
otherwise, all technical and scientific terms used herein have the
same meaning as commonly understood by one of ordinary skill in the
art to which this disclosure belongs. In this specification and in
the claims which follow, reference will be made to a number of
terms which shall be defined herein.
[0026] As used in the specification and the appended claims, the
singular forms "a," "an" and "the" include plural referents unless
the context clearly dictates otherwise. Thus, for example,
reference to "a chemical additive" includes mixtures of two or more
chemical additives.
[0027] As used herein, the term "combination" is inclusive of
blends, mixtures, alloys, reaction products, and the like.
[0028] Ranges can be expressed herein as from one value (first
value) to another value (second value). When such a range is
expressed, the range includes in some aspects one or both of the
first value and the second value. Similarly, when values are
expressed as approximations, by use of the antecedent `about,` it
will be understood that the particular value forms another aspect.
It will be further understood that the endpoints of each of the
ranges are significant both in relation to the other endpoint, and
independently of the other endpoint. It is also understood that
there are a number of values disclosed herein, and that each value
is also herein disclosed as "about" that particular value in
addition to the value itself. For example, if the value "10" is
disclosed, then "about 10" is also disclosed. It is also understood
that each unit between two particular units are also disclosed. For
example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are
also disclosed.
[0029] As used herein, the terms "about" and "at or about" mean
that the amount or value in question can be the designated value,
approximately the designated value, or about the same as the
designated value. It is generally understood, as used herein, that
it is the nominal value indicated .+-.10% variation unless
otherwise indicated or inferred. The term is intended to convey
that similar values promote equivalent results or effects recited
in the claims. That is, it is understood that amounts, sizes,
formulations, parameters, and other quantities and characteristics
are not and need not be exact, but can be approximate and/or larger
or smaller, as desired, reflecting tolerances, conversion factors,
rounding off, measurement error and the like, and other factors
known to those of skill in the art. In general, an amount, size,
formulation, parameter or other quantity or characteristic is
"about" or "approximate" whether or not expressly stated to be
such. It is understood that where "about" is used before a
quantitative value, the parameter also includes the specific
quantitative value itself, unless specifically stated
otherwise.
[0030] As used herein, the terms "optional" or "optionally" means
that the subsequently described event or circumstance can or cannot
occur, and that the description includes instances where said event
or circumstance occurs and instances where it does not. For
example, the phrase "optional curing treatment" means that the
curing treatment may or may not be applied and that the description
includes fabrics to which the curing treatment has been applied and
also fabrics that have not been subjected to a curing
treatment.
[0031] As used herein, the term "effective amount" refers to an
amount that is sufficient to achieve the desired modification of a
physical property of the composition or material. For example, an
"effective amount" of a curing additive refers to an amount that is
sufficient to achieve the desired improvement in the property
modulated by the formulation component, e.g., achieving the desired
level of curing. The specific level in terms of wt % in a
composition required as an effective amount will depend upon a
variety of factors including, but not limited to, the fabric and
chemical additive selected and the end use of the fabric or
garment.
[0032] Disclosed are the components to be used to prepare the
compositions of the disclosure as well as the compositions
themselves to be used within the methods disclosed herein. These
and other materials are disclosed herein, and it is understood that
when combinations, subsets, interactions, groups, etc. of these
materials are disclosed that while specific reference of each
various individual and collective combinations and permutation of
these compounds cannot be explicitly disclosed, each is
specifically contemplated and described herein. For example, if a
particular compound is disclosed and discussed and a number of
modifications that can be made to a number of molecules including
the compounds are discussed, specifically contemplated is each and
every combination and permutation of the compound and the
modifications that are possible unless specifically indicated to
the contrary. Thus, if a class of molecules A, B, and C are
disclosed as well as a class of molecules D, E, and F and an
example of a combination molecule, A-D is disclosed, then even if
each is not individually recited each is individually and
collectively contemplated meaning combinations, A-E, A-F, B-D, B-E,
B-F, C-D, C-E, and C-F are considered disclosed. Likewise, any
subset or combination of these is also disclosed. Thus, for
example, the sub-group of A-E, B-F, and C-E would be considered
disclosed. This concept applies to all aspects of this application
including, but not limited to, steps in methods of making and using
the compositions of the disclosure. Thus, if there are a variety of
additional steps that can be performed it is understood that each
of these additional steps can be performed with any specific aspect
or combination of aspects of the methods of the disclosure.
[0033] References in the specification and concluding claims to
parts by weight of a particular element or component in a
composition or article, denotes the weight relationship between the
element or component and any other elements or components in the
composition or article for which a part by weight is expressed.
Thus, in a compound containing 2 parts by weight of component X and
5 parts by weight component Y, X and Y are present at a weight
ratio of 2:5, and are present in such ratio regardless of whether
additional components are contained in the compound.
[0034] A weight percent of a component, unless specifically stated
to the contrary, is based on the total weight of the formulation or
composition in which the component is included.
[0035] As used herein the terms "weight percent," "wt %," and "wt.
%," which can be used interchangeably, indicate the percent by
weight of a given component based on the total weight of the
composition, unless otherwise specified. That is, unless otherwise
specified, all wt % values are based on the total weight of the
composition. It should be understood that the sum of wt % values
for all components in a disclosed composition or formulation are
equal to 100.
[0036] Unless otherwise stated to the contrary herein, all test
standards are the most recent standard in effect at the time of
filing this application.
[0037] Each of the materials disclosed herein are either
commercially available and/or the methods for the production
thereof are known to those of skill in the art.
[0038] It is understood that the compositions disclosed herein have
certain functions. Disclosed herein are certain structural
requirements for performing the disclosed functions and it is
understood that there are a variety of structures that can perform
the same function that are related to the disclosed structures, and
that these structures will typically achieve the same result.
Methods for Laser-Treating Fabrics and Garments
[0039] With reference to FIG. 1, aspects of the disclosure relate
to methods 10 for treating a fabric 100. The fabric has a body side
and a face side. As used herein, body side refers to the side of
the fabric facing of the body of the wearer (assuming the fabric
will be incorporated into a garment) and face side refers to the
side of the fabric facing away from the body of the wearer. The
method 10 includes applying a laser treatment 200 to at least the
body side of the fabric 100. The laser treatment 200 forms a
plurality of pores on fibers of at least the body side of the
fabric. The method 10 further includes applying at least one
chemical additive 300 to the fabric such that the at least one
chemical additive is embedded within or anchored to the plurality
of pores. The pores have a pore size of from about 1 nm to about 20
.mu.m. In some aspects a curing treatment 400 is optionally applied
to the fabric to cure the at least one chemical additive.
[0040] At the step of applying at least one chemical additive 300
to the fabric, which follows the step of applying a laser treatment
200 to the fabric, the at least one chemical additive can enter the
plurality of pores or attach to the pores, which improves the
durability of the chemical additive(s) in the fabric; i.e., the
chemical additive is retained within the fabric longer during use
and laundering.
[0041] In some aspects the step of applying a laser treatment 200
to the fabric to form a plurality of pores on fibers of at least
the body side of the fabric provides the fabric with an increased
surface area as compared to a substantially similar fabric that has
not been subjected to a laser treatment. The plurality of pores
open up the surface of the fibers, increasing the surface area of
the fibers and the fabric including them. In addition, the removal
of material from the surface of the fibers reduces contact points
of the fabric against the skin of the wearer (assuming the fabric
is the inside layer of a garment). The reduced contact points and
pores in the fibers provides a microclimate that reduces friction
and enhances comfort of the fabric against the skin, as heat and
moisture (sweat) generated from a wearer can more easily dissipate
from the surface of the skin. Thus, in some aspects the step of
applying a laser treatment 200 to the fabric provides the fabric
with an enhanced microclimate as compared to a substantially
similar fabric that has not been subjected to a laser
treatment.
[0042] As used herein "substantially similar fabric" means a fabric
that includes the same fibers or fiber blends, is the same fabric
type (e.g., woven, knit, nonwoven), has the same fabric weight, and
includes the same amount and type of chemical additive(s). In other
words, the fabric is the same fabric as the fabric according to
aspects described herein but it has not been laser-treated to
create a plurality of pores on fibers thereof.
[0043] In certain aspects the laser treatment 200 is applied to
both the body side and the face side of the fabric such that the
plurality of pores is located on both the body side and the face
side of the fabric.
[0044] The fibers of the fabric can be any suitable fiber that,
when the laser treatment 200 is applied thereto, will have pores
formed thereon. The fibers may be natural fibers, synthetic fibers,
or a combination thereof. Purely exemplary natural fibers suitable
for use in fabrics of the present disclosure include, but are not
limited to, cotton, wool, leather, silk, and combinations thereof.
In particular aspects the fibers are cotton or cotton blends.
Purely exemplary synthetic fibers suitable for use in fabrics of
the present disclosure include, but are not limited to, viscose,
polyester, nylon, polypropylene, modacrylic, aramid,
polybenzimidazole (PBI), polybenzoxazole (PBO), melamine and
combinations thereof.
[0045] The step of applying the laser treatment 200 may include
using any suitable type of laser to treat the fabric. Exemplary
lasers include but are not limited to an yttrium aluminum garnet
(YAG) laser and a fiber laser. In some aspects the laser has a
narrow beam so that it affects individual fibers of the fabric at a
micro or nano level, in contrast to current laser fabric treating
technology which has a wide beam and affects entire fibers of the
fabric, such as at a macro level. In a particular aspect the laser
may have a wavelength of 10.6 .mu.m, although any wavelength
suitable for forming a plurality of pores on the fibers may be
used. Laser parameters may be adjusted depending on fabric type and
other properties. For example, a lower power laser may be desirable
for use on fibers such as nylon which could melt when treated with
a high power laser.
[0046] The at least one chemical additive in the step of applying
at least one chemical additive 300 can be any chemical additive
that provides desired properties to the fabric. Purely exemplary
chemical additives suitable for use in aspects of the disclosure
include, but are not limited to, silver (for antimicrobial and/or
odor control properties), titanium dioxide (for ultraviolet (UV)
protection and moisture transport properties), zinc peroxide (for
antistatic properties), aerogels (for thermal insulation) and
keratin (for shrink resistance). The step of applying the at least
one chemical additive 300 may be performed using any suitable
chemical application process. Exemplary processes include but are
not limited to spray-coating, pad-dipping, foaming, dyeing, spin
coating, powder coating, kiss roll coating, screen printing,
digital printing, or any combination of these processes.
[0047] The at least one chemical additive may be in the form of
nanoparticles 310 (have a particle size in the nanometer (nm)
range), microparticles 320 (have a particle size in the micrometer
(.mu.m) range) or in the form of larger particles 330 (i.e.,
macromolecules). If the particles are smaller than the pore size of
the fibers the particles can fit within the pores and be embedded
within. If the particles are larger than the pore size of the
fibers or if they are not within the pores they may be anchored
partially within the pores or to the edge of the pores. Embedding
of the chemical additive within the pores or anchoring of the
chemical additive to the pore improves the durability of the
chemical additive in the fabric, as discussed above. It will be
recognized that a particular chemical additive may have particles
of varying sizes, and that some particles of the chemical additive
may be embedded within some pores in the fibers, and that other
particles of the chemical additive may be partially anchored within
some pores and/or anchored to the edge of some pores.
[0048] Exemplary chemical additives suitable for use in aspects of
the disclosure include, but are not limited to, cellulose nano
crystals (CNC) and cellulose nano filaments (CNF). In one purely
nonlimiting example cellulose nano crystals have a nominal average
length of 150 nm and a nominal average diameter of 7.5 nm,
providing a nominal aspect ratio of 20. One gram of CNC nominally
contains over 125 quadrillion (10.sup.16) particles, each with a
nominal surface area of 4500 nm.sup.2, theoretically providing a
surface area of about 550 square meters per gram of material. As a
result, the CNC has a high degree of interaction with its
surroundings.
[0049] Cellulose nano filaments are rope-like and have a high
aspect ratio with width of approximately 5-60 nm and lengths of
0.5-5 CNFs may also be more flexible as compared to CNCs.
[0050] CNCs and CNFs may be useful as chemical additives in the
step of applying at least one chemical additive 300 for enhancing
textile functional finishing properties. The large surface area of
these chemicals can enhance the durability of these additives. In
addition, they have high thermal stability, which may provide an
improvement in mechanical strength improvement, and they may
further contribute to a better hand feel. Both CNC and CNF can be
modified to improve their compatibility with various resins used in
clear coatings.
[0051] Another potential benefit of using CNCs/CNFs is that because
they are nano-sized, they can fit within the pores formed during
the step of applying a laser treatment 200 to the fabric, which
will improve the durability of the CNCs/CNFs in the fabric.
[0052] In some aspects the at least one chemical additive may be
fixed to the fabric--and particles of the chemical additive
embedded within the pores or anchored to the pores--by curing the
additive in an optional curing treatment 400. Any suitable process
may be applied to the chemical additive to cure it. Exemplary
curing treatments include, but are not limited to, laser curing 410
and ultraviolet (UV) curing 420. It will be recognized that certain
chemical additives need not be cured, and that other known
processes such as drying processes may fix the additive to the
fabric.
[0053] The optional curing treatment 400 may offer one or more
advantages over conventional finishing methods. Curing treatments
offer high productivity and can be completed in a matter of
seconds, in contrast to conventional methods that can take several
minutes or up to an hour. In addition, they are more suited to
zonal application of chemical additives to discrete regions of the
fabric/garment, which can reduce waste and allow for functional
properties only in areas in which the chemical is required. Other
potential benefits of curing treatments include, but are not
limited to, process consistency, energy savings, and smaller
equipment footprint.
[0054] In a curing treatment, laser light irradiates a substrate
(e.g., a fabric/garment) and generates thermal energy, which is
then used to cure the substrate. Methacrylate double bonds are a
commonly used functionality for energy-based curing treatments. A
photoinitiator may be present in such formulations to absorb the
laser light and generate free radicals. The free radicals react
with the double bonds, causing a chain reaction and
polymerization.
[0055] Particular chemical additives may be more useful in certain
regions of a fabric, such as chemical additives to provide
antimicrobial, odor control and/or moisture transport properties in
regions of the fabric that will be proximate a wearer's armpit or
crotch. In another example, stain resistance chemical additives may
be more useful in regions of the fabric that will be proximate a
wearer's shirt collar or shirt cuff. Accordingly, in certain
aspects the laser treatment 200 is applied only to discrete regions
of the fabric such that the plurality of pores are formed in the
discrete regions of the fabric.
[0056] In further aspects the method 10 includes applying an
optional pretreatment process 500 to the fabric prior to applying
the laser treatment 200. Exemplary pretreatment processes 500
include, but are not limited to, mercerization treatments and
chemical coating treatments. Mercerization of fabrics, and in
particular cotton fabrics, affects various fabric properties. Of
note, however, mercerization can cause swelling of the fibers in
the fabric and increase the surface area of the fabric. Pretreating
a fabric with a mercerization process prior to laser-treating the
fabric can thus result in a fabric having an even greater surface
area as compared to a fabric that has only been mercerized or only
been laser treated. Similarly, chemical coating pretreatments can
be applied to the fabric to improve certain fabric processes prior
to the laser treatment. For example, a polydimethylsiloxane (PDMS)
coating may provide the fabric with hydrophobic properties and
improve its water resistance.
[0057] In certain aspects a post-wash process 600 may be applied to
the laser-treated fabric 100. Exemplary post-wash processes 600
include, but are not limited to, rinsing, enzyme washing, chemical
bleaching, applying a softener, ozone color removal treatment and
combinations thereof. In one aspect a post-wash process 600 such as
rinsing may be particularly desirable to remove ash and/or loose
particles that result from the laser treatment 200 and/or the
optional curing treatment 400. In another aspect a post-wash
process 600 that may be applied to denim fabrics includes an enzyme
washing step which removes warp indigo color from the denim and
improves the aesthetic appearance of the denim. In a further aspect
a post-wash process 600 may include applying a softener, which
enhances the hand (feel) of the fabric.
[0058] In certain aspects a fabric to which the method 10 described
herein has been applied has improved properties as compared to a
substantially similar fabric that does not include the plurality of
pores on fibers of the fabric. Improved properties may include, but
are not limited to, one or more of antibacterial properties, odor
control properties, ultraviolet (UV) protection, moisture transport
properties, antistatic properties, thermal insulation properties,
shrink resistance, abrasion resistance, and stain repellant
properties. In particular aspects the at least one chemical
additive in the fabric exhibits improved wash fastness as compared
to a chemical additive in a substantially similar fabric that does
not comprise the plurality of pores.
[0059] In some aspects of the disclosure the plurality of pores
have a pore size of from about 1 nm to about 20 .mu.m. In certain
aspects the plurality of pores have a pore size of from about 20 nm
to about 10 .mu.m, or from about 50 nm to about 5 .mu.m, or from
about 100 nm to about 2 .mu.m. In particular aspects the plurality
of pores have a pore size less than about 20 .mu.m, or less than
about 15 .mu.m, or less than about 10 .mu.m, or less than about 5
.mu.m, or less than about 2 .mu.m.
Laser-Treated Fabrics and Garments Made Therefrom
[0060] Certain aspects of the disclosure relate to a laser-treated
fabric 100 and garments incorporating the laser-treated fabric 100.
The fabric 100 has a body side and a face side. The fabric 100
includes a plurality of pores located on at least some fibers on at
least the body side of the fabric 100, and at least one chemical
additive embedded within or anchored to the plurality of pores. In
certain aspects the pores have a pore size of from about 1 nm to
about 20 .mu.m.
[0061] The plurality of pores are formed by applying a laser
treatment to at least the body side of the fabric 100. The laser
treatment applied to the fibers of the fabric 100 creates pores in
the fibers. The chemical additive(s) can enter the pores or attach
to the pore, which improves the durability of the chemical
additive(s) in the fabric; i.e., the chemical additive is retained
within the fabric longer during use and laundering.
[0062] In some aspects the plurality of pores on fibers of at least
the body side of the fabric 100 provide the laser-treated fabric
with an increased surface area as compared to a substantially
similar fabric that has not been subjected to a laser treatment.
The plurality of pores open up the surface of the fibers,
increasing the surface area of the fibers and the fabric including
them. In addition, the removal of material from the surface of the
fibers reduces contact points of the fabric against the skin of the
wearer (assuming the fabric is the inside layer of a garment). The
reduced contact points and pores in the fibers provides a
microclimate that reduces friction and enhances comfort of the
fabric against the skin, as heat and moisture (sweat) generated
from a wearer can more easily dissipate from the surface of the
skin. Thus, in some aspects the fabric has an enhanced microclimate
as compared to a substantially similar fabric that has not been
subjected to a laser treatment.
[0063] In certain aspects the laser treatment is applied to both
the body side and the face side of the fabric 100 such that the
plurality of pores is located on both the body side and the face
side of the fabric 100.
[0064] The fibers of the fabric 100 can be any suitable fiber that,
when laser-treated, will have pores formed thereon. The fibers may
be natural fibers, synthetic fibers, or a combination thereof.
Purely exemplary fibers include but are not limited to those
described above.
[0065] In some aspects the plurality of pores have a pore size of
from about 1 nm to about 20 .mu.m. In certain aspects the plurality
of pores have a pore size of from about 20 nm to about 10 .mu.m, or
from about 50 nm to about 5 .mu.m, or from about 100 nm to about 2
.mu.m. In particular aspects the plurality of pores have a pore
size less than about 20 .mu.m, or less than about 15 .mu.m, or less
than about 10 .mu.m, or less than about 5 .mu.m, or less than about
2 .mu.m.
[0066] The at least one chemical additive can be any chemical
additive that provides desired properties to the fabric 100. Purely
exemplary chemical additives suitable for use in aspects of the
disclosure include, but are not limited to, those described above.
The at least one chemical additive may be in the form of
nanoparticles, microparticles, or in the form of larger particles
as described above.
[0067] In some aspects the at least one chemical additive may be
cured in order to fix the chemical additive within the pores or
anchor the chemical additive to the pores. Suitable processes for
curing the chemical additive are described above.
[0068] In further aspects the fabric may be pretreated prior to
application of the laser treatment to the fabric 100. Exemplary
pretreatment processes include, but are not limited to, those
processes described above.
[0069] In certain aspects the laser-treated fabric described herein
has improved properties as compared to a substantially similar
fabric that does not include the plurality of pores on fibers of
the fabric. Improved properties may include, but are not limited
to, one or more of antibacterial properties, odor control
properties, ultraviolet (UV) protection, moisture transport
properties, antistatic properties, thermal insulation properties,
shrink resistance, abrasion resistance, and stain repellant
properties. In particular aspects the at least one chemical
additive in the fabric exhibits improved wash fastness as compared
to a chemical additive in a substantially similar fabric that does
not comprise the plurality of pores.
[0070] Aspects of the disclosure also relate to a garment including
a laser-treated fabric. The laser-treated fabric includes a body
side and a face side, and includes a plurality of pores located on
at least some fibers on at least the body side of the fabric and at
least one chemical additive embedded within or anchored to the
plurality of pores. In certain aspects the pores have a pore size
of from about 1 nm to about 20 .mu.m.
[0071] The fabric in the garment may be laser-treated such that the
plurality of pores are located in discrete regions of the garment
according to aspects described above. In some aspects the garment
is a shirt or a jacket and the discrete regions comprise one or
more of a shirt collar region, a shirt cuff region or a shirt
armpit region. In further aspects the garment is pants and the
discrete regions comprise one or more of a knee region or a crotch
region.
[0072] Various combinations of elements of this disclosure are
encompassed by this disclosure, e.g., combinations of elements from
dependent claims that depend upon the same independent claim.
Aspects of the Disclosure
[0073] In various aspects, the present disclosure pertains to and
includes at least the following aspects.
[0074] Aspect 1: A laser-treated fabric having a body side and a
face side, comprising, consisting of, or consisting essentially
of:
[0075] a plurality of pores located on at least some fibers on at
least the body side of the fabric; and
[0076] at least one chemical additive embedded within or anchored
to the plurality of pores,
[0077] wherein the pores have a pore size of from about 1 nm to
about 20 .mu.m.
[0078] Aspect 2: The laser-treated fabric according to Aspect 1,
wherein the plurality of pores are formed by applying a laser
treatment to at least the body side of the fabric.
[0079] Aspect 3: The laser-treated fabric according to Aspect 1 or
2, wherein at least the body side of the fabric has an increased
surface area as compared to a substantially similar fabric that has
not been subjected to a laser treatment.
[0080] Aspect 4: The laser-treated fabric according to any of
Aspects 1 to 3, wherein at least the body side of the fabric has an
enhanced microclimate as compared to a substantially similar fabric
that has not been subjected to a laser treatment.
[0081] Aspect 5: The laser-treated fabric according to any of
Aspects 1 to 4, wherein the plurality of pores is located on both
the body side and the face side of the fabric.
[0082] Aspect 6: The laser-treated fabric according to Aspect 5,
wherein the plurality of pores on both the body side and the face
side of the fabric are formed by applying a laser treatment to both
the body side and the face side of the fabric.
[0083] Aspect 7: The laser-treated fabric according to any of
Aspects 1 to 6, wherein the fibers comprise natural fibers,
synthetic fibers, or a combination thereof.
[0084] Aspect 8: The laser-treated fabric according to Aspect 7,
wherein the natural fibers comprise cotton, wool, leather, silk or
a combination thereof.
[0085] Aspect 9: The laser-treated fabric according to Aspect 7,
wherein the synthetic fibers comprise viscose, polyester, nylon,
polypropylene, modacrylic, aramid, polybenzimidazole (PBI),
polybenzoxazole (PBO), melamine and combinations thereof.
[0086] Aspect 10: The laser-treated fabric according to any of
Aspects 1 to 9, wherein the at least one chemical additive is
cured.
[0087] Aspect 11: The laser-treated fabric according to any of
Aspects 1 to 10, wherein the at least one chemical additive
comprises silver, titanium dioxide, zinc peroxide, aerogel, keratin
or a combination thereof.
[0088] Aspect 12: The laser-treated fabric according to any of
Aspects 1 to 11, wherein the at least one chemical additive is in
the form of nanoparticles, microparticles or macromolecules, and
the nanoparticles, microparticles or macromolecules are embedded
within or anchored to the plurality of pores.
[0089] Aspect 13: The laser-treated fabric according to any of
Aspects 1 to 12, wherein the at least one chemical additive is in
the form of nanoparticles or microparticles, and the nanoparticles
or microparticles are embedded within or anchored to the plurality
of pores.
[0090] Aspect 14: The laser-treated fabric according to Aspect 12
or 13, wherein the at least one chemical additive comprises
cellulose nano crystals (CNC), cellulose nano filaments (CNF) or a
combination thereof.
[0091] Aspect 15: The laser-treated fabric according to any of
Aspects 1 to 14, wherein the fabric has improved properties as
compared to a substantially similar fabric that has not been
subjected to a laser treatment, wherein the improved properties
include one or more of antibacterial properties, odor control
properties, ultraviolet (UV) protection, moisture transport
properties, antistatic properties, thermal insulation properties,
shrink resistance, abrasion resistance, and stain repellant
properties.
[0092] Aspect 16: The laser-treated fabric according to any of
Aspects 1 to 15, wherein the at least one chemical additive in the
fabric exhibits improved wash fastness as compared to a chemical
additive in a substantially similar fabric that has not been
subjected to a laser treatment.
[0093] Aspect 17: The laser-treated fabric according to any of
Aspects 1 to 16, wherein the plurality of pores are formed by
applying a laser treatment to at least the body side of the fabric,
and the fabric is pretreated prior to application of the laser
treatment.
[0094] Aspect 18: The laser-treated fabric according to Aspect 17,
wherein the pretreatment is a mercerization treatment or a chemical
coating treatment.
[0095] Aspect 19: A garment comprising a laser-treated fabric, the
laser-treated fabric having a body side and a face side and
comprising, consisting of, or consisting essentially of:
[0096] a plurality of pores located on at least some fibers on at
least the body side of the fabric; and
[0097] at least one chemical additive embedded within or anchored
to the plurality of pores,
[0098] wherein the pores have a pore size of from about 1 nm to
about 20 .mu.m.
[0099] Aspect 20: The garment according to Aspect 19, wherein the
fabric is laser-treated such that the plurality of pores are
located in discrete regions of the fabric.
[0100] Aspect 21: The garment according to Aspect 19 or 20, wherein
the garment is a shirt or a jacket and the discrete regions
comprise one or more of a shirt collar region, a shirt cuff region
or a shirt armpit region.
[0101] Aspect 22: The garment according to Aspect 19 or 20, wherein
the garment is pants and the discrete regions comprise one or more
of a knee region or a crotch region.
[0102] Aspect 23: The garment according to any of Aspects 19 to 22,
wherein the plurality of pores are formed by applying a laser
treatment to at least the body side of the fabric, and the fabric
is pretreated prior to application of the laser treatment.
[0103] Aspect 24: The garment according to Aspect 23, wherein the
pretreatment is a mercerization treatment or a chemical coating
treatment.
[0104] Aspect 25: The garment according to any of Aspects 19 to 24,
wherein at least the body side of the fabric has an increased
surface area as compared to a substantially similar fabric that has
not been subjected to a laser treatment.
[0105] Aspect 26: The garment according to any of Aspects 19 to 25,
wherein at least the body side of the fabric has an enhanced
microclimate as compared to a substantially similar fabric that has
not been subjected to a laser treatment.
[0106] Aspect 27: The garment according to any of Aspects 19 to 26,
wherein the plurality of pores is located on both the body side and
the face side of the fabric.
[0107] Aspect 28: The garment according to Aspect 27, wherein the
plurality of pores on both the body side and the face side of the
fabric are formed by applying a laser treatment to both the body
side and the face side of the fabric.
[0108] Aspect 29: The garment according to any of Aspects 19 to 28,
wherein the fibers comprise natural fibers, synthetic fibers, or a
combination thereof.
[0109] Aspect 30: The garment according to Aspect 29, wherein the
natural fibers comprise cotton, wool, leather, silk or a
combination thereof.
[0110] Aspect 31: The garment according to Aspect 29, wherein the
synthetic fibers comprise viscose, polyester, nylon, polypropylene,
modacrylic, aramid, polybenzimidazole (PBI), polybenzoxazole (PBO),
melamine and combinations thereof.
[0111] Aspect 32: The garment according to any of Aspects 19 to 31,
wherein the at least one chemical additive is cured.
[0112] Aspect 33: The garment according to any of Aspects 19 to 32,
wherein the at least one chemical additive comprises silver,
titanium dioxide, zinc peroxide, aerogel, keratin or a combination
thereof.
[0113] Aspect 34: The garment according to any of Aspects 19 to 33,
wherein the at least one chemical additive is in the form of
nanoparticles, microparticles or macromolecules, and the
nanoparticles, microparticles or macromolecules are embedded within
or anchored to the plurality of pores.
[0114] Aspect 35: The garment according to any of Aspects 19 to 34,
wherein the at least one chemical additive is in the form of
nanoparticles or microparticles, and the nanoparticles or
microparticles are embedded within or anchored to the plurality of
pores.
[0115] Aspect 36: The garment according to Aspect 34 or 35, wherein
the at least one chemical additive comprises cellulose nano
crystals (CNC), cellulose nano filaments (CNF) or a combination
thereof.
[0116] Aspect 37: The garment according to any of Aspects 19 to 36,
wherein the fabric has improved properties as compared to a
substantially similar fabric that has not been subjected to a laser
treatment, wherein the improved properties include one or more of
antibacterial properties, odor control properties, ultraviolet (UV)
protection, moisture transport properties, antistatic properties,
thermal insulation properties, shrink resistance, abrasion
resistance, and stain repellant properties.
[0117] Aspect 38: The garment according to any of Aspects 19 to 37,
wherein the at least one chemical additive in the fabric exhibits
improved wash fastness as compared to a chemical additive in a
substantially similar fabric that has not been subjected to a laser
treatment.
[0118] Aspect 39: A method for treating a fabric, the fabric having
a body side and a face side, the method comprising, consisting of,
or consisting essentially of:
[0119] applying a laser treatment to at least the body side of the
fabric to form a plurality of pores on fibers of at least the body
side of the fabric; and
[0120] applying at least one chemical additive to the fabric such
that the at least one chemical additive is embedded within or
anchored to the plurality of pores,
[0121] wherein the pores have a pore size of from about 1 nm to
about 20 .mu.m.
[0122] Aspect 40: The method according to Aspect 39, further
comprising applying a curing treatment to the fabric to cure the at
least one chemical additive.
[0123] Aspect 41: The method according to Aspect 40, wherein the
curing treatment is an additional laser treatment or a heat
treatment.
[0124] Aspect 42: The method according to any of Aspects 39 to 41,
wherein the laser treatment is applied to both the body side and
the face side of the fabric.
[0125] Aspect 43: The method according to any of Aspects 39 to 42,
wherein the laser treatment is applied to the fabric using a laser
having a wavelength of about 10.6 .mu.m.
[0126] Aspect 44: The method according to any of Aspects 39 to 43,
wherein the laser treatment is applied to discrete regions of the
fabric such that the plurality of pores are formed in only the
discrete regions of the fabric.
[0127] Aspect 45: The method according to any of Aspects 39 to 44,
further comprising pretreating the fabric prior to applying the
laser treatment to the fabric.
[0128] Aspect 46: The method according to Aspect 45, wherein the
pretreatment is a mercerization treatment or a chemical coating
treatment.
[0129] Aspect 47: The method according to any of Aspects 39 to 46,
wherein at least the body side of the fabric has an increased
surface area as compared to a substantially similar fabric that has
not been subjected to a laser treatment.
[0130] Aspect 48: The method according to any of Aspects 39 to 47,
wherein at least the body side of the fabric has an enhanced
microclimate as compared to a substantially similar fabric that has
not been subjected to a laser treatment.
[0131] Aspect 49: The method according to any of Aspects 39 to 48,
wherein the fibers comprise natural fibers, synthetic fibers, or a
combination thereof.
[0132] Aspect 50: The method according to Aspect 49, wherein the
natural fibers comprise cotton, wool, leather, silk or a
combination thereof.
[0133] Aspect 51: The method according to Aspect 49, wherein the
synthetic fibers comprise viscose, polyester, nylon, polypropylene,
modacrylic, aramid, polybenzimidazole (PBI), polybenzoxazole (PBO),
melamine and combinations thereof.
[0134] Aspect 52: The method according to any of Aspects 39 to 51,
further comprising curing the at least one chemical additive to
embed the at least one chemical additive within the plurality of
pores or anchor the at least one chemical additive to the plurality
of pores.
[0135] Aspect 53: The method according to any of Aspects 39 to 52,
wherein the at least one chemical additive comprises silver,
titanium dioxide, zinc peroxide, aerogel, keratin or a combination
thereof.
[0136] Aspect 54: The method according to any of Aspects 39 to 53,
wherein the at least one chemical additive is in the form of
nanoparticles, microparticles or macromolecules, and the
nanoparticles, microparticles or macromolecules are embedded within
or anchored to the plurality of pores.
[0137] Aspect 55: The method according to any of Aspects 39 to 54,
wherein the at least one chemical additive is in the form of
nanoparticles or microparticles, and the nanoparticles or
microparticles are embedded within or anchored to the plurality of
pores.
[0138] Aspect 56: The garment according to Aspect 54 or 55 wherein
the at least one chemical additive comprises cellulose nano
crystals (CNC), cellulose nano filaments (CNF) or a combination
thereof.
[0139] Aspect 57: The method according to any of Aspects 39 to 56,
wherein the fabric has improved properties as compared to a
substantially similar fabric that has not been subjected to a laser
treatment, wherein the improved properties include one or more of
antibacterial properties, odor control properties, ultraviolet (UV)
protection, moisture transport properties, antistatic properties,
thermal insulation properties, shrink resistance, abrasion
resistance, and stain repellant properties.
[0140] Aspect 58: The method according to any of Aspects 39 to 57,
wherein the at least one chemical additive in the fabric exhibits
improved wash fastness as compared to a chemical additive in a
substantially similar that has not been subjected to a laser
treatment.
[0141] Aspect 59: A garment comprising a fabric treated according
to the method of any of Aspects 39 to 58.
[0142] Aspect 60: The garment according to Aspect 59, wherein the
fabric comprises the plurality of pores in only discrete regions of
the fabric.
[0143] Aspect 61: The garment according to Aspect 60, wherein the
garment is a shirt or a jacket and the discrete regions comprise
one or more of a shirt collar region, a shirt cuff region or a
shirt armpit region.
[0144] Aspect 62: The garment according to Aspect 60, wherein the
garment is pants and the discrete regions comprise one or more of a
knee region or a crotch region.
EXAMPLES
[0145] The following examples are put forth so as to provide those
of ordinary skill in the art with a complete disclosure and
description of how the compounds, compositions, articles, devices
and/or methods claimed herein are made and evaluated, and are
intended to be purely exemplary and are not intended to limit the
disclosure. Efforts have been made to ensure accuracy with respect
to numbers (e.g., amounts, temperature, etc.), but some errors and
deviations should be accounted for. Unless indicated otherwise,
parts are parts by weight, temperature is in .degree. C. or is at
ambient temperature, and pressure is at or near atmospheric. Unless
indicated otherwise, percentages referring to composition are in
terms of wt %.
[0146] There are numerous variations and combinations of reaction
conditions, e.g., component concentrations, desired solvents,
solvent mixtures, temperatures, pressures and other reaction ranges
and conditions that can be used to optimize the product purity and
yield obtained from the described process. Only reasonable and
routine experimentation will be required to optimize such process
conditions.
Example 1
Prior Art
[0147] A cotton weft fabric at 250.times. and 1000.times.
magnification is illustrated in FIGS. 2A and 2B. The fiber surface
can be seen as continuous (i.e., generally unbroken and having no
pores thereon).
Example 2
[0148] Fibers on the body side of a denim fabric were treated with
a 2500 watt (W) carbon dioxide (CO.sub.2) laser from LasX. The
laser had a wavelength of 10.6 .mu.m. As shown in FIGS. 3A and 3B
at 250.times. magnification and 1000.times. magnification,
respectively, individual fibers of the fabric had a plurality of
pores located thereon. A chemical additive may be applied to the
fabric such that the at least one chemical additive is embedded
within or anchored to the plurality of pores.
Example 3
[0149] A polydimethylsiloxane (PDMS) coating was applied to a denim
fabric. Fibers on the body side of the PDMS-coated fabric were then
treated with a 2500 W CO.sub.2 laser from LasX. The laser had a
wavelength of 10.6 .mu.m. Pores were not readily apparent in the
fabric (see FIGS. 4A and 4B at 250.times. magnification and
1000.times. magnification, respectively). It is possible that the
laser parameters used for this Example did not allow the laser to
penetrate the PDMS coating and create pores in the fibers of the
fabric. Although not tested, the laser treatment step may have had
a curative effect on the PDMS coating, resulting in the PDMS
coating being more durable on the fabric.
Example 4
[0150] Fibers on the body side of a prewashed denim fabric were
treated with a 2500 W CO.sub.2 laser from LasX. The laser had a
wavelength of 10.6 .mu.m. As shown in FIGS. 5A and 5B at 250.times.
magnification and 1000.times. magnification, respectively,
individual fibers of the fabric had a plurality of pores located
thereon. A chemical additive may be applied to the fabric such that
the at least one chemical additive is embedded within or anchored
to the plurality of pores.
Example 5
[0151] A polydimethylsiloxane (PDMS) coating was applied to a denim
fabric. Fibers on the body side of the PDMS-coated fabric were then
treated with a 2500 W CO.sub.2 laser from LasX. The laser had a
wavelength of 10.6 .mu.m. Pores were not readily apparent in the
fabric (see FIGS. 6A and 6B at 250.times. magnification and
1000.times. magnification, respectively). It is possible that the
laser parameters used for this Example did not allow the laser to
penetrate the PDMS coating and create pores in the fibers of the
fabric. Although not tested, the laser treatment step may have had
a curative effect on the PDMS coating, resulting in the PDMS
coating being more durable on the fabric.
Example 6
[0152] The fabric of Example 3A and the fabric of Example 5A are
shown in FIGS. 7 and 8, respectively, at a magnification of
approximately 5000.times.. These images show a plurality of
micropores and/or nanopores in individual fibers of the fabrics,
with the identified pores in the fiber of FIG. 7 having a pore size
ranging from 187.2 nm to 1.605 .mu.m and the identified pores in
the fiber of FIG. 8 having a pore size ranging from 447.2 nm to
1.862 .mu.m.
Example 7
[0153] Prewashed (1-hour stone enzyme wash) and unwashed (rigid)
100% denim fabrics were subjected to a laser treatment step on both
the front side and the back side of the fabric. The front side of
each fabric was the blue warp side; the back side of each fabric
was the white fill side. The influence of varying degrees of laser
intensity (low, medium and high) and beam diameter (low, medium and
high) on pore size and pore density was evaluated. The laser
applied to the samples was a 2500 watt (W) laser. All laser-treated
samples were rinsed in water for about 10 minutes to remove ash
(laser burnt spots).
[0154] Scanning electron microscope (SEM) images of exemplary
samples are shown in FIGS. 9A-9F. FIGS. 9A-9C are images for
unwashed denim treated with a laser having a 1.2 millimeter (mm)
beam diameter at a low intensity (40% power) (FIG. 9A), medium
intensity (70% power) (FIG. 9B) and high intensity (100% power)
(FIG. 9C). FIGS. 9D-9F are images for washed denim treated with a
laser having a 1.2 mm beam diameter at a low intensity (40% power)
(FIG. 9D), medium intensity (70% power) (FIG. 9E) and high
intensity (FIG. 9F). Magnification of all images is 100.times..
[0155] From the images it is evident that the unwashed/rigid denim
had more pores than the washed denim, and the pores were smaller in
size (average diameter <3 micrometer (.mu.m)). Washed denim
generally tends to have yarns of larger yarn diameter as a result
of longer exposure to warm/hot conditions, caustic washings, etc.,
which can lead to some amount of fiber swelling and a higher yarn
surface area; as a result the pore size of the washed denim
appeared to be larger (average diameter <4 .mu.m).
[0156] Overall, the pore size ranged from <1 .mu.m to about 20
.mu.m. For rigid denim, a linear trend was observed in that average
pore size increased with increased laser power at all tested beam
diameters--SEM images for 1.2 mm beam diameter are shown but the
same trend was observed for a beam diameter of 0.75 mm. For washed
denim, there was no trend observed with respect to average pore
size and laser power, although it was observed that as beam
diameter was increased (e.g., to 1.2 mm) larger pores were formed
than at lower beam diameters (e.g., 0.75 mm). Further, it was
observed that denim treated at a lower beam diameter (e.g., 0.75
mm) had a higher number of pores than at a higher beam diameter
(e.g., 1.2 mm). A substantial difference in performance/results
between warp and fill yarns was not observed, although it is noted
that it was difficult to exclude specific yarns (e.g., warp or
fill) while imaging them at higher resolutions.
Example 8
[0157] Curing treatments using acrylated chemistry to cure the
chemical additive(s) described herein were evaluated. Several
formulations of energy-curable formulations based on acrylated
resin monomers and oligomers (mono, di, tri and tetra functional)
were considered. The resins were tested with and without additives
(such as with varying concentrations of photoinitiator) and at
varying viscosities.
[0158] Concentrated and diluted resin formulations were applied
onto prewashed denim samples with spraying, stamping, blades and/or
screen printing methods. Organic solvents were used to dilute the
resins. The influence of a range of laser operating conditions
(intensity, speed, number of passes, etc.) on curing was studied.
Multiple passes of a laser beam were applied over the laser surface
to cure the chemical additive. Fine-tuning of laser settings was
achieved to provide complete curing of chemistry. In this example,
rapid curing was observed at pass #20, which suggests a residual
buildup of heat followed by rapid free radical reaction and
polymerization. FIGS. 10A-10D provide SEM images (100.times.
magnification) of a laser-cured fabric (FIG. 10D) as compared to
conventional untreated denim (FIG. 10A), heat-cured resin (FIG.
10B) and UV-cured resin (FIG. 10C). As observed, the chemical
additive on the laser-cured fabric appeared to be smoothly
distributed/cured onto the fibers of the fabric, resulting in a
highly crosslinked hard coating. This coating could result in
fabrics having a harsh hand feel (similar to that found in
conventional UV-cured samples), but it is believe that this could
be improved with further modification to the chemistry and
processing conditions.
[0159] From the results, it was apparent that the curing
performance was affected by a combination of various factors,
including but not necessarily limited to the chemical formulation,
the application method and the laser energy. It was thus possible
to optimize laser curing properties and parameters to result in
complete polymerization. Modifications included using different
concentrations of benzoyl peroxide photoinitiator additive and
monofunctional/trifunctional monomer and oligomer to improve the
flexibility or hand feel of the coatings. Other fabric/garment
properties that may be improved by modifying the factors described
herein include, but are not limited to, tear resistance, abrasion
resistance, coating transparency, coating weight, fabric color
change, breathability, and a combination thereof.
[0160] Method examples described herein can be machine or
computer-implemented at least in part. Some examples can include a
computer-readable medium or machine-readable medium encoded with
instructions operable to configure an electronic device to perform
methods as described in the above examples. An implementation of
such methods can include code, such as microcode, assembly language
code, a higher-level language code, or the like. Such code can
include computer readable instructions for performing various
methods. The code may form portions of computer program products.
Further, in an example, the code can be tangibly stored on one or
more volatile, non-transitory, or non-volatile tangible
computer-readable media, such as during execution or at other
times. Examples of these tangible computer-readable media can
include, but are not limited to, hard disks, removable magnetic
disks, removable optical disks (e.g., compact disks and digital
video disks), magnetic cassettes, memory cards or sticks, random
access memories (RAMs), read only memories (ROMs), and the
like.
[0161] The above description is intended to be illustrative, and
not restrictive. For example, the above-described examples (or one
or more aspects thereof) may be used in combination with each
other. Other embodiments can be used, such as by one of ordinary
skill in the art upon reviewing the above description. The Abstract
is provided to comply with 37 C.F.R. .sctn. 1.72(b), to allow the
reader to quickly ascertain the nature of the technical disclosure.
It is submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims. Also, in the
above Detailed Description, various features may be grouped
together to streamline the disclosure. This should not be
interpreted as intending that an unclaimed disclosed feature is
essential to any claim. Rather, inventive subject matter may lie in
less than all features of a particular disclosed embodiment. Thus,
the following claims are hereby incorporated into the Detailed
Description as examples or embodiments, with each claim standing on
its own as a separate embodiment, and it is contemplated that such
embodiments can be combined with each other in various combinations
or permutations. The scope of the invention should be determined
with reference to the appended claims, along with the full scope of
equivalents to which such claims are entitled.
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