U.S. patent number RE40,362 [Application Number 08/049,227] was granted by the patent office on 2008-06-10 for apparatus and method for hydroenhancing fabric.
This patent grant is currently assigned to Polymer Group, Inc.. Invention is credited to John M. Greenway, Jodie M. Siegel, Herschel Sternlieb.
United States Patent |
RE40,362 |
Sternlieb , et al. |
June 10, 2008 |
Apparatus and method for hydroenhancing fabric
Abstract
An apparatus 10 and related process for enhancement of woven and
knit fabrics through use of dynamic fluids which entangle and bloom
fabric yarns. A two stage enhancement process is employed in which
top and bottom sides of the fabric are respectively supported on
members 22, 34 and impacted with a fluid curtain including high
pressure jet streams. Controlled process energies and use of
support members 22, 34 having open areas 26, 36 which are aligned
in offset relation to the process line produces fabrics having a
uniform finish and improved characteristics including, edge fray,
drape, stability, abrasion resistance, fabric weight and
thickness.
Inventors: |
Sternlieb; Herschel (Brunswick,
ME), Siegel; Jodie M. (Watertown, MA), Greenway; John
M. (Westwood, MA) |
Assignee: |
Polymer Group, Inc. (Charlotte,
NC)
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Family
ID: |
27365924 |
Appl.
No.: |
08/049,227 |
Filed: |
April 14, 1989 |
PCT
Filed: |
April 14, 1989 |
PCT No.: |
PCT/US85/01593 |
371(c)(1),(2),(4) Date: |
May 18, 1989 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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07184350 |
Apr 21, 1988 |
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07041542 |
Apr 23, 1987 |
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Reissue of: |
07382160 |
Apr 14, 1989 |
04967456 |
Nov 6, 1990 |
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Current U.S.
Class: |
28/104; 28/167;
68/205R; 8/151.2 |
Current CPC
Class: |
D06C
29/00 (20130101); D04H 1/492 (20130101); D04H
3/11 (20130101); D04H 18/04 (20130101) |
Current International
Class: |
D04H
1/46 (20060101) |
Field of
Search: |
;26/19 ;28/104,167
;428/225 ;8/151.2 ;68/205R |
References Cited
[Referenced By]
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0177277 |
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46-9876 |
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54-11433 |
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57-35051 |
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61-6368 |
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61-252336 |
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61-252339 |
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JP |
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61-58573 |
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JP |
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62-28466 |
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JP |
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62-55253 |
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JP |
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62-69866 |
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Mar 1987 |
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JP |
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62-149961 |
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JP |
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63-303173 |
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81218 |
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PT |
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89/09850 |
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Oct 1989 |
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WO |
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89/10441 |
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Nov 1989 |
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WO |
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Other References
America's Fabrics, Origin and History, Manufacture, Characteristics
and Uses, Bendure and Pfeiffer, MacMillan Co, 1947, pp. 542-3.
cited by examiner .
Textile Science, An Introductory Manual, Marsh, Chapman & Hall
Ltd. 1949, pp. 329-333. cited by examiner .
Woolen and Worsted, Beaumont, G. Bell and Sons, Ltd., 1915 pp.
625-627. cited by examiner .
Kenneth R. Randall, "Hydroentanglement Technology for Wet-Laid
Applicaitons", Nonwovens World, pp. 28-31, Mar., 1989. cited by
other.
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Primary Examiner: Worrell; Danny
Attorney, Agent or Firm: Kilyk & Bowersox, PLLC
Calloway; Valerie
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Ser. Nos.
07/041,542 and 07/184,350, respectively filed Apr. 23, 1987; and
Apr. 21, 1988, and now both abandoned.
Claims
We claim:
1. A method for enhancing .Iadd.textile fabrics over the fabrics
before treatment .Iaddend.and .Iadd.for .Iaddend.finishing textile
fabrics.Iadd., the fabrics .Iaddend.including .Iadd.either or both
of .Iaddend.spun .[.and/or.]. .Iadd.and .Iaddend.spun filament
yarns which intersect at cross-over points, and first and second
sides.[., the fabric including yarn fibers having deniers and
lengths in the range of 0.3 to 16.0 and 0.5 to 8 inches,
respectively, and yarn counts in the range of 0.5s to 80s.]. , the
method comprising the steps of: supporting the fabric on a first
support member, .Iadd.the fabric including yarn fibers having
deniers and lengths in the range of 0.3 to 16.0 and 0.5 to 8
inches, respectively, and yarn counts in the range of 0.5s to 80s,
.Iaddend.and traversing the first side of said fabric with a first
continuous curtain of .Iadd.non-compressible .Iaddend.fluid for
sufficient duration to effect entanglement of said yarns at the
cross-over points, thereby enhancing fabric cover and quality, said
curtain of fluid impacting the fabric with .[.an.]. .Iadd.a
cumulative .Iaddend.energy in the range .Iadd.of .Iaddend.0.1
.[.and.]. .Iadd.to .Iaddend.2.0 hp-hr/lb.
2. The method of claim 1, wherein said fluid curtain is provided by
columnar fluid .[.jet.]. .Iadd.jets having .Iaddend.orifices having
a diameter of approximately 0.005 inches, center-to-center spacing
of approximately 0.017 inches, and spacing from said first support
member of approximately 0.5 inches, said fluid jets impinging the
fabric with fluids at a pressure of approximately 1500 psi.
3. The method of claim 2, wherein said support member includes a
pattern of closely spaced fluid pervious open areas aligned in a
first direction to effect fluid passage through said support
member.
4. The method of claim 3, wherein said open areas occupy
approximately 17 to 40% of said support member.
5. The method of claim 1, comprising the further steps of:
supporting said enhanced fabric on a second support member, and
traversing the second side of said enhanced fabric in a second
enhancement stage with a second continuous .[.fluid.]. curtain of
.Iadd.non-compressible fluid .Iaddend.for sufficient duration to
further enhance fabric cover and provide a uniform fabric finish,
said second .[.enhancement stage.]. .Iadd.fluid curtain
.Iaddend.impacting the fabric with .[.an.]. .Iadd.a cumulating
.Iaddend.energy in the range .Iadd.of .Iaddend.0.1 .[.and.].
.Iadd.to .Iaddend.2.0 hp-hr/lb.
6. The method of claim 5, wherein.[.:.]. said .[.first and
second.]. fluid curtains are provided by columnar fluid jets.Iadd.,
.Iaddend.each having a diameter of approximately 0.005 inches and
center-to-center spacing of approximately 0.017 inches, said fluid
curtains .[.are spaced.]. .Iadd.originate .Iaddend.approximately
0.5 inches from said first and second members, and .[.said fluid
jets.]. impinge approximately the fabric with fluids at a pressure
of approximately 1500 psi, .Iadd.and .Iaddend. said first and
second support members each include a pattern of closely spaced
fluid pervious open areas, respectively aligned in first and second
directions, said open areas being dimensioned to effect fluid
passage through said support members without imparting a patterned
effect to the fabric.
7. The method of claim 6, wherein said open areas occupy
approximately 17 to 40% of each of said first and second support
members.
8. The method of claim 7, wherein said first and second support
members respectively have flat and drum configurations.
9. The method of claim 8, wherein said first and second directions
are offset approximately 45.degree..
10. The method of claim 7, wherein said first and second support
members have drum configurations.
11. The method of claim 10, wherein said first and second
directions are offset approximately 45.degree..
12. The method of claim 6, comprising the .[.further.].
.Iadd.subsequent .Iaddend.step.[., following said further
enhancement.]. of drying the .[.enhanced.]. fabric to a specified
width under tension.
13. An enhanced textile fabric .Iadd.enhanced over the fabric
before treatment and .Iaddend.made by the method of claim 6,.[.the
fabric including yarn fibers having deniers and lengths in the
range of 0.3 to 16 and 0.5 to 8 inches, respectively, and thread
counts in the range of 0.5s to 80s, the yarn cross-over points in
the fabric weave define interstitial open areas,.]. wherein the
.[.process.]. .Iadd.method .Iaddend.effects .[.enhancement.].
.Iadd.blooming .Iaddend.of the yarns in .[.the.]. interstitial open
areas .Iadd.defined by the cross-over points in the fabric
weave.Iaddend., thereby enhancing fabric cover .Iadd.and
quality.Iaddend..
14. .[.An.]. .Iadd.The .Iaddend.enhanced textile fabric .[.made by
the method.]. of claim .[.6.]. .Iadd.13.Iaddend., .Iadd.wherein
.Iaddend.the fabric .[.including.]. .Iadd.includes .Iaddend.yarn
fibers having deniers and lengths in the range of 0.5 to 6 and 0.5
to 8 inches, respectively, and thread counts in the range of 0.5s
to 50s, .[.the yarn cross-over points in the fabric weave define
interstitial open areas, wherein the process effects enhancement of
the yarns in the interstitial open areas, thereby enhancing fabric
cover, and yields.]. .Iadd.and demonstrates .Iaddend.a reduction in
fabric air permeability in the range of 10 to 90% .Iadd.after
finishing.Iaddend..
15. An enhanced woven polyester fabric .Iadd.enhanced over the
fabric before treatment and .Iaddend.made by the method of claim 6,
wherein the fabric includes 2 denier, 1.9 inch polyester fiber,
open-end cotton spun yarn having a yarn number of 17s and count of
49.times.23 per inch, and the process yields an approximate 48%
reduction in air permeability in the fabric.
16. An enhanced woven acrylic fabric .Iadd.enhanced over the fabric
before treatment and .Iaddend.made by the method of claim 6,
wherein the fabric includes 3 denier, 1.5 inch fiber, open-end
cotton warp yarn having a yarn number of 9s, 28 ends per inch, and
a 3 denier, 3 inch acrylic fiber open-end wool spun fill yarn
having a number of 4s, 16 picks per inch, and the process yields an
approximate 36% reduction in air permeability in the fabric.
17. An enhanced acrylic wrap spun fabric .Iadd.enhanced over the
fabric before treatment and .Iaddend.made by the method of claim 6,
wherein the fabric includes 3 denier, 3.0 inch acrylic fiber, wrap
spun with 100 denier textured polyester yarn having a yarn number
of 4s and count of 14.times.16 per inch, and the process yields an
approximate 65% reduction in air permeability in the fabric.
18. An enhanced woven acrylic fabric .Iadd.enhanced over the fabric
before treatment and .Iaddend.made by the method of claim 6,
wherein the fabric includes 3 denier, 1.5 inch acrylic fiber,
open-end cotton spun warp yarn having a yarn number of 9s, 28 ends
per inch, and a 3 denier, 3 inch acrylic fiber, hollow wrap spun
fill yarn, 6 twists per inch having a number of 4s, 16 picks per
inch, and the process yields an approximate 48% reduction in air
permeability in the fabric.
19. An enhanced woven acrylic fabric .Iadd.enhanced over the fabric
before treatment and .Iaddend.made by the method of claim 6,
wherein the fabric includes 3 denier, 1.5 inch acrylic fiber,
open-end wool spun warp yarn having a yarn number of 4s, 14 ends
per inch, and a 3 denier, 3 inch acrylic fiber, open-end wool spun
fill yarn having a yarn number of 2.6s, 16 picks per inch, and the
process yields an approximate 48% reduction in air permeability in
the fabric.
20. An enhanced woven .Iadd.fabric enhanced over the fabric before
treatment .Iaddend.and made by the method of claim 6, wherein the
fabric includes 80% wool/20% nylon in a 2.times.1 twill weave, and
the process yields an approximate 49.5% reduction in air
permeability in the fabric.
21. An enhanced 53% polyester/47% cotton fabric .Iadd.enhanced over
the fabric before treatment and .Iaddend.made by the method of
claim 6, wherein the fabric includes a 3.times.1 twill weave, a
thread count of 120 ends.times.38 picks, and the process yields an
approximate 50.6% reduction in air permeability in the fabric.
22. An enhanced 50% polyester/50% cotton doubleknit fabric
.Iadd.enhanced over the fabric before treatment and .Iaddend.made
by the method of claim 6, wherein the fabric includes wrap spun
yarn with 100 denier polyester wrap, and the process yields an
approximate 16% reduction in air permeability in the fabric.
23. .[.An enhanced.]. .Iadd.A uniformly finished .Iaddend.woven or
knit textile fabric .[.which comprises:.]. .Iadd.comprising either
or both of .Iaddend.spun .[.and/or.]. .Iadd.and .Iaddend.spun
filament yarns which intersect at cross-over points to define
interstitial open areas, .Iadd.said yarns defining a top and bottom
surface, .Iaddend. said yarns including fibers having deniers and
lengths in the range of 0.3 to 16.0 and 0.5 to 8 inches,
respectively, wherein .Iadd.said fiber of .Iaddend.said yarns are
fluid entangled in said interstitial open areas.Iadd., at least in
a plane between said surfaces of said fabric, .Iaddend.by
application of .Iadd.a continuous curtain of non-compressible
.Iaddend.fluid energy in the range of 0.1 to 2.0 hp-hr/lb.
24. An enhanced woven or knit textile fabric according to claim 23,
wherein the yarn is cotton spun.
25. An enhanced woven or knit textile fabric according to claim 23,
wherein the yarn is wrap spun.
26. An enhanced woven or knit textile fabric according to claim 23,
wherein the yarn is wool spun.
27. A method for hydrobonding woven or knit fabric materials to
form a composite textile fabric, the fabric including .Iadd.either
or both of .Iaddend.spun .[.and/or.]. .Iadd.and .Iaddend.spun
filament yarns in a structured pattern including yarns which
intersect at cross-over points, the method comprising the steps of:
napping first and second surfaces of the fabric to raise surface
fibers thereof, arranging said first and second surfaces in
opposing and overlying layered relation, supporting the layered
fabric on a support member, and traversing one side of said layered
fabric with a first continuous curtain of fluid for sufficient
duration to effect entanglement of said raised surface fibers in
said first and second surfaces, said curtain of fluid impacting the
fabric with an energy in the range .Iadd.of .Iaddend.0.1 .[.and.].
.Iadd.to .Iaddend.2.0 hp-hr/lb.
28. The method of claim 27, wherein said fluid curtain is provided
by columnar fluid jet orifices having a diameter of approximately
0.005 inches and center-to-center spacing of approximately 0.017
inches, said fluid curtain impinging the fabric with fluids at
pressure of approximately 1500 psi.
29. The method of claim 28, wherein said support member includes a
pattern of closely spaced fluid pervious open areas aligned in a
first direction to effect fluid passage through said support
member.
30. The method of claim 29 wherein said open areas occupy
approximately 17 to 40% of said support member.
31. The method of claim 27, comprising the further steps of:
supporting said layered fabric on a second support member, and
traversing the other side of said layered fabric in a second
entanglement stage with a second continuous fluid curtain to effect
a uniform composite fabric bond and finish, said second
entanglement stage impacting the layered fabric with an energy in
the range .Iadd.of .Iaddend.0.1 .[.and.]. .Iadd.to .Iaddend.2.0
hp-hr/lb.
32. The method of claim 31, wherein: said first and second fluid
curtains are provided by columnar fluid jets having a diameter of
approximately 0.005 inches and center-to-center spacing of
approximately 0.017 inches, said fluid jets impinging the fabric
with fluids at pressure of approximately 1500 psi, said first and
second support members each include a pattern of closely spaced
fluid pervious open areas, respectively aligned in first and second
directions, said open areas being dimensioned to effect fluid
passage through said support members without imparting a patterned
effect to the fabric.
33. An enhanced composite woven or knit textile fabric .[.which
comprises.]. .Iadd.which is enhanced by the bonding together of at
least two fabric layers, the fabric comprising.Iaddend.: at least
two fabric layers which each include .Iadd.either or both of
.Iaddend.spun .[.and/or.]. .Iadd.and .Iaddend.spun filament yarns
in a structured pattern of yarns which intersect at cross-over
points, said fabric layers including first and second napped
surfaces which have raised surface fibers, said napped surfaces
being arranged in overlying and opposed relation and bonded
together by dynamic fluid energy through entanglement of said
raised surface fibers in said first and second surfaces.
34. An apparatus for enhancing .Iadd.woven and knit fabric over the
fabric before treatment .Iaddend.and .Iadd.for .Iaddend.finishing
woven and knit fabric.Iadd., the fabric .Iaddend.including
.Iadd.either or both of .Iaddend.spun .[.and/or.]. .Iadd.and
.Iaddend.spun filament yarn.Iadd., .Iaddend.by impacting the fabric
with pressurized fluid jets, the fabric including yarns which
intersect at cross-over points, and first and second sides, the
apparatus comprising: conveyor means for conveying the fabric in a
machine direction ("MD") through a production line including a
first enhancing station, said conveying means supporting a first
support member which underlies the fabric in said enhancing
station; curtain means spaced from said first support member for
directing a .Iadd.continuous .Iaddend.curtain of
.Iadd.non-compressible .Iaddend.fluid onto .[.the.]. .Iadd.a
.Iaddend.first side of the fabric, said curtain means including a
plurality of densely spaced .Iadd.jet .Iaddend.orifices which eject
high pressure fluid .[.jets.]. ; said curtain means coacting with
said first support member.Iadd., and impacting the fabric with a
cumulative energy in the range of 0.1 to 2.0 hp-hr/lb, .Iaddend.to
entangle fabric yarns at .[.the.]. .Iadd.their .Iaddend.cross-over
points, .[.enhancing.]. .Iadd.enhance .Iaddend.fabric cover and
.[.imparting.]. .Iadd.impart .Iaddend.a uniform finish to the
fabric.
35. An apparatus as set forth in claim 34, wherein said fluid
orifices have a columnar configuration, a diameter of approximately
0.005 inches and center-to-center spacing of approximately 0.17
inches, and impart energy to the fabric of approximately 0.1 to 2.0
hp-hr/lb.
36. An apparatus as set forth in claim 35, wherein said fluid jets
have a spray pressure of approximately 1500 psi.
37. An apparatus as set forth in claim 34, further comprising a
second enhancing station, a second support member which underlies
the fabric and is supported for movement on the production line by
said conveyor means, and a second curtain means spaced from said
second support member for directing a .Iadd.continuous
.Iaddend.curtain of .Iadd.non-compressible .Iaddend.fluid onto the
second side of the fabric, said second curtain means including a
second plurality of densely spaced .Iadd.jet .Iaddend.orifices
which eject high pressure fluid .[.jets.]. , thereby further
enhancing the fabric.
.[.38. An apparatus as set forth in claim 37, wherein said first
and second fluid curtains respectively impart energy to the fabric
of approximately 0.1 to 2.0 hp-hr/lb..].
39. An apparatus as set forth in claim .[.38.]. .Iadd.37.Iaddend.,
wherein said .Iadd.first and .Iaddend.second support .[.member
is.]. .Iadd.members are .Iaddend.fluid pervious and .[.has.].
.Iadd.have .Iaddend.open areas aligned on a bias relative to the
machine direction of the line.
40. An apparatus as set forth in claim 39, wherein said first and
second curtain means are spaced approximately 0.5 inches from said
first and second support members, said fluid jets have a spray
pressure of approximately 1500 psi, and conveyor means speed is
approximately 100 fpm.
41. An apparatus as set forth in claim 40, wherein said first and
second support members respectively have generally flat and
cylindrical configurations.
42. .Iadd.A method for uniformly finishing woven or knitted textile
fabrics including either or both of spun and spun filament yarns
which intersect at cross-over points, and first and second sides,
the method comprising the steps of: supporting the fabric on a
support member, the fabric including yarn fibers having deniers and
lengths in the range of 0.3 to 16.0 and 0.5 to 8 inches,
respectively, and yarn counts in the range of 0.5s to 80s;
conveying the supported fabric in a machine direction; traversing
the conveyed fabric on at least a first side with a proximate
stationary array of closely and uniformly spaced liquid jets
aligned in a cross-direction relative to the machine direction and
emanating from orifices, each having an axis substantially
perpendicular to the fabric; selecting conveying speed, jet
pressure, and the diameter and center-to-center spacing of the
orifices, as a function of fabric type and weight, to impact the
fabric with a cumulative energy of 0.1 to 2.0 hp-hr/lb in order to
effect entanglement of yarns at cross-over points and to provide a
uniformly finished fabric; and drying the fabric. .Iaddend.
.Iadd.43. A method according to claim 42, wherein conveying speed
is approximately 100 fpm, jet pressure is approximately 1500 psi,
and the jets are columnar and have diameters and center-to-center
spacings of approximately 0.005 inches and approximately 0.034
inches respectively. .Iaddend.
.Iadd.44. A method according to claim 43, wherein the jets are
approximately 0.5 inches from the support member. .Iaddend.
.Iadd.45. A method according to claim 42, wherein the support
member is liquid pervious and includes open areas of 17-40% and has
a fine mesh pattern which permits fluid passage without imparting a
patterned effect to the fabric. .Iaddend.
.Iadd.46. A method according to claim 45, wherein the support
includes a fine mesh screen arranged in offset relation to the
machine direction. .Iaddend.
.Iadd.47. A method according to any of claims 42-46, wherein the
fabric is treated on both sides. .Iaddend.
.Iadd.48. A method according to any of claims 42-46, wherein the
array of jets is provided by a plurality of parallel manifolds
spaced approximately 8 inches apart. .Iaddend.
.Iadd.49. A method according to claim 42, wherein the pressure is
approximately 1500 psi, the jet diameter is approximately 0.005
inches, the center-to-center spacing of the jets provides
approximately 60 jets per inch, and the fabric is impacted with a
cumulative energy of approximately 0.46 hp-hr/lb. .Iaddend.
.Iadd.50. A method according to any of claims 42-46, wherein the
fabric includes low denier, short length fibers and loosely twisted
yarns. .Iaddend.
.Iadd.51. An apparatus for uniformly enhancing and finishing woven
or knitted textile fabrics of either or both of spun and spun
filament yarns by impacting the fabric with pressurized fluid jets,
the fabric including yarns which intersect at cross-over points,
and first and second sides, the apparatus comprising: a fabric
support member underlying the fabric; means for conveying the
supported fabric in a machine direction through a production line
including a first enhancing station; means for impacting the
conveyed fabric on at least one side thereof with a proximate
stationary array of closely and uniformly linearly spaced high
pressure liquid jets aligned in a cross-direction relative to the
machine direction and emanating from orifices, each having an axis
substantially perpendicular to the fabric forming a curtain, the
liquid jets spaced from the support member; wherein the conveying
speed, jet pressure, and the diameter and center-to-center spacing
of the jet orifices are selected as a function of fabric type and
weight, to impact the fabric with a cumulative energy of 0.1 to 2.0
hp-hr/lb through coaction with the support member to entangle
fabric yarns at cross-over points, enhance fabric cover, and impart
an enhanced and uniform finish to the fabric. .Iaddend.
.Iadd.52. An apparatus according to claim 51, wherein the conveyor
speed is approximately 100 fpm, jet pressure is approximately 1500
psi, and the jets are columnar and have diameters and
center-to-center spacings of approximately 0.005 inches and
approximately 0.017 inches respectively. .Iaddend.
.Iadd.53. An apparatus according to claim 52, wherein the jets are
approximately 0.5 inches from the support member. .Iaddend.
.Iadd.54. An apparatus according to claim 51, wherein the support
member is liquid pervious and includes open areas of 17-40% and has
a fine mesh pattern which permits fluid passage without imparting a
patterned effect to the fabric. .Iaddend.
.Iadd.55. An apparatus according to claim 54, wherein the support
includes a fine mesh screen arranged in offset relation to the
machine direction. .Iaddend.
.Iadd.56. An apparatus according to any of claims 51-55, wherein
the fabric is treated on both sides. .Iaddend.
.Iadd.57. An apparatus according to any of claims 51-55, wherein
the array of jets is provided by a plurality of parallel manifolds
spaced approximately 8 inches apart. .Iaddend.
.Iadd.58. An apparatus according to claim 51, wherein the pressure
is approximately 1500 psi, the jet diameter is approximately 0.005
inches, the center-to-center spacing of the jets provides
approximately 60 jets per inch, and the fabric is impacted with a
cumulative energy of approximately 0.46 hp-hr/lb. .Iaddend.
.Iadd.59. An apparatus according to any of claims 51-55, wherein
the fabric includes low denier, short length fibers and loosely
twisted yarns. .Iaddend.
.Iadd.60. An apparatus for uniformly enhancing and finishing woven
or knitted textile fabrics of either or both of spun and spun
filament yarns by impacting the fabrics with pressurized fluid
jets, the fabric including yarns which intersect at cross-over
points, and first and second sides, the apparatus comprising: a
fabric support member underlying the fabric; a conveyor for moving
the supported fabric in a machine direction through a production
line including a first enhancing station; a plurality of stationary
parallel manifolds aligned in a cross-direction relative to the
machine direction, each of said plurality of stationary parallel
manifolds having a plurality of densely spaced high pressure liquid
jets spaced from and directed substantially perpendicular to the
fabric for forming a curtain; wherein conveyor speed, and the
pressure, diameter and center-to-center spacing of the manifold
jets are selected as a function of fabric type and weight, to
impact one side of the fabric with a cumulative energy of 0.1 to
2.0 hp-hr/lb through coaction with the support member to entangle
fabric yarns at cross-over points, enhance fabric cover, and impart
an enhanced and uniform finish to the fabric. .Iaddend.
.Iadd.61. An apparatus according to claim 60, wherein the conveyor
speed is approximately 100 fpm, jet pressure is approximately 1500
psi, and the jets are columnar and have diameters and
center-to-center spacings of approximately 0.005 inches and
approximately 0.017 inches respectively. .Iaddend.
.Iadd.62. An apparatus according to claim 61, wherein the jets are
approximately 0.5 inches from the support member. .Iaddend.
.Iadd.63. An apparatus according to claim 60, wherein the support
member is liquid pervious and includes open areas of 17-40% and has
a fine mesh pattern which permits fluid passage without imparting a
patterned effect to the fabric. .Iaddend.
.Iadd.64. An apparatus according to claim 63, wherein the support
includes a fine mesh screen arranged in offset relation to the
machine direction. .Iaddend.
.Iadd.65. An apparatus according to any of claims 60-64, wherein
the fabric is treated on both sides. .Iaddend.
.Iadd.66. An apparatus according to claim 60, wherein the pressure
is approximately 1500 psi, the jets are columnar and have a
diameter of approximately 0.005 inches, with center-to-center
spacing which provides approximately 60 jets per inch, and wherein
the fabric is impacted with a cumulative energy of approximately
0.46 hp-hr/lb..Iaddend.
.Iadd.67. An apparatus according to any of claims 60-64, wherein
the fabric includes low denier, short length fibers and loosely
twisted yarns. .Iaddend.
.Iadd.68. A uniformly enhanced woven or knitted textile fabric made
according to claim 42, wherein the fabric yarns are bloomed and
entangled at cross-over points defined by intersecting warp and
fill yarns of the fabric, thereby filling interstitial open areas
between adjacent yarns. .Iaddend.
.Iadd.69. A uniformly enhanced fabric according to claim 68,
wherein the fabric includes low denier, short length fibers and
loosely twisted yarns. .Iaddend.
.Iadd.70. A uniformly enhanced woven or knit textile fabric
comprising either or both of spun and spun filament yarns which
intersect at cross-over points to define interstitial open areas,
the yarns including fibers having deniers and lengths in the range
of 0.3 to 16.0 and 0.5 to 8 inches, respectively, wherein the yarns
are uniformly bulked, entangled in the interstitial open areas, and
bloomed by an array of densely packed liquid jets which deliver
from 0.1 to 2.0 hp-hr/lb of energy, and the enhanced fabric
demonstrates a substantial improvement in at least two of air
permeability, abrasion resistance, tensile strength, edge fray,
seam slippage, wrinkle recovery, torque resistance, and fabric
weight. .Iaddend.
.Iadd.71. A uniformly enhanced fabric according to claim 70, made
from loosely twisted yarns. .Iaddend.
Description
FIELD OF INVENTION
This invention generally relates to a textile finishing process for
upgrading the quality of woven and knit fabrics. More particularly,
it is concerned with a hydroentangling process which enhances woven
and knit fabrics through use of dynamic fluid jets to entangle and
cause fabric yarns to bloom. Fabrics produced by the method of the
invention have enhanced surface finish and improved characteristics
such as cover, abrasion resistance, drape, stability as well as
reduced air permeability, wrinkle recovery, seam slippage, and edge
fray.
BACKGROUND ART
The quality of a woven or knit fabric can be measured by various
properties, such as, the yarn count, thread count, abrasion
resistance, cover, weight, yarn bulk, yarn bloom, torque
resistance, wrinkle recovery, drape and hand.
Yarn count is the numerical designation given to indicate yarn size
and is the relationship of length to weight.
Thread count is woven or knit fabrics, respectively, defines the
number ends and picks, and wales and courses per inch of fabric.
For example, the count of cloth is indicated by enumerating first
the number of warp ends per inch, then the number of filling picks
per inch. Thus, 68.times.72 defines a fabric having 68 warp ends
and 72 filling picks per inch.
Abrasion resistance is the ability of a fabric to withstand loss of
appearance, utility, pile or surface through destructive action of
surface wear and rubbing.
Cover is the degree to which underlying structure in a fabric is
concealed by surface material. A measure of cover is provided by
fabric air permeability, that is, the ease with which air passes
through the fabric Permeability measures fundamental fabric
qualities and characteristics such as filtration and cover.
Yarn bloom is a measure of the opening and spread of filters in
yarn.
Fabric weight is measured in weight per unit area, for example, the
number of ounces per square yard.
Torque of fabric refers to that characteristic which tends to make
it turn on itself as a result of twisting. It is desirable to
remove or diminish torque in fabrics. For example, fabrics used in
vertical blinds should have no torque, since such torque will make
the fabric twist when hanging in a strip.
Wrinkle recovery is the property of a fabric which enables it to
recover from folding deformations.
Hand refers to tactile fabric properties such as softness and
drapability.
It is known in the prior art to employ hydroentangling processes in
the production of nonwoven materials. In conventional
hydroentangling processes, webs of nonwoven fibers are treated with
high pressure fluids while supported on apertured patterning
screens. Typically, the patterning screen is provided on a drum or
continuous planar conveyor which traverses pressurized fluid jets
to entangle the web into cohesive ordered fiber groups and
configurations corresponding to open areas in the screen.
Entanglement is effected by action of the fluid jets which cause
fibers in the web to migrate to open areas in the screen, entangle
and intertwine.
Prior art hydroentangling processes for producing patterned
nonwoven fabrics are represented by U.S. Pat. Nos. 3,485,706 and
3,498,874, respectively, to Evans and Evans et al., and U.S. Pat.
Nos. 3,873,255 and 3,917,785 to Kalwaites.
Hydroentangling technology has also been employed by the art to
enhance woven and knit fabrics. In such applications warp and pick
fibers in fabrics are hydroentangled at crossover points to effect
enhancement in fabric cover. However, conventional processes have
not proved entirely satisfactory in yielding uniform fabric
enhancement. The art has also failed to develop apparatus and
process line technology which achieves production line
efficiencies.
Australian Patent Specification 287821 to Bunting et al. is
representative of the state of the art. Bunting impacts high speed
columnar fluid streams on fabrics supported on course porous
members. Preferred parameters employed in the Bunting process,
described in the Specification Example Nos. XV-XVII, include 20 and
30 mesh support screens, fluid pressure of 1500 psi, and jet
orifices having 0.007 inch diameters on 0.050 inch centers. Fabrics
are processed employing multiple hydroentangling passes in which
the fabric is reoriented on a bias direction with respect to the
process direction in order to effect uniform entanglement. Data set
forth in the Examples evidences a modest enhancement in fabric
cover and stability.
Another approach of art is represented by European Patent
Application No. 0 177 277 to Willbanks et al. which is directed to
hydropatterning technology. Willbanks impinges high velocity fluids
onto woven, knitted and bonded fabrics for decorative effects.
Patterning is effected by redistributing yarn tension within the
fabric - yarns are selectively compacted, loosened and opened - to
impart relief structure to the fabric.
Fabric enhancement of limited extent is obtained in Willbanks as a
secondary product of the patterning process. However, Willbanks
fails to suggest or teach a hydroentangling process that can be
employed to uniformly enhance fabric characteristics. See Willbanks
Example 4, page 40.
There is a need in the art for an improved woven textile
hydroenhancing process which is commercially viable. It will be
appreciated that fabric enhancement offers aesthetic and functional
advantages which have application in a wide diversity of fabrics.
Hydroenhancement improves fabric cover through dynamic fluid
entanglement and bulking of fabric yarns for improved fabric
stability. These results are advantageously obtained without
requirement of conventional fabric finishing processes.
The art also requires apparatus of uncomplex design for
hydroenhancing textile materials. Commercial production requires
apparatus for continuous fabric hydroenhancing and in-line drying
of such fabrics under controlled conditions to yield fabrics of
uniform specifications.
Accordingly, it is a broad object of the invention to provide an
improved textile hydroenhancing process and related apparatus for
production of a variety of novel woven and knit fabrics having
improved characteristics which advance the art.
A more specific object of the invention is to provide is
hydroenhancing process for enhancement of fabrics made of spun and
spun/filament yarn.
Another object of the invention is to provide a hydroenhancing
process having application for the fabrication of novel composite
and layered fabrics.
A further object of the invention is to provide a hydroenhancing
production line apparatus which is less complex and improved over
the prior art.
DISCLOSURE OF THE INVENTION
In the present invention, these purposes, as well as others which
will be apparent, are achieved generally by providing an apparatus
and a related method for hydroenhancing woven and knit fabrics
through dynamic fluid action. A hydroenhancing module is employed
in the invention in which the fabric is supported on a member and
impacted with a fluid curtain under controlled process energies.
Enhancement of the fabric is effected by entanglement and
intertwining of yarn fibers at cross-over points in the fabric
weave or knit. Fabrics enhanced in accordance with the invention
have a uniform finish and improved characteristics, such as, edge
fray, drape, stability, wrinkle recovery, abrasion resistance,
fabric weight and thickness.
According to the preferred method of the invention, the woven or
knit fabric is advanced on a process line through a weft
straightener to two in-line fluid modules for first and second
stage fabric enhancement. Top and bottom sides of the fabric are
respectively supported on members in the modules and impacted by
fluid curtains to impart a uniform finish to the fabric. Preferred
support members are fluid pervious, include open areas of
approximately 25%, and have fine mesh patterns which permit fluid
passage without imparting a patterned effect to the fabric. It is a
feature of the invention to employ support members in the modules
which include fine mesh patterned screens which are arranged in
offset relation with respect to the process line. This offset
orientation limits fluid streaks and eliminates reed marking in
processed fabrics.
First and second stage enhancement is preferably effected by
columnar fluid jets which impact the fabric at pressures within the
range of 200 to 3000 psi and impart a total energy to the fabric of
approximately 0.10 to 2.0 hp-hr/lb.
Following enhancement, the fabric is advanced to a tenter frame
which dries the fabric to a specified width under tension to
produce a uniform fabric finish.
Advantage in the invention apparatus is obtained by provision of a
continuous process line of uncomplex design. The first and second
enhancement stations include a plurality of cross-directionally
("CD") aligned and spaced manifolds. Columnar jet nozzles having
orifice diameters of approximately 0.005 inches with
center-to-center spacings of approximately 0.017 inches are mounted
approximately 0.5 inches from the screens. At the process energies
of the invention, this spacing arrangement provides a curtain of
fluid which yields a uniform fabric enhancement. Use of fluid
pervious support members which are oriented in offset relation,
preferably 45.degree., effectively limits jet streaks and
eliminates reed markings in processed fabrics.
Optimum fabric enhancement results are obtained in fabrics woven or
knit of yarns including fibers with deniers and staple lengths in
the range of 0.5 to 6.0, and 0.5 to 5 inches, respectively, and
yarn counts in the range of 0.5s to 50s. Preferred yarn spinning
systems of the invention fabrics include cotton spun, wrap spun,
wool spun and friction spun.
Other objects, features and advantages of the present invention
will be apparent when the detailed description of the preferred
embodiments of the invention are considered in conjunction with the
drawings which should be construed in an illustrative and not
limiting sense as follows:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a production line including a weft
straightener, flat and drum hydroenhancing modules, and tenter
frame, for the hydroenhancement of woven and knit fabrics in
accordance with the invention;
FIGS. 2A and B are photographs at 10.times. magnification of
36.times.29 90.degree. and 40.times.40 45.degree. mesh plain weave
support members, respectively, employed in the flat and drum
enhancing modules of FIG. 1;
FIGS. 3A and B are photomicrographs at 10.times. magnification of a
fine polyester woven fabric before and after hydroenhancement in
accordance with the invention;
FIGS. 4A and B are photomicrographs at 16.times. magnification of
the control and processed fabric of FIGS. 3A and B;
FIGS. 5A and B are photomicrographs at 10.times. magnification of a
control and hydroenhanced woven acrylic fabric;
FIGS. 6A and B are photomicrographs at 10.times. magnification of a
control and hydroenhanced acrylic fabric woven of wrap spun
yarn;
FIGS. 7A and B are photomicrographs at 10.times. magnification of a
control and hydroenhanced acrylic fabric woven of wrap spun
yarn;
FIGS. 8A and B are photomicrographs at 10.times. magnification of a
control and hydroenhanced acrylic fabric including open end wool
spun yarn;
FIGS. 9A and B are photomicrographs at 16.times. magnification of a
control and hydroenhanced wool nylon (80/20%) fabric;
FIGS. 10A and B are photomicrographs at 16.times. magnification of
a control and hydroenhanced spun/filament polyester/cotton twill
fabric;
FIGS. 11A and B are photomicrographs at 16.times. magnification of
a control and hydroenhanced doubleknit fabric;
FIGS. 12A and B are front and back side photomicrographs at
16.times. magnification of a control wall covering fabric;
FIGS. 13A and B are front and back side photomicrographs at
16.times. magnification of the wall covering fabric of FIGS. 12A
and B hydroenhanced in accordance with the invention;
FIG. 14 is a photomacrograph at 0.09.times. magnification of a
control and hydroenhanced acrylic fabric strips, the fabric of
FIGS. 7A and B, showing the reduction in fabric torque achieved in
the invention process;
FIGS. 15A-C are photomacrographs at 0.23.times. magnification,
respectively, of the woven acrylic fabrics of FIGS. 5, 7 and 8,
comprised of wrap spun and open end wool spun yarns, showing
washability and wrinkle characteristics of control and processed
fabrics;
FIG. 16 is a schematic view of an alternative production line
apparatus for the hydroenhancement of woven and knit fabrics in
accordance with the invention; and
FIG. 17 illustrates a composite fabric including napped fabric
components which are bonded into an integral structure employing
the hydroenhancing process of the invention.
BEST MODE OF CARRYING OUT THE INVENTION
With further reference to the drawings, FIG. 1 illustrates a
preferred embodiment of a production line of the invention,
generally designated 10, for hydroenhancement of a fabric 12
including spun and/or spun/filament yarns. The line includes a
conventional weft straightener 14, and drum enhancing modules 16,
18, and a tenter frame 20.
Modules 16, 18 effect two sided enhancement of the fabric through
fluid entanglement and bulking of fabric yarns. Such entanglement
is imparted to the fabric in areas of yarn crossover or
intersection. Control of process energies and provision of a
uniform curtain of fluid produces fabrics having a uniform finish
and improved characteristics including, edge fray, torque, wrinkle
recovery, cupping, drape, stability, abrasion resistance, fabric
weight and thickness.
METHOD AND MECHANISM OF THE ENHANCING MODULES
Fabric is advanced through the weft straightener 14 which aligns
the fabric weft prior to processing in enhancement modules 16, 18.
Following the hydroenhancement, the fabric is advanced to the
tenter frame 20, which is of conventional design, where it is dried
under tension to produce a uniform fabric or specified width.
Module 16 includes a first support member 22 which is supported on
an endless conveyor means including rollers 24 and drive means (not
shown) for rotation of the rollers. Preferred line speeds for the
conveyor are in the range of 10 to 500 ft/min. Line speeds are
adjusted in accordance with process energy requirements which vary
as a function of fabric type and weight.
Support member 22, which preferably has a flat configuration,
includes closely spaced fluid pervious open areas 26. A preferred
support member 22, shown in FIG. 2A, is a 36.times.29 90.degree.
mesh plain weave having a 23.7% open area, fabricated of polyester
warp and shute round wire. Support member 22 is a tight seamless
weave which is not subject to angular displacement or snag.
Specifications for the screen, which is manufactured by Albany
International, Appleton Wire Division, P.O. Box 1939, Appleton,
Wis. 54913 are set forth in Table I.
TABLE-US-00001 TABLE I Support Screen Specifications Property 36
.times. 29 90.degree. flat mesh 40 .times. 40 45.degree. drum mesh
Wire polyester stainless steel Warp wire .0157 0.010 Shute wire
.0157 0.010 Weave type plain plain Open area 23.7% 36%
Module 16 also includes an arrangement of parallel and spaced
manifolds 30 oriented in a cross-direction ("CD") relative to
movement of the fabric 12. The manifolds which are spaced
approximately 8 inches apart each include a plurality of closely
aligned and spaced columnar jet orifices 32 which are spaced
approximately 0.5 inches from the support member 22.
The jet orifices have diameters and center-to-center spacings in
the range of 0.005 to 0.010 inches and 0.017 to 0.034 inches,
respectively, and are designed to impact the fabric with fluid
pressures in the range of 200 to 3000 psi. Preferred orifices have
diameters of approximately 0.005 inches with center-to-center
spacings of approximately 0.017 inches.
This arrangement of fluid jets provides a curtain of fluid
entangling streams which yield optimum enhancement in the fabric.
Energy input to the fabric is cumulative along the line and
preferably set at approximately the same level in modules 16, 18
(two stage system) to impart uniform enhancement to top and bottom
surfaces of the fabric. Effective first stage enhancement of fabric
yarn is achieved at an energy output of at least 0.05 hp-hr/lb and
preferably in the range of 0.1 to 2.0 hp-hr/lb.
Following the first stage enhancement, the fabric is advanced to
module 18 which enhances the other side of the fabric. Module 18
includes a second support member 34 of cylindrical configuration
which is supported on a drum. The member 34 includes closely spaced
fluid pervious open areas 36 which comprise approximately 36% of
the screen area. A preferred support member 34, shown in FIG. 2B,
is a 40.times.40 45.degree. mesh stainless steel screen,
manufactured by Appleton Wire, having the specifications set forth
in Table I.
Module 18 functions in the same manner as the planar module 16.
Manifolds 30 and jet orifices 32 are provided which have
substantially the same specifications as in the first stage
enhancement module. First energy to the fabric of at least 0.5
hp-hr/lb and preferably in the range of 0.1 to 2.0 hp-hr/lb effects
second stage enhancement.
Conventional weaving processes impart reed marks to fabrics.
Illustrations of such markings are shown in FIGS. 3A and 4A which
are photomicrographs at 10.times. and 16.times. magnification of a
polyester LIBBEY brand fabric style no. S/x-A805 (see Table II).
Reed marks in FIGS. 3A and 4A are designated by the letter "R".
The invention overcomes this defect in conventional weaving
processes through use of a single and preferably two stage
hydroenhancement process. Advantage is obtained in the invention
process by orienting the drum support member 34 in offset relation,
preferably 45.degree., relative to machine direction ("MD") of the
hydroenhancing line. See FIGS. 2A and B.
Support members 22 and 34 are preferably provided with fine mesh
open areas which are dimensioned to effect fluid passage through
the members without imparting a patterned effect to the fabric. The
preferred members have an effective open area for fluid passage in
the range of 17-40%.
Comparison of the control and processed polyester fabric of FIGS.
3A, B and 4A, B illustrates the advantages obtained through use of
the enhancement process. Reed marks R in control polyester fabric
are essentially eliminated through enhancement of the fabric. The
offset screen arrangement is also effective in diminishing linear
jet streak markings associated with the enhancement process.
EXAMPLES I-XIII
FIGS. 3-15 illustrate representative woven and knit fabrics
enhanced in accordance with the method of the invention, employing
test conditions which simulate the line of FIG. 1. Table II sets
forth specifications for the fabrics illustrated in the
drawings.
As in the FIG. 1 line, the test manifolds 30 were spaced
approximately 8 inches apart in modules 16, 18, and provided with
densely packed columnar jet orifices 32 of approximately 60/inch.
Orifices 32 each had a diameter of 0.005 inches and were spaced
approximately 0.5 inches from the first and second support members
22, 34.
The process line of FIG. 1 includes enhancement modules 16, 18
which, respectively, are provided with six manifolds. In the
Examples, modules 16, 18 were each fitted with two manifolds 34. To
simulate line conditions, the fabrics were advanced through
multiple runs on the line. Three processing runs in each two
manifold module was deemed to be equivalent to a six manifold
module.
Fabrics were hydroenhanced at process pressures of approximately
1500 psi. Line speed and cumulative energy output of the modules
were respectively maintained at approximately 30 fpm and 0.46
hp-hr/lb. Adjustments in the line speed and fluid pressure were
made to accommodate differences in fabric weight for uniform
processing and to maintain the preferred energy level.
Fabrics processed in the Examples exhibited marked enhancement in
aesthetic appearance and quality including, characteristics such as
cover, bloom, abrasion resistance, drape, stability, and reduction
in seam slippage, and edge fray.
Tables III-XI set forth data for fabrics enhanced in accordance
with invention on the test process line. Standard testing
procedures of The American Society for Testing and Materials (ASTM)
were employed to test control and processed characteristics of
fabrics. Data set forth in the Tables was generated in accordance
with the following ASTM standards:
TABLE-US-00002 Fabric Characteristic ASTM Standard Weight D3776-79
Thickness D1777-64 (Ames Tester) Tensile Load D1682-64 (1975) (Cut
strip/grab) Elongation D1682-64 (1975) Air Permeability D737-75
(1980) (Frazier) Thread Count D3775-79 Ball Burst D3787-80A Seam
Slippage D4159-82 Tongue Tear D2261-71 Wrinkle Recovery D1295-67
(1972) Abrasion Resistance D3884-80 Pilling D3514-81
Washability tests were conducted in accordance with the following
procedure. Weight measurements ("before wash") were taken of
control and processed fabric samples each having a dimension of
8.5.times.11'' (8.5'' fill direction and 11'' warp direction). The
samples were then washed and dried in conventional washer and
dryers three consecutive times and "after wash" measurements were
taken. The percent weight loss of the pre and post wash samples was
determined in accordance the following formula: % weight
loss=D/B.times.100 where, B=before wash sample weight; A=after wash
sample weight; and D=B-A.
Photomicrographs of the fabrics, FIGS. 4-15, illustrate the
enhancement in fabric cover obtained in the invention. Attention is
directed to open areas in the unprocessed fabrics, photographs
designated A, these areas are of reduced size in the processed
fabrics in the photographs designated B. Hydroenhancement caused
fabric yarns to bloom and entangle at cross-over points, filling in
open areas to improve cover and reduce air permeability in the
fabrics.
FIGS. 12 and 13 are photomicrographs of a HYTEX brand wall covering
fabric, manufactured by Hytex, Inc., Randolph, Mass. A
multi-textured surface appearance of the fabric is provided by
yarns which are woven through discrete areas of the front fabric
surface. Free floating weave stitches, designated by the letter "S"
in FIGS. 12B and 13B, are formed on the backside of the fabric.
Hydroenhancement of HYTEX wall covering fabric secured the
free-floating stitches S to the fabric backside enhancing fabric
stability and cover. See FIGS. 12B, 13B. In wall covering
applications, fabric enhancement and associated stabilizing effects
reduces or eliminates the need for adhesive backcoatings.
Enhancement of the fabric also limits wicking of wall cover
application adhesives through the fabric. Further advantage is
obtained when enhanced fabrics are used in acoustic applications;
elimination of backcoating reduces sound reflection and furthers
efficient transmission of sound through the fabric.
TABLE-US-00003 TABLE II Fabric Specifications Fiber Brand and Style
Designation Figure (s) NOMEX S/x-A805* 3 A,B, 4 A,B Fiber: 2 denier
- 1.9 inch Yarn: Open end cotton spun 17s LIBBEY S/022** 5 A,B
Warp: Fiber: 3 denier - 1.5 inch acrylic Yarn: Open end cotton spun
9s 28 ends per inch Fill: Fiber: 3 denier - 3 inch acrylic Yarn:
Open end wool spun 4s 14, 16 or 18 picks per inch LIBBEY S/x-1160 6
A,B Fiber: 3 denier - 3 inch acrylic Yarn: Wrap spun w/100 den
textured polyester 4s 14 ends .times. 16 picks per inch LIBBEY
S/406 7 A,B, 14 A,B Warp: Fiber: 3 denier - 1.5 inch acrylic Yarn:
Open end cotton spun 9s 28 ends per inch Fill: Fiber: 3 denier - 3
inch acrylic Yarn: Hollow spun 6 twists/inch 4s 14, 16 or 18 picks
per inch LIBBEY S/152 8 A,B Warp: Fiber: 3 denier - 2.5 inch
acrylic Yarn: Open end cotton spun 4s 14 ends per inch Fill: Fiber:
3 denier - 3 inch acrylic Yarn: Open end wool spun 2.6s 14, 16 or
18 picks per inch Guilford Wool/Nylon 9 A,B 80% wool/20% nylon
Polyester/cotton (53/47) 10 A,B Weight: 10 ounces/yd.sup.2 Yarn:
Spun Filament Weave: 3 .times. 1 Twill Thread Count: 120 .times. 38
50% Polyester/50% cotton Doubleknit 11 A,B Yarn: warp spun with 100
denier polyester wrap HYTEX Wall covering*** 12, 13 *LIBBEY is a
trademark of W. S. Libbey Co., One Mill Street, Lewistown, ME
04240. **NOMEX is a trademark of E. I. Du Pont de Nemours and
Company, Wilmington, Del. ***HYTEX is a trademark of Hytex, Inc.
Randolph, MA.
TABLE-US-00004 TABLE III Nomex A805 - FIG. 4 Control Processed %
Chance Weight (gsy) 195 197 +1.0 Thickness (mils) 42 42 0 Air Perm.
(ft.sup.3/ft.sup.2/ 331 156 -52.9 min) Strip Tensile (lbs/in) warp
115 132 +14.8 fill 59 47 -20.3 Elongation % warp 48 50 +4.2 fill 62
71 +14.5
TABLE-US-00005 TABLE IV 022/6075 (16 ppi) - FIG. 5 Control
Processed % Change Weight (gsy) 158 165 +4.4 Thickness (mils) 48 49
+2.1 Air Perm. (ft.sup.3/ft.sup.2 406 259 -36.2 min) Strip Tensile
(lbs/in) warp 34 36 +5.9 fill 37 31 -16.2 Elongation (%) warp 33 27
-18.2 fill 27 28 +3.7 Seam Slippage (lbs/in) warp 5 60 +1100.0 fill
7 55 +685.7 Tongue Tear (lbs) warp 18 10 -44.4 fill 21 8 -61.9 Wt.
Loss In Wash (%) 37 5 -86.5 Wrinkle Recovery* 123* 138* +12.2
(recovery angle) *Under ASTM test standards (D1295-67) improvements
in the wrinkle recovery of a fabric are indicated by an increase in
the recovery angle.
TABLE-US-00006 TABLE V LIBBEY S/x-1160 - FIG. 6 Control Processed %
Change Weight (gsy) 146.8 160.2 9.1 Thickness (mils) 38.1 52.7 38.3
Air Perm. (ft.sup.3/ft.sup.2 457.2 188.5 -58.8 min) Grab Tensile
(lbs/in) warp 80.2 89.3 11.4 fill 105.0 111.4 6.1 Elongation (%)
warp 30.0 34.0 13.3 fill 32.0 46.0 43.8 Ball Burst (lbs) 190 157
-17.4
TABLE-US-00007 TABLE VI 406/6075 (16 ppi) - FIG. 7 Control
Processed % Change Weight (gsy) 159 166 +4.4 Thickness (mils) 48 50
+4.2 Air Perm. (ft.sup.3/ft.sup.2 351 184 -47.6 min) Strip Tensile
(lbs/in) warp 42 36 -14.3 fill 66 58 -12.1 Elongation (%) warp 23
31 +34.8 fill 49 33 -32.7 Seam Slippage (lbs) warp 29 36 +89.5 fill
21 76 +261.9 Tongue Tear (lbs) warp 23 18 -21.7 fill 19 15 -1.1 Wt.
Loss In Wash (%) 28 4 -85.7 Wrinkle Recovery 140* 148* +5.7
(recovery angle)
TABLE-US-00008 TABLE VII 152/6076 (16 ppi) - FIG. 8 Control
Processed % Change Weight (gsy) 231 257 +11.3 Thickness (mils) 259
238 -8.1 Air Perm. (ft.sup.3/ft.sup.2/ 204 106 -48.0 min) Strip
Tensile (lbs/in) warp 48 58 +20.8 fill 56 72 +28.6 Elongation (%)
warp 33 33 0 fill 34 39 +14.7 Seam Slippage (lbs) warp 64 81 +26.6
fill 78 112 +43.6 Tongue Tear (lbs) warp 21 18 -14.3 fill 17 15
-11.8 Wt. Loss In Wash (%) -- -- -- Wrinkle Recovery 117* 136*
+16.2 (recovery angle)
TABLE-US-00009 TABLE VIII Guilford Wool (80% wool/20% nylon) - FIG.
9 Control Processed % Change Air Perm. 243 147 -39.5
TABLE-US-00010 TABLE IXA Spun/Filament - Bottom Weights - FIG. 10
Sample #1 Sample #2 Sample #3 Sample #4 Control Proc Control Proc
Control Proc Control Proc Weight (gsy) 259.2 275.4 240.3 248.4
286.2 297.2 267.3 280.8 Thickness (mils) 39.7 39.2 35.0 35.3 44.2
41.5 40.0 38.0 Strip Tensiles (lbs./in.) Warp 206.98 208.87 195.90
200.86 183.09 189.95 206.43 207.87 Fill 85.55 56.23 84.21 71.83
80.88 83.01 80.16 82.14 Normalized Tensiles (lbs./in.) Warp 7.98
7.58 8.05 8.09 6.40 6.39 7.65 7.40 Fill 3.30 2.04 3.54 2.89 2.83
2.79 3.03 2.93 Elongation (%) Warp 42.0 55.3 36.5 39.1 40.9 43.5
46.1 51.2 Fill 23.6 25.6 24.0 20.0 23.5 20.3 22.9 22.4 Air Perm.
50.9 27.3 43.5 28.8 45.8 21.8 51.4 25.4 (ft..sup.3/ft..sup.2/min)
Thread Count (wxf) 120 .times. 40 120 .times. 41 120 .times. 45 120
.times. 45 120 .times. 38 120 .times. 42 120 .times. 42 120 .times.
43 Mullen Burst (lbs.) 161.2 222.2 187.2 228.8 161.0 217.8 205.0
242.2 Normalized Burst 62.2 80.7 77.9 92.1 56.2 73.3 76.7 86.3
(lbs./g .times. 10.sup.2)
TABLE-US-00011 TABLE IXB Abrasion - Spun Filament-Bottom Weights -
FIG. 10 ASTM Standard - Twill side up; 500 cycles; 500 g weight;
H-18 wheels Weight Before Weight Weight % Improve- Sample (g) After
(g) Loss (g) % Loss ment 1C 3.32 3.02 0.30 9.0 23% 1P 3.36 3.13
0.23 6.9 2C 4.64 4.16 0.48 10.4 48% 2P 4.83 4.57 0.26 5.4 3C 4.73
4.47 0.26 5.5 18% 3P 4.91 5.13 0.22 4.5 4C 4.47 4.18 0.29 6.5 41%
4P 4.71 4.53 0.18 3.8
TABLE-US-00012 TABLE X Doubleknit - FIG. 11 Control Processed %
Change Air Perm. (Ft.sup.3/ft.sup.2 113.1 95.1 -15.9 min) Abrasion
1.0 0.6 -40.0 ASTM (D-3884-80); 250 Cycles, H-18 wheel Pilling (1-5
rating) 4.3 4.3 0 ASTM (D-3914-81); 300 cycles
FIGS. 14A, B are photomacrographs of control and processed acrylic
vertical blind fabric, manufactured by W. S. Libbey, style
designation S/406. Enhancement of the fabric reduces fabric torque
which is particularly advantageous in vertical blind applications.
The torque reduction test of FIGS. 14A, B employed fabric strips
84'' long and 3.5'' wide, which were suspended vertically without
restraint. Torque was measured with reference to the angle of
fabric twist from a flat support surface. As can be seen in the
photographs, a torque of 90.degree. in the unprocessed fabric, FIG.
14A, was eliminated in the enhancement process.
FIGS. 15A-C are macrophotographs of control and processed acrylic
fabrics, LIBBEY style nos. 022, 406 and 152, respectively, which
were tested for washability. Unprocessed fabrics exhibited
excessive fraying and destruction, in contrast to the enhanced
fabrics which exhibit limited fraying and yarn (weight) loss. Table
XI sets forth washability test weight loss data.
TABLE-US-00013 TABLE XI 022, 406, 152 - FIGS. 15 A-C Percent Weight
Loss (3 wash/dry cycles) Sample Control Processed 022 36.5 5.0 406
28.0 4.0 152 28.1 7.2
FIG. 16 illustrates an alternative embodiment of the invention
apparatus, generally designated 40. The apparatus includes a
plurality of drums 42a-d over which a fabric 44 is advanced for
enhancement processing. Specifically, the fabric 44 traverses the
line in a sinuous path under and over the drums 42 in succession.
Rollers 46a and b are provided at opposite ends of the line
adjacent drums 42a and d to support the fabric. Any or all of the
drums can be rotated by a suitable motor drive (not shown) to
advance the fabric on the line.
A plurality of manifolds 48 are provided in groups, FIG. 16
illustrates groups of four, which are respectively spaced from each
of the drums 42a-d. An arrangement of manifold groups at 90.degree.
intervals on the sinuous fabric path successively positions the
manifolds in spaced relation with respect to opposing surfaces of
the fabric. Each manifold 40 impinges columnar fluid jets 50, such
as water, against the fabric. Fluid supply 52 supplies fluid to the
manifolds 48 which is collected in liquid sump 54 during processing
for recirculation via line 56 to the manifolds.
The support drums 42 may be porous or non-porous. It will be
recognized that advantage is obtained through use of drums which
include perforated support surfaces. Open areas in the support
surfaces facilitate recirculation of the fluid employed in the
enhancement process.
Further advantage is obtained, as previously set forth in
discussion of the first embodiment, through use of support surfaces
having a fine mesh open area pattern which facilitates fluid
passage. Offset arrangement of the support member orientations, for
example at 45.degree. offset orientation as shown in FIG. 2, limits
process water streak and weave reed marks in the enhanced
fabric.
Enhancement is a function of energy which is imparted to the
fabric. Preferred energy levels for enhancement in accordance with
the invention are in the range of 0.1 to 2.0 hp-hr/lb. Variables
which determine process energy levels include line speed, the
amount and velocity of liquid which impinges on the fabric, and
fabric weight and characteristics.
Fluid velocity and pressure are determined in part by the
characteristics of the fluid orifices, for example, columnar versus
fan jet configuration, and arrangement and spacing from the process
line. It is a feature of the invention to impinge a curtain of
fluid on a process line to impart an energy flux of approximately
0.46 hp-hr/lb to the fabric. Preferred specifications for orifice
type and arrangement are set forth in description of the embodiment
of FIG. 1. Briefly, orifices 16 are closely spaced with
center-to-center spacings of approximately 0.017 inches and are
spaced 0.5 inches from the support members. Orifice diameters of
0.005 inches and densities of 60 per manifold inch eject columnar
fluid jets which form a uniform fluid curtain.
The following Examples are representative of the results obtained
on the process line illustrated in FIG. 17.
EXAMPLE XIV
A plain woven 100% polyester fabric comprised of friction spun yarn
having the following specifications was processed in accordance
with the inventive: count of 16.times.10 yarns/in.sup.2, weight of
8 ounces/yd.sup.2, an abrasion resistance of 500 grams (measured by
50 cycles of a CS17 abrasion test wheel) and an air permeability of
465 ft.sup.3/ft.sup.2/min.
The fabric was processed on a test line to simulate a speed of 300
ft/min. on process apparatus including four drums 42 and eighteen
nozzles 16 at a pressure of approximately 1500 psi. Energy output
to fabric at these process parameters was approximately 0.46
hp-hr/lb. Table XII sets forth control and processed
characteristics of the fabric.
TABLE-US-00014 TABLE XII 100% Polyester Friction Spun Fabric Fabric
Characteristic Control Processed Count (yarns/in..sup.2) 16 .times.
10 17 .times. 10 Weight (ounces/yd..sup.2) 8 8.2 Abrasion
resistance (cycles) 50 85 Air permeability (ft.sup.3ft.sup.2/min.)
465 181
EXAMPLES XV AND XVI
The process conditions of Example XIV were employed to process a
plain woven cotton osnaburg and plain woven polyester ring spun
fabrics yielding the results set forth in Tables XIV and XV.
TABLE-US-00015 TABLE XV Plain Woven Cotton Osnaburg Fabric
Characteristic Control Processed Count (yarns/in..sup.2) 32 .times.
26 32 .times. 32 Abrasion resistance (cycles) 140 344 Air
permeability (ft.sup.3ft.sup.2/min.) 710 120
TABLE-US-00016 TABLE XIV Fabric Characteristic Control Processed
Count (yarns/in..sup.2) 44 .times. 28 48 .times. 32 Abrasion
resistance (cycles) 100 225 Air permeability
(ft..sup.3/ft.sup.2/min.) 252 63
Fabrics processed in Examples XIV-XVI are characterized by a
substantial reduction in air permeability and increase in abrasion
resistance. Process energy levels in these Examples were
approximately 0.46 hp-hr/lb. It has been discovered that there is a
correlation between process energy and enhancement. Increased
energy levels yield optimum enhancement effects.
The foregoing Examples illustrate applications of the
hydroenhancing process of the invention for upgrading the quality
of single ply woven and knit fabrics.
In an alternative application of the hydroenhancing process of the
invention, fabric strata are hydrobonded into integral composite
fabric. FIG. 17 illustrates a composite flannel fabric 60 including
fabric layers 62, 64. Hydrobonding of the layers is effected by
first napping opposing surfaces 62a, 64a of each of the layers to
raise surface fibers. The opposing surfaces 62a, 44a are then
arranged in overlying relation and processed on the production line
of the invention. See FIGS. 1 and 16. Enhancement of the layers 62,
64 effects entanglement of fibers in the mapped surfaces and
bonding of the layers to form a integral composite fabric 60.
Exterior surfaces 62b, 64b are also enhanced in the process
yielding improvements in cover and quality in the composite
fabric.
Napped surfaces 62a, 62b are provided by use of conventional
mechanical napping apparatus. Such apparatus include cylinders
covered with metal points or teasel burrs which abrade fabric
surfaces.
Advantageously, composite fabric 60 is manufactured without
requirement of conventional laminating adhesives. As a result, the
composite fabric breaths and has improved tactile characteristics
than obtained in prior art laminated composites. It will be
recognized that such composite fabrics have diverse applications in
field such as apparel and footwear.
Optimum enhancement (in single and multi-ply fabrics) is a function
of energy. Preferred results are obtained at energy levels of
approximately 0.46 hp-hr/lb. Energy requirements will of course
vary for different fabrics as will process conditions required to
achieve optimum energy levels. In general, process speeds, nozzle
configuration and spacing may be varied to obtain preferred process
energy levels.
Enhanced fabrics of the invention are preferably fabricated of
yarns including fibers having deniers and lengths, respectively, in
the range of 0.3 to 10.0 and 0.5 to 6.0 inches, and yarn counts of
0.5s to 80s. Optimum enhancement is obtained in fabrics having
fiber deniers in the range of 0.5 to 6, staple fibers of 0.5 to 6.0
inches, and yarn counts in the range of 0.5s to 50s. Preferred yarn
spinning systems employed in the invention fabrics include cotton
spun, wrap spun and wool spun. Experimentation indicates that
preferred enhancement results are obtained in fabrics including low
denier, short lengths fibers, and loosely twisted yarns.
The invention advances the art by recognizing that superior fabric
enhancement can be obtained under controlled process conditions and
energy levels. Heretofore, the art has not recognized the
advantages and the extent to which hydroenhancement can be employed
to upgrade fabric quality. It is submitted that the results
achieved in the invention reflect a substantial and surprising
contribution to the art.
Numerous modifications are possible in light of the above
disclosure. For example, although the preferred process and
apparatus employ fluid pervious support members, non-porous support
members are within the scope of the invention. Similarly, FIGS. 1
and 16 respectively illustrate two and four stage enhancement
process lines. System configurations which include one or more
modules having flat, drum or other support member configuration may
be employed in the invention.
It will be recognized that the process of the invention has wide
application for the production of a diversity of enhanced fabrics.
Thus, the Examples are not intended to limit the invention.
Finally, although the disclosed enhancement process employs
columnar jet orifices to provide a fluid curtain, other apparatus
may be employed for this purpose. Attention is directed to the
International Patent Application (RO/US) to Siegel at al., entitled
"Apparatus and Method For Hydropatterning Fabric", filed
concurrently herewith, assigned to Veratec, Inc., which discloses a
divergent jet fluid entangling apparatus for use in hydropatterning
woven and nonwoven textile fabrics.
Therefore, although the invention has been described with reference
to certain preferred embodiments, it will be appreciated that other
hydroentangling apparatus and processes may be devised, which are
nevertheless within the scope and spirit of the invention as
defined in the claims appended hereto.
* * * * *