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WO2003039863A1 - Tissu texture en non-tisse - Google Patents

Tissu texture en non-tisse Download PDF

Info

Publication number
WO2003039863A1
WO2003039863A1 PCT/US2002/035543 US0235543W WO03039863A1 WO 2003039863 A1 WO2003039863 A1 WO 2003039863A1 US 0235543 W US0235543 W US 0235543W WO 03039863 A1 WO03039863 A1 WO 03039863A1
Authority
WO
WIPO (PCT)
Prior art keywords
nonwoven fabric
distressed
fabric
permanently
textured
Prior art date
Application number
PCT/US2002/035543
Other languages
English (en)
Inventor
Cheryl Carlson
Wayne Rhodes
James Lenox
Original Assignee
Polymer Group, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Polymer Group, Inc. filed Critical Polymer Group, Inc.
Publication of WO2003039863A1 publication Critical patent/WO2003039863A1/fr

Links

Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C23/00—Making patterns or designs on fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D04H1/495—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/689—Hydroentangled nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials
    • Y10T442/698—Containing polymeric and natural strand or fiber materials

Definitions

  • the present invention relates to a method of creating a textured nonwoven fabric for apparel and home fashions applications, and more specifically, a nonwoven fabric comprising a permanent distressed texture upon laundering of the nonwoven fabric.
  • the drawn sliver is then fed into a roving frame to produce roving by further reducing its diameter as well as imparting a slight false twist.
  • the roving is then fed into the spinning frame where it is spun into yarn.
  • the yarns are next placed onto a winder where they are transferred into larger packages. The yarn is then ready to be used to create a fabric.
  • the yarns are designated for specific use as warp or fill yarns.
  • the fill yarn or fiber packages (which run in the cross direction and are known as picks) are taken straight to the loom for weaving.
  • the warp yarns are taken straight to the loom for weaving.
  • the packages of warp yarns are used to build a warp beam.
  • the packages are placed onto a warper, which feeds multiple yarn ends onto the beam in a parallel array.
  • the warp beam yarns are then run through a slasher where a water-soluble sizing is applied to the yarns to stiffen them and improve abrasion resistance during the remainder of the weaving process.
  • the yarns are wound onto a loom beam as they exit the slasher, which is then mounted onto the back of the loom.
  • the warp and fill yarns are interwoven in a complex process to produce yardage of cloth.
  • Nonwoven fabrics are suitable for use in a wide variety of applications where the efficiency with which the fabrics can be manufactured provides a significant economic advantage for these fabrics versus traditional textiles.
  • a review of prior art indicates wrinkles have been introduced into woven fabrics for aesthetic as well as functional reasons.
  • U.S. Patent No. 6,025,284 discloses a sun protective fabric that is a permanently wrinkled polyester fabric with UV absorbers. Incorporating wrinkles into the fabric functionally serves as an additional barrier to provide protection from UV light. The wrinkles are permanently fixed into the fabric by stuffing a jet-dyeing machine with an excessive amount of fabric and then heat setting the resultant wrinkles into the fabric.
  • U.S. Patent No. 5,679,438 discloses a method of decorating woven fabrics by imparting wrinkles into the fabric and then heat setting the wrinkles.
  • the wrinkles are imparted by a wrinkler, in which the conventional printing apparatus is modified by the addition of a wrinkler.
  • the present invention relates to a method of creating a textured nonwoven fabric for apparel and home fashions applications, wherein the nonwoven fabric becomes aesthetically altered upon laundering. Once laundered during manufacture, the nonwoven fabric exhibits a permanent distressed appearance that becomes an integral part of the fabric. Subsequent to laundering, the fabric can be formed into a roll for shipment and storage. The distressed appearance of the nonwoven fabric is best described by comparing the laundered fabric to an elephant's skin.
  • the disclosed nonwoven fabric is characterized as unique since it is first textured with an image on an image-transfer device, then the imaged fabric is given a second distressed texture without being subsequently chemically treated, compoundly imaged on an image-transfer device, or embossed by a roll.
  • the resultant hydroentangled nonwoven fabric of the present invention has a distress-free appearance until laundered, after which a controlled amount of wrinkling is imparted.
  • FIGURE 1 is a diagrammatic view of the apparatus for forming the nonwoven fabric.
  • FIGURE 2 shows the fabric before and after laundering.
  • the fabric is formed from a fibrous matrix, which comprises fibers selected to promote economical manufacture.
  • the fibrous matrix is preferably carded and subsequently cross-lapped to form a precursor web, designated P.
  • FIGURE 1 illustrates a hydroentangling apparatus for forming nonwoven fabrics in accordance with the present invention.
  • the apparatus includes a foraminous- forming surface in the form of a flat bed entangler 12 upon which the precursor web P is positioned for pre-entangling.
  • Precursor web P is then sequentially passed under entangling manifolds 14, whereby the precursor web is subjected to high-pressure water jets 16.
  • the entangling apparatus of FIGURE 1 further includes an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now-entangled precursor web.
  • the precursor web is trained over a guide roller 20 and directed to the image transfer device 18, where a three-dimensional image is imparted into the fabric on the foraminous-forming surface of the device.
  • the web of fibers is juxtaposed to the image transfer device 18, and high pressure water from manifolds 22 is directed against the outwardly facing surface from jet spaced radially outwardly of the image transfer device 18.
  • the image transfer device 18, and manifolds 22, may be formed and operated in accordance with the teachings of commonly assigned U.S. Patents No. 4,098,764, No. 5,244,711,
  • the precursor web P be given a three-dimensional image suitable to provide fluid management, as will be further described, to promote use of the present nonwoven fabric in apparel and home fashions.
  • the entangled fabric can be vacuum dewatered at 24, and dries at an elevated temperature on drying cans 26.
  • Hydroentanglement results in portions of the precursor web being displaced from on top of the three-dimensional surface elements of the imaging surface to form an imaged and patterned nonwoven fabric.
  • the imaged nonwoven layer is dyed by any commonly known practice such as a jet dying or stock dying.
  • the imaged nonwoven fabric is wound into a roll and transferred to a separate practicable printing means.
  • the laundered end product will have more or less of a distressed texture. It is believed that the nonwoven fabric has a small degree of fiber movement occurring and the movement of the fiber in a wet environment (under relaxed conditions) allows the fibers to move relative to the planar construction of the nonwoven fabric causing the fabric to "pucker" and appear distressed. The more the nonwoven fabric is hydroentangled, the more restricted in movement the fibers are and therefore, the fabric appears less distressed.
  • Coloration of the fabric will affect the amount of texture since colors can obfuscate or accentuate the wrinkles due to light refraction.
  • the amount of texture in the fabric is also affected by the fiber type or fiber blend that makes up the fabric. Dissimilar fibers react or behave differently to hydroentanglement and therefore the laundered end product will have more or less texture depending on the fiber type.
  • polyester fibers entangle better than lyocell, cotton, or rayon fibers, therefore the resultant laundered end- products comprised of 100% polyester have less of a distressed texture compared to a fabric comprised of 100% lyocell fabric. It can also be concluded that fabrics comprised of polyester blends would be more entangled and have less fiber movement when laundered than a fabric comprised of 100% cotton. Due to the limited fiber movement, the fabrics comprised of polyester blends would have less texture after laundered. It is believed that the laundered nonwoven of the present invention becomes textured due to differential shrinkage of the different fiber types during the wetting process, home laundering, or commercial laundering of a garment or roll good.
  • nonwoven fabric of a single fiber composition such as cotton, or fibrous blends
  • a nonwoven fabric of a single fiber composition such as cotton, or fibrous blends
  • slippage between fibers creates the permanently distressed appearance of the present fabric when it is subjected to laundering during fabric manufacture.
  • slippage can be increased when there is a lack of compatibility of the fibers, such as by use of fibers having differing surface characteristics for fabric formation. This can include fibers having differing compositions, or fibers having differing surface finishes.
  • the nonwoven fabric utilized in the present invention may be a composite or laminate comprised of fibers selected from either synthetic or natural fibers or a combination thereof.
  • Synthetic fibers may be selected from a group of thermoplastic polymers such as polyesters, poly amides, polyolefins, such as polyethylene or polypropylene, their derivatives and combinations thereof.
  • the fibers may also be cellulosic in nature such as cotton, wood pulp, or rayon.
  • the nonwoven fabric may also be a blend of said synthetic and natural fibers.
  • the fibers may be splittable fibers or fibers of differing geometric configurations.
  • Preferred fibrous blends of the present invention include the combinations of cotton, rayon, polyester, and lyocell fibers; Lyocell fibers are man-made fibers made of wood pulp and available commercially under the name Tencel® as a registered to Courtaulds PLC Corporation of London, England.
  • the combination of fibers mentioned above can result in both heavier and lighter fabrics.
  • the resultant heavier fabrics have a preferred basis weight range from about 3.0-8.0 ounces per square yard and a more preferred weight range from 5.0-6.0 ounces per square yard.
  • the resultant lighter fabrics have a basis weight range from about 1.0-3.0 ounces per square yard and a more preferred basis weight range from 1.5-2.5 ounces per square yard.
  • the nonwoven fabric comprises a chemical or mechanical finish or a combination of the two finishes.
  • Such finishes can be a jet dye finish or one that affects the fabric's drape or hand.
  • Softening agents may also be used to impart a better hand and provide a nonwoven fabric with better conformability.
  • the preferred fibrous blend for the home fashions industry includes polyester and lyocell fiber blends or polyester and rayon fibrous blends.
  • a fibrous blend of cotton and polyester is preferred.
  • Strip Tensile Test (O 5035 ⁇ 1 This test is meant to measure the breaking strength of the fabric in units of either grams or pounds as well as measure the elongation of the fabric. Crockfastness (AATCC TM8- 19881
  • This test may be preformed with a wet or dry sample. The sample is rubbed against a testing surface for a designated number of passes. Test results are rated on a scale of 1-5, where a rating of 5 indicates the lack of color transfer.
  • test results reflect a sample that is a hydroentangled fibrous blend of 60% cotton and 40% polyester. Test results indicate that the sample remains unchanged after three home launderings. The sample has comparable strength and elongation in both the machine and cross direction. The data table indicates the multiple home launderings of the fabric do not have any negative affects on the fabric.
  • the disclosed nonwoven fabric is suitable for the apparel industry.
  • the imaged nonwoven fabric is utilized in a bottom weight article for men or women, such as pants or shorts, wherein the bottom weight article takes on a distressed appearance once laundered.
  • the nonwoven fabric of the present invention is suitable for the home fashions industry.
  • the imaged nonwoven fabric is utilized in window coverings, bed applications, such as duvet covers, bedspreads, or comforters, and furniture coverings, such couch, love seat, or arm chair covers, wherein the previously mentioned home fashions would also take on a distressed appearance after laundering.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Coloring (AREA)

Abstract

La présente invention concerne un procédé pour créer un tissu texturé en non-tissé utilisable dans les articles d'habillement et les accessoires de maison, ledit tissu non-tissé devenant esthétiquement modifié après lavage. Une fois lavé après fabrication, le non-tissé présente de façon permanente un aspect vieilli, qui devient associé à ce non-tissé. Après lavage, le tissu peut être conditionné, à savoir mis dans un rouleau prêt à l'expédition et au stockage. On décrit le mieux l'aspect vieilli du non-tissé en comparant le tissu lavé à une peau d'éléphant.
PCT/US2002/035543 2001-11-07 2002-11-06 Tissu texture en non-tisse WO2003039863A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/045,247 2001-11-07
US10/045,247 US20030087575A1 (en) 2001-11-07 2001-11-07 Textured nonwoven fabric

Publications (1)

Publication Number Publication Date
WO2003039863A1 true WO2003039863A1 (fr) 2003-05-15

Family

ID=21936805

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2002/035543 WO2003039863A1 (fr) 2001-11-07 2002-11-06 Tissu texture en non-tisse

Country Status (2)

Country Link
US (1) US20030087575A1 (fr)
WO (1) WO2003039863A1 (fr)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1453453A4 (fr) * 2001-11-09 2007-04-25 Polymer Group Inc Sous-vetements jetables en non tisse
CN102264970B (zh) 2008-09-11 2015-04-01 阿尔巴尼国际公司 工业织物及其制造方法
EP2334869B1 (fr) 2008-09-11 2018-01-17 Albany International Corp. Bande perméable pour la fabrication de mouchoirs, serviettes ou non-tissés
CA2746424A1 (fr) * 2008-12-12 2010-06-17 Albany International Corp. Tissu industriel comprenant des bandes de matiere enroulees en spirale
US8728280B2 (en) 2008-12-12 2014-05-20 Albany International Corp. Industrial fabric including spirally wound material strips with reinforcement
US8764943B2 (en) 2008-12-12 2014-07-01 Albany International Corp. Industrial fabric including spirally wound material strips with reinforcement
EP2391768B1 (fr) * 2009-01-28 2021-05-12 Albany International Corp. Toile de papeterie pour la production de papier toilette et serviettes en papier, et système et procédé pour fabriquer la toile

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5827597A (en) * 1993-09-13 1998-10-27 Mcneil-Ppc, Inc. Topographical support member for producing nonwoven fabrics
US5874159A (en) * 1996-05-03 1999-02-23 E. I. Du Pont De Nemours And Company Durable spunlaced fabric structures

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4188690A (en) * 1976-02-25 1980-02-19 Mitsubishi Rayon Company, Limited Nonwoven fabric and manufacturing method thereof

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5827597A (en) * 1993-09-13 1998-10-27 Mcneil-Ppc, Inc. Topographical support member for producing nonwoven fabrics
US5874159A (en) * 1996-05-03 1999-02-23 E. I. Du Pont De Nemours And Company Durable spunlaced fabric structures

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