Note: Descriptions are shown in the official language in which they were submitted.
~3~.~3
Description
APPARATUS AND METHOD FOR HYDROENHANCING FABRIC PROPERTIES
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 whieh enhanees woven and knit ~abries through use of
dynamic fluid jets to entangle and eause fabric yarns to bloom.
Fabrics produced by the method of the invention have enhaneed
surfaee finish and improved eharacteristics sueh as eover,
abrasion resistanee, drape, stability as well as redueed air
permeability, wrinkle reeovery, seam slippage, and edge fray.
Baekaround Art
The quality of a woven or knit fabric can be measured by
various properties, such as, the yarn count, thread eount,
abrasion resistanee, cover, weight, yarn bulk, yarn bloom, torque
resistance, wrinkle recovery, drape and hand.
Yarn eount is the numerical designation given to indieate
yarn size and is the relationship of length to weight.
; Thread count in woven or knit fabrics, respeeti~ely,
--2--
defines the nu~.~her e~lds and picks, and wales and courses per
inch vf 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, 6~ x 72 defines a fabric
5 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.
50ver is the degree to which underlying structure in a
10 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
fundamelltal fabric qualities and characteristics such as
filtration and cover.
Yarn bloom is a measure of the opening and spread of
f ibers 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
20 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
25 it to recover from folding deformations.
Hand refers to tactile fabric properties such as softness
and drapability.
~L3~3~53
It is known in the prior art to employ hydroentangling
processes in the production of nonwoven materials. In
conventional hydroentangling proceises, webs of nonwoven fibers
are treated T~rith high pressure fluids while supported on
5 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 efrected by
10 action of the fluid jets ~Ihich cause fibers in the web to
migrate to open areas in the screen, entangle and intertwine.
Prior art hydroentangling processes for produclng
patterned nonwoven fabrics are represented by U.S. Patent Nos.
3,485,706 and 3,498,874, respectively, to Evans and Evans et
15 al., and U.S. Patent 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 cross-
over points to effect enhancement in fabric cover. However,
20 conventional processes have not proved entirely satisfactory in
yielding uniform fabric enhancement. The art has also failed to
develop apparatus and process line technolog~ which achieves
production line efficiencies.
Australian Patent Specification 287821 to Bunting et al.
25 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
_4_ ~3~34~3
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
5 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 repr~sented by European Patent
10 Application 0 177 277 to Willb ~ s et al which is d~rec-ted to hydro-
patterning 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 -
~5 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
20 characteristics. See Willbanks, Example 4, page 40.
There is a need in the art for an improved woven textilehydroenhancing process which is commercially viable. It will be
appreciated that fabric enhancement offers aesthetic and
functional advantages which have application in a wide diversity
25 of fabrics. Hydroenhancement improves fabric cover through
dynamic fluid entanglement and bulking of fabric yarns for
improved fabric stability. These results are advantageously
,.
... .; .. .. .. ..
~" R~' ~ `3 ~ ~j 3
_F~_
obtained without requirement of conventional fabric finishing
processes.
The art also requires apparatus of uncomplex design for
hydroenhancing textile materials. Co}nmercial production
5 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 inv~ntion to
provide an improved textile hydroenhancing process and related
10 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 a
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 comple~
20 and improved over the prior art.
Disclosure of the Inventlon
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
25 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 ~luid
, :.. ::
-6- ~3~345~
curtain under con~rolled process energies. Enhancement of the
fabric is effected by entanglement and intertwinin~ of yarn fibers
at cross-over points in the fabric weave or knit. ~abrics
enhance~ in accor~ance with the invention have a uniform finish
5 and improved characteristics, such as, edge fray, drape,
stabllity, 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
10 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
15 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.
20 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 p5i and impart a total
25 energy to the fabric of approximately .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
. . .~.~. .
.. . . . . ..
~ . ~ s~ " .. .....
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--7--
to produce a uniform fabric finish.
Advanta~e in the invention apparatus is obtained by
provision of a continuous process llne of uncomplex design. The
first and second enhancement stations include a plurality of
5 cross-directionally ("C~") aligned and spaced manifolds.
Columnar jet no~zles having orifice diameters of approximately
0.005 inches with center-to-center spacings of approximately .017
inches are mounted approximately .5 inches from the screens. At
the process energies of the invention, this spacing arrangement
10 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~, efl`ectively limits
jet streaks and eliminates reed markings in processed fabrics.
Optimum fabric enhancement results are obtain~d in fabrics
15 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 .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:
25 Brief Descri~tion of the Drawinqs
Fig. 1 is a schematic view of a production line including
a weft straightener, flat and drum hydroenhancing modules, and
3~3
tenter frame, for the hydroenhancement of woven and knit fabrics
in accordance with the inventi,on;
Figs. 2A and B are photographs at lOX magnification of
36x29 90 and 40~40 45 mesh plain weave support members,
5 respectively, employed in the flat and drum enhancing modules of
Fig. l;
Figs. 3A and B are photomicrographs at lOX magnification
of a fine polyester woven fabric before and after
hydroenhancement in accordance with the invention;
Figs. 4A and B are photomicrographs at 16X magnification
of the control and processed fabric of Figs. 3A and B;
Figs. 5A and B are photomicrographs at lOX magni~ication
of a control and hydroenhanced woven acrylic fabric;
Figs. 6A and B are photomicrographs at lOX magnification of
15 a control and hydroenhanced acrylic fabric woven of wrap spun
yarn;
Figs. 7A and B are photomicrographs at lOX magnification
of a control and hydroenhanced acrylic fabric woven of wrap spun
yarn;
Figs. 8A and B are photomicrographs at lOX magnification
of a control and hydroenhanced acrylic fabric including open end
wool spun yarn;
Figs. 9A and B are photomicro~raphs at 16X magnification
of a control and hydroenhanced wool nylon (80/20~) fabric;
Figs. lOA and B are photomicrographs at 16X magnification
of a control and hydroenhanced spun/filament polyester/cotton
twill fabric;
~L3~3~
g
Figs. llA and B are photomicrographs at 16X magnification
of a control and hydroenhanced doubleknit fabric;
Figs. 12A and B are front and back side photomicrographs
at 16X magnification of a c~ntrol wall covering fabric;
Figs. 13A and B are front and back side photomicrographs
at 16X magnification of the wall covering fabric of Figs. 12A
and B hydroenhanced in accordance with the invention;
Flgs. 14A and B are photomacrographs a~ O.O9X magnification of a
control and hydroenhanced acrylic fabric strips, the fabric of
10 Figs. 7A and B, showing the reduction in fabric torque achieved
in the invention process;
Figs. 15 A-C are photomacrographs at 0.23X magnification,
respectively, of the woven acrylic fabrics of Figs. 5, 7 and 8
comprised of wrap spun and open end wool spun yarns, showing
15 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 nappe~
fabric components which are bonded into an integral structure
employing the hydroenhancing process of the invention.
Best Mode of Carryinq out The Invention
~ith further reference to the drawings, Fig. l illustrates
a preferred embodiment of a productlon line of the invention,
generally designated lO, for hydroenhancement of a fabric 12
:3L3~3~i3
including spun and/or spun/filament yarns. The line includes a
conv~ntional weft straightener 1~, fla-t and drum enhancing
modules 16, 18, and a tenter frame 20.
Modules 16, 18 effect two sided enhancement of the fabric
5 through fluid entanglement and bulking of fabric yarns. Such
entanglement is imparted to the fabric in areas of yarn cross-
over 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,
lo wrinkle recovery, cupping, drape, stability, abrasion resistance,
fabric weight and thickness.
Method and ~echanism o~ the Enhancln~ Modules
Fabric is advanced through the weft straightener 14 which
aligns the fabric weft prior to processing in enhancement
15 modules 16, 18. Following 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 of specified width.
Module 16 includes a first support member 22 which is
20 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
25 weight.
Support member 22, which preferably has a flat
configuration, includes closely spaced fluid pervious open areas
~3~
26. A preferred support member 22, shown in Fig. 2A, ls a 36x29
90~ mesh plain weave having a 23.7% open area, fabricatecl of
polyester warp and shute round wire. Support member 22 i.s a
tight seamless weave which is not subject to angular
5 displacement or snag. Specifications for the screen, which is
manufactured by Albany International, Appleton Wire Division,
P.o. Box 1939, Appleton, Wisconsin 54913 are set forth in
Table I.
TABLE I
Support Screen Specifications
_ .
Property 36x29 90 flat mesh 40x40 45 drum mesh
15 Wire polyester stainless steel
Warp wire .0157 0.010
Shute w.ire .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
30 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 .5 inches from the support member 22.
I'he jet orifices have diameters and center-to-center
35 spacin~s in the range of .005 to .010 inches and .017 to .034
inches, respectively, and are designed to i.mpact the fabric with
-12~ 3
fluid pressures in the range of 200 to 3000 psi. Preferred
orifices have diameters of approximately .005 inches with
center~to-center spacings of approximately .017 inches~
This arrangement of fluid jets provides a curtain of fluid
5 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
10 of fabric yarn is achieved at an energy output of at least .05
hp-hr/lb and preferably in the range of .1 to 2.0 hp-hr/lb.
Following the Pirst 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
15 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 40x40 45
mesh stainless steel screen, manufactured by Appleton Wire,
~0 havlng 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
ha~e substantially the same specifications as in the first stage
enhancement module. Fluid energy to the fabric of at least 0.5
25 hp-hr/lb and preferably in the range of .1 to 2.0 hp-hr/lb
effects second stage enhancement.
Conventional weaving processes impart reed marks to
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fabrics. Illustrations of such markings are shown in Figs. 3A
and 4A which are photomicrographs at lOX and 16X magnification
of a polyester LIBBEY brand fabric style no. S/x-A805 (see Tab~e-
II). Reed marks in Yigs. 3A and 4A are designated by the let'~er
5 "~".
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 3~ in
lO offset relation, preferably 45, relative to machine direction
("MD") of the hydroenhancing line. See Figs. 2~ and B.
Support members 22 and 3~ 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
15 fabric. The preferred members have an effective open area for
fluid passage in the range of 17 - ~0%.
Comparison of the control and processed polyester fabric
of Figs. 3A, B and ~A, B illustrates the advantages obtained
through use of the enhancement process. Reed marks R in control
20 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.
Exam~lesI-XIII
Figs. 3 - 15 illustrate representative woven and knit
fabrics enhanced in accordance with the method of the invention,
i3
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employing test conditions which simulate the line of Fig. 1.
Table II sets forth specifications for the fabri~s illustrated in
the drawings.
As ln the Fig. l line, the -test manifolds 30 were spaced
5 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 .5 inches from the first and second support members
22, 3~.
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
15 manifold module was deemed to be equivalent to a SlX manifold
module.
Fabrics were hydroenhanced at process pressures of
approximately 1500 psi. Line speed and cumulative energy output
to the modules were respectively maintained at approximately 30
20 fpm and 0.~6 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
25 enhancement in aesthetic appearance and quality including,
characteristics such as cover, bloom, ~brasion resistance, drape,
stability, and reduction in seam slippage, and edge fray.
. ., , ~
3~;3
-15-
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
5 characteristics of fabrics. Data set forth in the Tables was
generated in accordance with the following ASTM standards:
Fabric Characteristic STM Standard
Weight D3776-79
Thickness Dl777-64 (Ames Tester)
Tensile Load D1682-6~ (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
25 taken of control and processed fabric samples each having a
dimension of 8.5"xll" (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
-
~3~3~53
-16-
of the pre and post wash samples was determined in accordance the
following formula:
% weight loss = D/B x 100
where, B = before wash sample weight; A = after wash sample
5 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
10 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
15 covering fabric, manufactured by Hytex, Inc, Randolph,
Massachuset~. 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
20 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 enhance~ent and associated stabilizing
25 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
:~3:~L3~3
-17-
ob-tained when enhanced fabrics are used in acoustic
applications; elimination of backcoating reduces sound reflection
and furthers efficient transmission of sound through the fabric.
TABLE II
.
Fabric Specifications
Fiber Brand and Styl~ Desiqnation Fiqure(s)
NOMEX S/x-A805* 3A,B, 4A,B
Fiber : 2 denier-1.9 inch
Yarn : Open end cotton spun 17s
LIBBEY SJ022** 5A,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
30 LIBBEy S/x-1160 6A,B
Fiber: 3 denier-3 inch acrylic
Yarn : Wrap spun w/100 den
textured polyester ~s
14 ends x 16 picks per inch
LIBBEY S/406 7A,B,
14A,B
~iO
Warp:
Fiber: 3 denier - 1.5 inch acrylic
Yarn : Open end cotton spun 9s
2~ ends per inch
Fill:
Fiber: 3 denier - 3.inch acrylic
Yarn : Hollow spun 6 twists/inch 4s
14, 16 or 18 picks per inch
, . . . . . .
. ~ .
~.
~33L3~53
-18-
Table II, continued
5 LIBBEY S/152 8A, 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 9A,B
80% wool/20~ nylon
., .
Polyester/cotton (53/47) 10A,B
Weight: 10 ounces/yd2
Yarn : Spun Filament
Weave : 3xl Twill
Thread Count: 120x38
30 50% Polyester/50% cotton Doubleknit llA,B
Yarn: wrap spun with 100
: denier polyester wrap
35 HYTEX Wall covering*** 12, 13
~LIBBEY is a trademark of W. S. Libbey Co., One Mill Street,
Lewiston, ME 04 2 4 0 .
40 **NOMEX is a trademark of E.I. Du Pont de Nemours and Company,
Wilminqton, Del.
HYTEX is a trademark of Hytex , Inc., Randolph, MA.
f ~' ~
, ,., , , , 1
' ~ i
-19 -
TABLæ III
Nomex A805 - Fiq. 4
ControlProcessed % Chance
20 Wei~ht (gsy) 195 197 +1.0
Thickness (mils) 42 42 0
Air Perm. (ft3/ft2/ 331 156 -52.9
min)
Strip Tensile (lbs/in)
warp 115 132 +14.8
~ill 59 47 -20.3
Elonqatlon
(%)
warp 48 50 +4.2
fill 62 71 +14.5
-20- ~3~3~3
TABLE IV
022/6075 (16 ppi) - Fi~. 5
Control Processed % Chanqe
15 Wei~ht (gsy)158 165 + 4.4
Thickness (mils) 48 49 ~ 2.1
Air Perm. (ft3/ft2 406 259 -36.2
min)
~I{L~ _ ile (lbs/in)
warp 34 36 + 5.9
fill 37 31 -16.2
Elon~ation (%)
warp 33 27 -18.2
fill 27 28 + 3.7
30 Seam Slippaqe (lbs/in)
warp 5 60 +1100.0
~ fill 7 55 + 685.7
`~ Tonaue Tear (lbs)
warp 18 10 ~-44.4
~ill 21 8 -~1.9
, Wt. Loss In Wash (%) 37 5 -86.5
40 Wrinkle Recoverv* 123 138 +12.2
(recovery angle)
* Under ASTM test standards (Dl295-67) improvements in the
45 wrinkle recovery of a fabric are indicated by an increase in the
recovery angle.
.~
,,, '. ..
~3~3453
-21-
TABLE V
Libbey S/x-1160 - Fi.g. 6
Control Processed % Chanqe
: 15
Weiqht (gsy)146.8 160.2 9.1
Thickness (mils) 38.1 52.7 38.3
~0
Ai ~ rm_ (ft3/ft2. 457.2 188.5 .-58.8
min)
25 Grab Tensile (lbs/in)
warp80.2 89.3 11.4
ill105.0 111.4 6.1
: Elonqation (%)
; 30 ~ warp 30.0 34~0 13.3
~ ~ill32.0 46.0 43.8
; Ball Burst (lbs) 190 157 -17.4
.
.
.~ ,
.
:. , . ~j
-22- 1~3~3
~ABLE VI
406/6075 (16 ppi) - Fig. 7
Control Processed % Chanqe
Weiqht (gsy)159 166 + 4.4
Thickness (mils) 48 50 -~ 4.2
20 Air Perm. (ft3/~t2 351 184 -47.6
mln)
nsile (lbs~in)
warp 42 36 -14.3
~ill 66 58 -12.1
Elonaation (%)
warp 23 31 +34.8
. fill 49 33 -32.7
Se~ S1iPDag~ (lbs)
warp 29 36 +89.5
fill 21 76 + 261.9
35 Tonque Tear (lbs)
warp 23 18 -21.7
~ill 19 . 15 - 1.1
Wt. Loss In Wash (%) 28 4 -85.7
Wrinkle Recovery 140 148 n + 5.7
(recovery angle)
:
~a3~3~;3
-23
TABLE VII
__
152~6076 (16 ppi) - Fia. 8
ControlProcessed % Chanae
10 Weiqht (gsy) 231 257 +11.3
Thickness (mils) 259 238 - 8.1
Air Perm. (ft3/ft2/ 204 106 -48.0
~in)
Strip Tensile (lbs/in)
warp 48 58 +20.8
fill 56 72 +28.6
Elonaation (%)
warp 33 33
f.ill 34 39 +14.7
25 _am Slippaae (lbs)
warp 6~ 81 +26.6
fill 78 112 +43.6
Tonaue Tear (lbs)
warp 21 18 -14.3
fill 17 15 -11.8
Wt. Loss In Wash (%) -- -- ----
35 Wrinkle Recovery 117 136 ~16.2
(recovery angle)
TABLE VIII
_
Guilford Wool (80% wool/20% nylon) - Fiq. 9
Control Process % Chanae
Air Perm. 243 147 -39.5
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o ~ o~ ~ X
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u ,~ ul 3 1:4 ul 3 ~ s: 3
Q ~ .q o h
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~l3~ 5~
-25-
TABLE IXB
A sion -- S~un Filam~nt~Bottom Weiqhts - _~ lo
ASTM Standard - Twill side up; 500 cycles; 500 g weight; H-18
wheels
Weight Weight Weight % Improve-
10 Sam~le Before(q) After(q) Loss(~)% I,oss ment
lC 3.32 3.020.30 9.0
lP 3.36 3.130.23 6.9 23%
2C 4.64 4.160.48 10.4
15 2P 4.83 4.570.26 5.4 48%
3C 4.73 4.470.26 5.5
3P 4.91 5.130.22 4.5 18%
20 4C 4.47 4.180.29 6.5
4P 4.71 4.530.18 3.8 41%
TABLE X
oubleknit - Fiq. 11
; Control Processed ~O Chan~e
Air Perm. (Ft3/ft2113.1 95.1 -15.9
min)
Abrasion 1.0 0.6 -40.0
40 ASTM (D-3884-80): 250 Cycles, H-18 wheel
~ (1-5 rating) 4.3 4.3 0
ASTM (D-3914-81): 300 cycles
Figs. 14A, B are photomacrographs of control and processed
50 acrylic vertical blind fabric, manufactured by W.S. Llbbey, style
designation S/406. Enhancement of the fabric reduces fabric
.
~3~3~
-26-
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
5 reference to the angle of fabric twist from a flat support
surface. As can be seen in the photographs, a torque of 90 in
the unprocessed fabric, Fig. 14A, was eliminated in the
enhancement process.
Figs. 15A-C are macrophotographs of control and processed
10 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
15 data.
TABLE XI
022. 406 152 - Fi~s. 15A-C
Percent Wei~ht Loss
(3 wash~dry cycles)
am~le Control Processed
022 36.5 5.0
406 28.0 4.0
30152 28.1 7.2
Fig. 16 illustrates an alternative embodiment of the
invention apparatus, generally designated 40. The apparatus
-27- ~3~3~3
includes a plurality of drums 42a-d over which a fabric 44 is
advanced for enhancement processing. Speci~ically, 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
5 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
10 each of the drums 42a-d. An arrangement of manifold groups at
90 inter~als on the slnuous fabric path successively positions
the manifolds in spaced relation with respect to opposing
surfaces of the fabric. Each manifold 48 impinges columnar
fluid jets 50, such as water, against the fabric. Fluid supply
15 52 supplies fluid to the manifolds 4~ 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
20 which include perforated suppor-t 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
25 surfaces having a fine mesh open area pattern which facilitates
flu.id passage. Offset arrangement of the support member
orientations, ~or example at 45~ offset orientation as shown in
"~ ;
:~3:~3~3
-28-
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
5 accordance with the invention are in the range of .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
10 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
15 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 lnches from the
support members. Orifice diameters of .005 inches and densities
20 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.
Exam~le XIV
A plain woven 100~ polyester fabxic comprised of friction
spun yarns having the following specifications was processed in
accor~ance with the inventionO count of 16 x 10 yarns/in2,
-` ~3~3'~
-29-
weight of 8 ounces/yd2, an abrasion resistance of 500 grams
(measured by 50 cycles of a CS17 abrasion test wheel) and an air
permeability of 465 ft3/ft2/min.
The fabric was processed on a test line to simulate a speed
5 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 .46 hp-hr/lb. Table XII sets forth control and
processed characteristics of the fabric.
TABLE XII
100% Polyester Friction Spun Fabric
:
15 Fabric Characteristic ControlProcessed
Count (yarns/in.2) 16xlO 17xlO
Weight (ounces/yd.2) 8 8.2
Abrasion resistance (cycles) 50 85
Air permeability (ft3ft2/min.) 4~5 181
__
Examples XV and XVI
The process conditions of Example XIV were employed to
process a plain woven cotton osnaburg and plain woven polyester
25 ring spun fabrics yielding the results set forth in Tables XIV
and XV.
~3~3~i3
-30-
TABLE XV
.. ..
~`
Plain Woven Cotton Osnabur~
5 Fabric Characteristic Control Processed
Count (yarns/in.2) 32x26 32x32
Abrasion resistance (cycles) 140 344
Air permeability (ft3ft2/min.) 710 120
_
TABLE XIV
Plain Woven PolYester Rinq Spun Yarn
15 Fabric Characteristic Control Processed
Count (yarns/in.2) 44x28 48x32
Abrasion resistance (cycles) 100 225
Air permeability (ft.3/ft2/min.) 252 63
Fabrics processed in Examplss XIV-XVI are characterized by
a substantial reduction in air permeability and increase in
abrasion resistance. Process energy levels in these Examples
were apprcximately .46 hp-hr/lb. It has been discovered that
25 there is a correlation between process energy and enhancement.
Increased energy levels yield optimum enhancement effects.
The foregoing Examples illustrate applications of the
~3~L3~
-31-
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
5 composite fabric. Fig. 17 illustrates a composite flannel fabric
60 including fabric layers 62, 64. ~Iydrobonding of the layers is
effected by first nappin~ 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
10 production line of the invention. See Figs. 1 and 16.
Enhancement of the layers 62, 6~ effects entanglement of fibers
in the napped surfaces and bonding of the layers to form a
integral composite Pabria 60. Exterior surfaces 62b, 6~b are
also enhanced in the process yielding improvements in cover and
15 quality in ~he 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
re~uirement 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
25 applications in fields such as apparel and footwear.
Optimum enhancement (in single and multi-ply fabrics) is a
function of energy. Preferred results are obtained at energy
,
~L3~L3~3
-32
levels of approximately .46 hp-hr/lb. Energy requirements will
of course vary for different fab~ics as will process conditions
required to achieve optimum energy levels. In general, process
speeds, nozzle configuration and spacing may be varied to obtain
5 preferred process energy levels.
Enhanced fabrics of the invention are preferably fabricated
of yarns including fibers having deniers and lengths,
respectively, in the ranges of 0.3 to 10.0 and 0.5 to 6.0 inches,
and yarn counts of .5s to 80s. Optimum enhancement is obtained
10 in fabrics having fiber deniers in the range of .5 to 6, staple
fibers of .5 to 6.0 inches, and yarn counts in the range of .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
15 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
20 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
25 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.
!~ .
~3~L3~3
-33
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 othex 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 inkended to limit the
invention.
Finally, although the disclosed enhancement process employs
10 columnar jet orifices to provide a fluid curtain, other apparatus
may be employed for this purpose. Attention is directed to U.S.
Patent No. 4,995,151, en-titled "~pparatus and Me-thod for Mydro-
patterning Fabric", dated February 26, 1991, assigned to Inter- ;
national Paper Company, the assignee of the present case, which
15 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 e~bodiments, it will be
appreciated that other hydroentangling apparatus and processes
20 may be devised, which are nevertheless within the scope and
spirit of the invention as defined in the claims appended
hereto.
; l
