Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
1 ~ S602~
This application is a divisional of Canadian patent
application Serial Number 362~586 filed on October 16, 1980.
The present invention relates to a process and
apparatus for surface finishing fabrics by mechanical means to
provide a fabric product having improved surface softness and
a desirable fabric hand. The present invention also relates to
a textile fabric with modified surface which may be made by
the process.
It is generally known that fabrics may be
mechanically face-finished to provide various effects on the
fabric, such as a soft surface feel, to generate cover, or even
to give fabrics made from filament yarns a spun-like hand. These
mechanical face-finishing techniques include napping and sanding
techniques, the particular technique employed as well as
operating parameters selected being determined by the desired
effect as well as by the nature of the fabric to be finished.
Sanding of textile fabrics, also variously referred to in the
art as buffing or emerizing, is generally accomplished according
to known methods by passing the fabric over rapidly-rotating
cylinders covered with an abrasive, e.g., sanding paper of a
suitable degree of fineness or coarseness. The sanding grains
which come into contact with the fabxic surface for a period
of time, depending upon operating conditions, abrade th~
surface ~ibexs of the ~abric and raise a cover which i9
generally ~horter than ~hat which i~ ob~ainable by napping.
In sanding type of face finlshing opexations it
iS al90 known that the textile abric may be forced onto the
abrading sur~ace by either tensioning or by setting a pre-
determined gap somewhat less than the ~abric thickness between
the abrading surface and a backing device~ Frequently the
fabric surface obtained by such mechanical finishing techniques
must be sheared after sanding or other treatment to provide a
1 ~56~28
product having the desired uniformity of the nap or pile height.
It has been found generally with regard to ~abrics
trea~ed using known mechanical surface finishing techniques that
frequently a considerable amount of fabric strength may be lost
especially if a significant alteration of the appearance or hand
of the fabric is sought. Also, where it is desired to surface
finish very rigid fabrics such as woven polyester-cotton fabrics
or woven all-polyester fabrics, the result, particularly after
sanding, may be a streaked surface resulting at least in part
from tight warp ends in the fabric. ~hese tight warp ends are,
furthermore, difficult to avoid in the fabric as a practical
matter. Moreoverr on many fabrics it is difficult to obtain a
dense and uniform modification of the fabric surface. On fabrics
made from relatively strong fibers, such as polyester in
particular, the cover obtained is frequently thin, non-uniform
and "choppy," so that the fabric product is aesthetically un-
appealing, and there is little or no benefit to the hand
characteristics of the product.
Also, mechanical surface finishing techniques may
result in a fabric surface nap or pile which is longer than
desired so that the length of the nap or pile must be reduced
by shearing whlch may result in an inadequate amount o~ cover on
the fabric product, known as a "hungryi' cover. Thus, lt is
quitc di~ficult, using conventional surface finishing techniques,
ko provide aonsistently ~ood quality, uniform p~oducts with
little or no de~ects. Furthermore, some Eabrics, espeaially
Eor instance very lightweight Eabrias, canno~ be face finished
at all using aonventional techniques.
Accordin~ly, the process oE the present invention
has been developed to pxovide a more uniEorm sur~ace finish to
fabrics than conventional methGds, even on fabrics with tight
warp ends; streaking has been minimized or prevented entirely.
1 156028
I'he process can be easily controlled and finish char~cteristics
can be adjusted predict~bly by varying operating parameters.
The surface finish obtained, depending on operatiny conditions
and the fabric substrate, may have few broken fibers although
it may be characterized as having a very soft touch, or, if
desired, may have a dense but very short cover. Depending upon
substrate characteristics and operating parameters selected the
surface hand of the treated fabric may be suede-like, cotton-like
or it may even have the desirable feel characteristics of wool.
These different results are not solely dependent on su~strate
type and may frequently be achieved even on the same fabric
substrate type when desired by varying operating parameters. The
fabric itself may be caused to develop more drape, or, iE desired,
processing parameters may be adjusted so as to change primarily
only the fabric finish, e.g., surface feel, with little or no
effect on the fabric drape and crispness. Thus, it has been
observed that appearance and hand characteristics of fabrics
treated according to the process of the present invention differ
significantly and desirably from the fabric appearance and feel
obtainable by conventional methods.
It has also been observed that fabrics that
generally cannot be surface finished mechanically at all by
conven-tional methods may be convenien~ly and easily processed
by the pre~ent process, For instance, certain lightweiyht
~abrics, such as some jersey knit fahrics, cannot be sanded or,
at least, cannot be conventionally sanded conveniently since
they tend to "neck down" considerably under the tension required
~or ordinary sanding and they may, in addition, tend to wrap
around the sanding roll. The process of the present invention,
however, permits better control o surface ~inishing conditions
and it has been found that even very lightweight jersey knits
may be surface finished. Also, a common fabric deficiency is
1 ~56~
"tight selvedges." This deficiency makes conventional sanding
nearly impossible,but according to the process of the present
invention such fabrics may be easily finished and there is little
or no adverse efect resulting from the "tight selvedges." It
has been found that even embossed fabrics may be mechanically
surface finished by the present process providing a product
having improved hand and appearance in both the embossed and
non-embossed areas, and the undesirable "glossy" or "plastic"
look in the embossed areas is reduced.
Synthetic filament fabrics, such as polyester
filament fabrics, processed according to the present invention
may acquire many of the desired hand and appearance character-
istics of spun fabrics and frequently also may acquire a
desirable surface feel normally associated with fabrics made
from finer denier fibers. Fabrics processed according to the
present invention, furthermore, may possess enhanced adhesion
characteristics, that is, they can be caused to adhere better
than untreated materials to another material, such as for
instance polyurethane shee~ material, using a suitable adhesive.
Accordingly, the present invention relates to a
process for mechanically surface finishing a textile fabric,
which comprises continuously eeding said fabric from a source
o~ supply such that, said fabric lies in a single plane,
sub~ecting successive adjacent sections o~ the fabric -to
~5 intermittent mechanical impact with an abrasive means across
the width o~ ~aid ~abriG thereby avoiding substantial sustained
contact between said Eabric and said ab~asive means, said
mechanical impact b~ing at a force and ~requency suEficient
to cause a substantially uniorm modification o the surace
Gharacteristics of said ~abric.
The pr~sent invention also relates to a tex~ile
material which may be made according to the process of the
1 1~6028
invention having a body portion containing a plurality of
fibers, of which at least 20 percent by weight, and preferably
at least 45 percent by weight, are synthetic fibers, e.g.,
thermoplastic synthetic fibers sl}ch as polyester or nylon fibers.
The remaining portion of the textile material, if it is not
totally synthetic, may be made up of natural fibers and may
even include some nonfibrous materials. The fibers in the
textile material have a curva-ture and are arranged so as to have
convex side portions and concave side portions. Those convex
side portions o~ the fibers of the material which are exposed,
e.g., those that are at or near the surface of the material and
not covered by other fibers, are substantially scarred and they
contain a multiplicity of generally short, rather thick lamella-
shaped protrusions extending therefrom. While the actual length
and number of these protrusions may vary considerably according
to the invention depending upon the type of material treated and
the severity of treatment, on the average it has been determined
that the length of such protrusions will in general be quite
short, e~g., less than about .05 mm., preferably less than about
.03 rQm. from the base of the protrusions where they are joined
to the main body portion of the fiber to the tip of the pro-
trusions. As mentioned, it has also been observecl that the
extent of modification of these exposed conve~ side portions o~
~he tex~ile material may va~y dependlng upon the ~abric substrate
2S composition. It is quite appaxent, however, that the modi~ication
o~ such characteristics is si~ni~ican~ and quite unique as applied
to a brQad range o~ ~abrics and may be easily identi~ied by
comparison o~ the Eabric substrate aPter modi~ication to an
untreated control sample or even to a sample o~ the same
composition and structure which has been surace finished using
conventional techniques, and thus will be very clearly shown in
the examples below.
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1 15602~
The shape oE the protrusions has been described in
general as being lamella-shaped. This characterization is not
meant to imply that individual protrusions have a precisely
identifiable and reproducible shape. Rather, the term "lamella"
is used in i-ts conventional sense to refer to a thin, flat scale
or part (see Webster's Seventh New Collegiate Dictionary, 1965
ed.). Individual protrusions, furthermore, may be of a rather
irregular shape, some even being rather long by comparison to
their cross-sectional dimension. Nonetheless, on the average,
the protrusions are rather short and are rather flat in cross-
sectional dimension rather than being of a generally circular
cross-sectional dimension which might characterize a true "fibril."
It has also been observed particularly with regard to
the pre~erred products of the present invention that fre~uently
the cross-sectional dimension of the fibers on or near the
surface of the textile material themselves may be distorted as
a result of the mechanical surface treatment o the present
invention while the dimension of the fibers not at the surface
may remain undisturbed. This has been observed in certain
instances, such as where the fabric sample is a thin, hard fabric,
as a "smearing" of the synthetic fibers which are thermoplastic
in nature. This smearin~ may be a xesult of thermoplastic
defQxmation although appliaant is not ce~tain o~ the mechanism
by means of which such "smearing" occurs and is not to be bound
thereby. Furthermore, individual syn-thetic ~ibers at or near
the~ surface of the tex-tile makerial may actually be ~lattened
somewhat as a result o~ the mechanical su~face finishing. For
example, if the cross-sectional dimension o~ the individual fibers
is substantially circular prio~ to mechanical surEace treatment,
lt may be observed that after mechanical surface finishing the
cross-sectional dimension becomes somewhat ovoid. If the cross-
sectional dimension is multi-lobal on the other hand, there may
11 5B02 8
be a s~bstantial deformation of this configuration with regard
to fibers at or near the surface. This observed smearing effect
and the distortion of the cross-sectional dimension of the
individual fibers at or near the surface of the textile material
may con~ribute to the beneficial surface characteristics of the
textile material product of the invention.
Figure l is a preferred apparatus o~ the invention
designed to carry out the process of the present invention, and
the apparatus oE the invention may be fully understood by
reference to the detailed description of the apparatus.
Figures 2 through 5 are schematic views of alternative
embodiments of the present invention, showing various means o~
obtaining intermittent mechanical impact between a sanding means
and the fabric being finished.
Figs. 6 and 7 are scanning electron pho~omicrographs
(SEPMs) of a double knit fabric that has had no mechanical
surface finishing at lOOX and 350X respectively, such fabric
being used for control purposes.
Figs. 8 and 9 are SEPMs at lOOX and 350X ot a knitted
yarn treated in accordance with the present invention.
Figs. lO and ll are SEPMs at lOOX and 350X of a fabric
conventionally surface finished by means oE a Gessner sander.
Figs. 12 through 52 are ~urther SEPMs at dif~ering
decJrees o~ magnification o~ Various control samples, variou5
25 produc-ts treated according to the process of the present
invention and certain produets havincJ conventional surEaeq
~inishes all as set out in Eurther detail in the ~ollowing
speci f i ca tion.
Referring now to the drawinys and in particular to
Figure l, the ~abric lO to be treated is unrolled fxom a
fabric supply roll l under eontrolled tensio~ and led to guide
rolls 2 and 3. Guide rolls 2 and 3 ma~ either be fixed or idling
~ 1 S6028
rolls, and they function to position the direction of the fabric
so that its continued path will be in approximately the vertical
direction while it maintains contact over substantially its
entire width with the lower guide plate 4a. The path of the
fabric continues over the upper guide plate 4b of the guide
plate set and passes between fabric stabilizing rods 5a and 5b
over fabric guide plate set 6a and 6b and to guide rolls 7 and
8 which function to change the direction of the abric, which
then moves to fabric take-up roll 9 onto which it is wound.
Guide plate sets 4a and 4b and 6a and 6b may be adjusted
in both the horizontal and vertical directions. The construction
of g~ide plate sets 4a, 4b, 6a and 6b may vary widely and may
consist of plates as illustrated or actual channels. Between
guide plates 4a and 4b and 6a and 6b the fabric passes between
abrasive rolls 11 and lla and corresponding flap rolls 12 and 12a.
The abrasive rolls are covered with a suitable abrasive material
such as sandpaper, the grit size of which may vary depending
upon the desired effect as described more fully below. Guide-
plates 4a and 4b and 6a and 6b are adjusted to position the
fabric accurately so that it will pass near to but not touch
sanding rolls 11 and lla unless it is impacted onto the sanding
rolls by ackion of flap rolls 1~ and l~a as described more fully
below. ~tkached by su~table means to rolls 12 and l~a are ~laps
illustraked in ~igure 1 as 13a, 13b, 13c and 13d on roll 12 and
2S flaps 13e, 13~, 13g and 13h on roll 12a. ~he flaps may he in-
8 talled as lllustrated by simply bolking them on~o ~he flap roll
so that when the rolls are at rqst the plane of the ~laps i9
essentially tangential to the rolls. In this embodiment, when
khe flap rolls are rapldly rotated, the centrifugal ~orce will
extend t.hem substantially radially from the roll. The ~laps may
also be installed so that they extend radially from the flap roll
even while the roll is at rest, i.e., in the absence of cen-
1 15~02~
trifugal forces. The flaps may be made of a wide variety ofsuitable reinforced or non-reinforced materials such as n~oprene
rubber, urethane, polyvinyl chloride, nylonl or even steel and
other sheet ma~erials and even composites thereof of sufficient
durability and flexibility to accomplish the desired result. The
flap rolls may be driven by motor 14 via drive shaft 24, pulleys
15 and 15a and 17 and 17a, belts 16 and 16a and shafts 18 and 18a.
Sanding rolls 11 and lla may be driven by motor 19 via drive
sha~t 25, pulleys 20 and 20a and 22 and 22a, belts 21 and 21a via
shafts 23 and 23a.
When in operation sanding rolls 11 and lla rotate as do
flap rolls 12 and 12a. The distance between flap rolls 12 and
12a and sanding rolls 11 and lla respectively is adjusted so that
in the absence of fabric 10 the flaps would impinge upon sanding
rolls 11 and lla to a predetermined depth of the flaps. When the
machine is operating and threaded up with fabric 10, flaps 13a-h
will be extended substantially radially by centrifugal force from
the rapidly rotating rolls 12 and 12a respectively and will inter-
mittently impact the fabric with considerable ~orce onto the
sanding rolls 11 and lla.
Depending upon the desired ef~ect, the sanding rolls 11
and lla and the flap rolls 12 and 12a may independently be
rotated either clockwise or counterclockwise. Speed of rotation
oP both the sandlng rolls and ~lap rolls may also vary widely
dependiny upon the deslred e~fect5 ~s described below.
Fiyure 2 provides a more detailed representation o~ a
treatment station which comprises the sanding roll 11 and ~lap
roll 12 with ~laps 13a, 13b, 13c and 13d and Eabric guideplates
4a and 4b. In this schema~ic drawiny the ~abric 10 is shown
while beiny impacted by ~lap 13c onto the abrasive cover of the
sanding roll 11. It should be noted that while Figure 1
illustrates only two treatment stations both oE which are of the
1 15602~
same type as that illustrated in Figure 2~ the actual apparatus
may include only one station or alternatively two or more
stations, e.g., three, four or even more stations may be provlded
on the apparatus ~or treatment o~ one or both sides of the fabric.
The treatment stations, furthermore, need not necessarily be all
of the same type as illustrated in Figure 1 but rather may
include stations of different types, e.g., those illustra-ted in
Figures 3 and 4 discussed below, as well, even on the same
apparatus.
As mentioned, Figures 3, 4 and 5 illustrate alternative
treatment stations provided with means by which the fabric may
be caused to impact onto a rapidly moving abrasive means, al-
though it should be appreciated that there may be others within
the scope of the present invention. In Figure 3 the fabric 10
is caused to impact onto the abrasive covered roll 11 by means
of a rapidly rotating non-circular bar, for instance as
illustrated a square bar 30 which will alternately allow the
fabric to clear the sanding roll and to impact it upon the roll.
In this embodiment the roll 11 may be covered with a compressible
foam which is placed on the xoll between its outer periphery and
the abrasive means so that the impact of the fabric 10 upon the
abrasive means is softened and jamming o~ the fabric between the
a~rasive means and the impacting means is prevented. Alt~rnatively
the non--circular bar 30 may be covered wi-th a compressiblq ~oam
~or the same purpose. Also, it is particularly advantageous in
the embodiment of the invention illustrated in Figurq 3 that the
impacting means 30 be dlsposed either above or below the point
oE closest proximity between the abrasive means 11 and the
impacting means. Such disposition o~ the impacting means may
also be advantageous in the alternative ~mbodiment illu~trated,
for instance, in Figures 2, ~ and 5 as well as in other embodiments
where the impactiny means may be, for instance, an oscillating
--10--
1 ~5~02~
bar or even a rotatin~ eccerltric roll, and the like.
Figure 4 illustrates a further embodimen~ where an
intermittent airstream 40 is emitted from a nozzle 42 to cause
the fabric 10 to be impacted intermittently upon the surface of
the sanding roll 11.
Figure 5 illustrates yet another embodiment of the
apparatus of the present invention. In this embodiment the
fahric 10 is moved over idler roll 50 changing its direction and
then over spacing rolls 51, 52, 53, 54 and 55. Then the fabric
is caused to move over idler roll 56 to again change the fabric
direction. The spacing rolls are designed to prevent contact
between the fa~ric 10 and the sanding surface unless impacted
upon it by the flaps as illustrated. Thus, during operation flap
rolls 62, 63, 64 and 65 impact the fabric 10 onto the abrasive-
covered surface of llb with flaps 66a through d, 67a through d,68a through d and 69a through d.
A wide variety of fabrics may benefit from being processed
according to the present invention. Examples of such fabrics
include woven, knit, non-woven fabrics, as well as coated fabrics
and the like. Even certain films may beneit from treatment
according to the present invention and films made from polymers,
paper, and even natural products in sheet ~orm such a~ leather
may be processed according to the present invention. Examples
of knit fabrlcs include doubl-~ knits~ jerseys, tricot~, warp
2S knit ~abrics, we~t insertion ~ahrics, eta. Woven ~abric~ may
be plain weaves, twills or other well-known constructions. Such
eabric may be constructed from spun or ~ilamen-t yarns or may be
constructed by using both types o~ yarns in the same ~abric.
Fabrics made ~rom natural ~ibers such as wool/ silk, cotton, linen
may also be treated, althou~h the preferred fabrics are those
made ~rom synthetic fibers such as polyester fibers, nylon ~ibers,
acrylic fibers, cellulosic ibers, acetate fibers, thei.r mixtures
:1 ~ S6~28
with natural fibers and the like. Particularly significant
improvemen-t in -the surface characteri~tics of fabrics has been
observed on ~abrics containing polyester fibers.
As noted above, fabrics processed according to the present
invention generally may be characteri~ed as having a more uniform
surface finish than fabrics processed according to conventional
methods. The process may be used to provide a finish on the
fabric surface which may be apparent to the naked eye, or a
finish may be achieved which may not be apparent to the naked eye
but which is quite apparent to the touch. The fabric may assume
a generally softer hand and the fabric bending modulus may be
reduced.
Fabric such as knit texturized polyester filament fabrics
may be caused to shrink upon being processed accoraing to the
present invention in the width direction resulting in a higher
fabric weight. Furthermore, even if the fabric is stretched
again to its original width and approximately its original weight
per unit area, the fabric may generally be characterized as
having a fuller, bulkier hand. Polyester filament fabrics may
lose their undesirable "plastic-like" feel and the hand of such
~abrics will become more simi}ar to ~abrics made ~rom natural
fibers such a~ wool or cotton. Products such as polyest~r douhle
knit ~abxics may, in cer~ain in~tances, be characteriæed as
having a density, uniformity and shortness o~ cover which cannot
~5 be obtained prac-tically by means o~ conventional sanding or
napping technlques
~ h~ p~ocess o~ the prasent invention permits inishing
o~ ~abrlcs which are generally too stretchy or -too light in
weight to be ~inished b~ conventional sanding techniques. Con-
ventional methods rely frequently on tension to bring the fabricinto contact with the sanding means. Where contact is
accomplished by compressing the fabric between a backing and the
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1 ~ ~6~8
sanding surface, tension is required to ]ceep the fabric frombeing grabbed by the sanding roll and wrapped around it. Due
to the in~ermitten-t na-ture of the contact with the sanding roll
and due to the proper use of fabric guiding plates a considerably
lower amount of tension is sufficient accorcling to the process
of the present invention so that it is possible to finish very
lightweight fabric such as ligh-tweight jersey knits. These light-
weight jerseys in conventional finishing techniques pose very
serious problems because they elongate very easily and neck down
under tension, and their selvedges have a tendency to roll under
tension. Also, in conventional sanding techniques it is almost
impossible to control the degree and uni~ormity of treatment of
lightweight woven fabrics while both results are possible accord-
ing to the process of the present invention.
It has been found that particularly good results may be
achieved according to the process of the present invention by
application of the process to a double knit such as that con-
structed from texturized polyester filament yarns, e.g., from
150/34 denier yarns. Ordinarily, in order to obtain an appealin~,
soft, spun-like, uniform surface finish by conventional sanding,
fabrics of this type must be constructed from more expensive
yarns, ~or example 150/50 denier or even 150/68 denier yarns.
Fabrics constructed from lS0/34 deniex yarns, however, generally
provide a choppy, coarse-feellng, non-unlform surface finish when
~5 sanded conven-tionally. ~t has been Eound, however, surprisingly
that fabric~ made ~rom such 150/3~ denier texturized polyester
yarns may be subjected to the process of the present invention
to obtain a spun-type finish on the fabric that is approximately
e~uivalent in hand and appearance to the ~inish obtained by con-
ventional sanding o more expensive fabrics constructed rom, orinstance, 150/50 denier texturized polyester filament yarns.
Because a heavier fabric generally must be constructed from, for
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1 1 58028
instance, 150/50 denier filament yarn in order to maintain fabric
crispness, the abili-ty to use a fabric constructed from 150/34
filament texturized polyester yarns yielding an e~uivalent finish
also permi~s the use of a lesser weight fabric.
The process of the present invention i5 not limited,
however, to textile materials per se and, for instance, appli-
cation of the process to clear films may result in a matte-type
finish providiny a translucent film. Application of the process
to paper of sufficient strength to undergo treatment may result
in a softening of the surface of the paper.
According to the process of the present invention,
successive adjacent sections of the fabric are intermittently
impacted upon an abrasive means across the entire width of the
fabric. The fabric is ordinarily extended to its open width
and may be moved in the warp or longitudinal direction. Sustained
substantial contact between the fabric and the abrasive means
is avoided, the mechanical impact being of a force and frequency
sufficient to cause a substantially uniform modification of
the surface characteristics of the fabric. As will be apparent
to those skilled in the art, the extent of modification of the
surface characteristics, the specific effects obtained, and the
rate at which thes~ effects may be obtained will depend upon
the opera~ing conditions of the machine used in the proc~s~ and
~he na~ure o~ the ~abric being treatecl, Operating parameters
~5 of -the appaxatu~ used in the process, e.g., Eorce and frequency
of impact, gri-t si~e Oe abrasive means ancl other variables, may
be adjusted over a broad range. For i.nstance, the linear speed
QE the fabric relative to the sanding means may vary from about
1 yard to abouk 200 yards per minute and will preferahly be
between about 5 and about 100 yardq pex minute, depending upon
the nur~er of treatment stations available, the type of fabric
and intensity and character of the treakment desired.
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1 15~2~
Where the abrasive means is a sanding paper, the grit of
the s~ndillg paper ma~ vary widely, wlth grit sizes of about 16
to about 600, preferably between about 80 and about 400, e.g.,
about l80 to about 320 beiny appropriate. On machines with
multiple treatment stations different size grits may be em-
ployed for the different sanding rolls in different sequences
to accomplish specific e~fects. For example, it has been found
desirable to pre~reat the fabric at a first sanding station wi~h
a airly coarse grit in order to make the fabric surface more
easily alterable by the subsequent finer grits at subsequent
treatment stations.
The use of finer grit sanding paper will be particularly
recommended for lightweiyht fabrics made from fine denier fibers
or filaments, and will also be recommended for other fabrics, if
a particularly subtle and fine finish is desired and when it is
desired that the effects of the treatment be confined primarily
to the fabric surface. The relative intensity of the treatment
accomplished by means of the pre~ent invention is dependent not
only upon the grit of the abrasive means but also on the force
of the impact of the fabric on the abrasive means. This is in
turn a function o the radius of the flap roll, flap length,
bending modulus of the ~laps, specific yravity or density of the
flaps and the extent to whiah the flap ~ront edge does not clear
the sur~ace of the opp~sing sanding roll and speed o~ xotation
o~ the Elap roll,
In general it has been Qbserved that a s:Lgni~icant ef~ect
may be obtained accordiny to the process o~ the pres~n-t invention
with a ~iner yrit sandpaper than that used in standard sanding
because the cutting edyes of the yrit are impacted upon the
~ibex~ o the ~abric with considerable force causiny most i~
not all o~ the sanding grains to cut into or abrade the surPace
of the tex~ile material. Since a signiicAnt efect is obtained
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1 1 5602~
with a finer grit and since simultaneously more cutting grains
of a finer c3rit are located on the surface of the sandpaper
per unit area it is thought tha-t the number of fibers a~fected
per unit surface area is consequently siqnificantly greater than,
and perhaps several times, that obtained with the coarser gxit
material in a normal sanding operation so that the ~inish which
results is more uniform, fine and dense. Thus, fre~uently
fabrics treated according to the process of the present invention
may not require shearing since the individual fiber ends which
are formed are generally very short and uniform in length which
also distinguishes the products of the present invention from
- those of conventional sanding techniques.
The surface speed of the sanding means relative to
the fabric may vary widely and may be between about 10 feet per
minute and about 8,000 feet per minute, preferablv between about
500 feet per minute and 2~500 feet per minute. As discussed
above in connection with the apparatus, the sanding roll may be
rotated clockwise or counterclockwise and the direction of
rotation of the flap rolls may either correspond to that of the
sanding roll or may be opposite thereto. For instance, where the
sanding xoll and the flap rolls are both rotated in a clockwise
direction very lightweight, stretchy fabric may have less
tendency to be grabbed hy the ~anding roll and to wrap around it.
~5 The force at which the ~abria is caused to impact
upon the abrasive means is a Eunction o~ the speed of rotation o~
the flap roll, ~he length and stifEness oE the Elaps, the diame-ter
o~ the Elap roll, as well as the density o~ the flap material,
and other variables, but ~enerally the flap roll will rotate at
speed~ ~rom about 100 to about 8,000 rpm's, pre~erably ~rom about
500 to about 6,000, e.ct. t abou-t 1,000 to about ~,001) rpm's.
Fabrics which have been processed pur~;uant to the
present invention may be subjected to various subse(~uent treatment
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11 SB02 8
operations. It has been found, for instance, that a particularly
appropriate post treatment for the products of the present
invention may be brushing. Thus, fabrics may be mechanically
surface finished according to the invention using comparatively
mild treatment conditions, e.g., a relatively fine grit sandpaper
as the abrasive means, or a relatively low impact force of the
fabric onto the abrasive means, or a comparatively lower frequency
of impact so that -the strength of the fabric is reduced less than
it might otherwise be. Then by brushing the fabric vigorously
using, for example, nylon or metal brushes, such as brass or
steel brushes, modification of the surface characteristics of
the fabric may be desirably enhanced.
I have illustrated and described what I consider to be
the preferred embodiments of my invention. It will be apparent,
however, that various modifications may be resorted to without
departing from the broader scope of the invention as defined by
the claims.
EXAMPLE 1.
A doubleknit fabric was prepared from 1/150/50
~o Monsanto* type 446 100 percent texturized polyester filament yarn.
The fabric was scoured, jet-dyed to a light blue color, slit and
then heat set to provide a control sample. The finished weight
was betwe~n 13-3/~ and 14~ ounces per yard, with a width of
hetween 60 and 62 inches. q'he Mullen Burst Strength (ASrrM No.
D-231 (1975)) was ~76 lbs, Flgures 6 and 7 are scanning electron
photomicrograph~ (SEPM) kaken o~ the ~abric at lOOX and 350X
respectively.
A separate sample o~ the above yarn was knitted and
the resulting doublekni-t was then processed by scouring, jet-
dyeing to a ligh-t blue color and ~litting. A~ter slitting, but
prior to heat settin~ the ~abric was mechanically sur~ace treated
according to the process of the present invention to provide a
*Trademark
-17-
1 15~028
product of the present invention. SEPMs of the sample are pro-
vided in Figures 8 and 9 at 100X and 350X. The processing
parameters are set forth below in the Table. After treatment,
the Mullen Burst value was 235 lbs.
Another sample of the above fabric was treated in
substantially the same manner as set forth above for the sample
according to the invention, although it was colored navy blue and
instead of mechanically surface finishing prior to heat setting
according to the present invention it was Gessner sanded. The
Mullen Burst value for the Gessner-sanded product after treatment
was 230 lbs. SEPMs of the Gessner-sanded product are set forth
below in Figures 10 and 11 at 100X and 350X.
Observation of the fabric treated according to the
present invention revealed that it had a very luxurious, warm and
soft surface hand and a very short, dense cover. The cover was
readily apparent to the naked eye although because of its relative
shortness it permitted the construction of the fabric to be fully
visible. The control fabric, that is the fabric that has had no
mechanical surface finishing, by contrast had a clear surface,
no cover, and had the typical hard, "plastic", somewhat slick
appearance and hand of texturized polyester doubleknits. The
appearance and hand of the sample trea~ed according to the present
lnven-~ion was compara~le -to -that o~ a ~abric prepared ~rom ~ine
wool yarns. The ~ample which was conventionally surface ~inlshed
by means of a Gessner sander clid not approach the desirable
characteristics o~ the sample -treatecl according to the present
invention, especially with regard to sotnes~ oE ~land, den~ity oE
cover, and similarity to a fahric made o ine wool yarn~.
Reference to the S~PM of the control sample, the sample treated
according to the present invention, and the conventionally sanded
sample at magnifications oE 100X and 350X shows that the fibers
of the abric of the present invention are broken to some extent
-18-
1 ~5~0~8
but are predominantly extensively modified by the formation oflamella shaped protrusions on the fiber surfaces and by the
formation of scar type surface modifications on the fiber surfaces.
The Gessner-sanded samples by contrast show a substantial number
of cut and broken fibers with only very minor modifications of
the surface characteristics of the individual fibers.
EXAMPLE 2.
Example 1 was repeated using a 1/150/34 100 percent
texturized polyester filament yarn. A control (untreated) sample,
~essner-sanded sample and a sample treated according to the
invention were prepared. In this example the Gessner-sanded
sample exhibited no significant difference from the untreated
control sample, and the product in fact did not have a commercially
acceptable finish due to the relativ~ly coarse nature of the
150/34 texturized poly~ster yarns from which it was made. This
same fabric which was treated according to the present invention,
however, had a significantly improved surface feel and a warm,
pleasant wool-like hand as compared to the control sample. In
fact, the sample compares very favorably to the Gessner-sanded
version made according to Example 1 from the more expensive
150/50 texturized polyester filament yarns. The Mullen Burst
value fox the untreated control was 280 lbs.as compared to 220
l~s. after Gessner-sanding and 240 lbs. af~er surface ~ini~hing
accox~ing to the pre~nt lnvention. ~hus, while the surface
2$ modi~i~ation i~ si~nificant according to the process of the
present invention, les.s strength lo~s is observed compared to
Gessner-sanding.
~X~MPLE 3.
The ~abxic used in thi.s Example was a yarn-dyed,
polyester doubleknit. The yarn used was a 1/lS0/34 texturized
100 percent polyester filament yarn. The control sample was
prepared by sponging, slitting and drycleaning the knitted fabric.
--19--
6 0 2 8
The finished weight was 12.~ ounces per yard, with a width of
64 inches, and a Mullen Burst strength of 215 lbs. The sample
of the present invention was then processed as set forth in the
Table. The Mullen Burst value was 120 lbs. After surface
finishing the fabric was heat set, sheared, heat set again and
decated. The finished weight was 11.6 ounces per yard, with a
width of 60 inches.
A sample of the same cloth was then processed in the
same manner as described above except that instead of mechanical
surace treating according to the present invention the fabric
was napped after the first heat setting operation, and then
sheared, heat set again and decated. The finished weight was
11.70 ounces per yard with a width of 59-1/4 inches.
The fabric treated according to the process of the
invention had a very soft, cotton-like surfac~ hand as compared
to the typical hard, sl'ck, "plastic" and unappealing hand of
the untreated control sample. Because of the relative shortness
of the cover on the fabric treated according to the invention the
clarity of the pattern o~ the fabric was not obscured to any
measurable extent except for a very minor reduction of color
contrast. The fabric construction, however, was still discern-
able. The napped fabrie made from the same control fabric had
a much harsher, drier somewha~ wool-like hand. Both the eolor
patt~rn on the sur~ace anA the construction ~eatures o~ the ~abric
w~re extensively obscur~d by napping. Figures 12l 13 and 14 are
SEP~ at 35X, lOOX and 350X of the control sample. Figures 15,
16 and 17 are SEPMs at 3SX, lOOX and 350X of khe doubleknit yarn
dyed produc~ which has been kreated according to the process o~
the present inv~ntion. Figures 1~, 19 and 20 show SEPMs at 35X,
lOOX and 350X xespeetively o~ the napped samples. Comparison o~
the SEPMs reveals that the ibers at or near the suraee of the
sample which has been kreated aeeording to the process o the
-20-
1 ~5~028
invention are relatively severely modified with the ormation of
lamella~type protrusions and scars as well as by a very small
amoun~ of cut fibers. The napped samples by con~rast show very
little or no actual fiber surface modification although there are
a substantial n~er of cu-t fibers. Visual observation reveals
that the napped sample has a random layer of disoriented fibers
established on the surface forming a substantially flat cover on
the fabric. The yarn structure has been substantially disturbed,
and the original construction is lar~ely obscured. On the sample
treated according to the process of the present invention, by
contrast, the original yarn structure is substantially intact
and very few randomly oriented fibers are observed on the surface
of the fabric.
EXAMPLE 4.
T~e characteristics of 100 percent acrylic doubleknit
were compared before surface finishing according to the present
invention and after such finishing. The processing conditions for
the mechanical surface finishing according to the invention are
set forth in the Table.
It was found that the sample which was treated accord-
ing to the invention had a more natural, wool-like feel and a soft
surface hand, while -the control sample by comparison had a some
what pla~tic-like hand typical of synthetic ~abrics, although the
pla~tic-llke appearanae was ~omewhat less apparenk than would be
2S the case ~or ~abrics made from polye~ter ibers~ Examination o~
the 5EPMs o~ the abrlc according to the present inventlon shown
in Figures 21 and 22 at 100X and 350X respectiv~ly show the
ormation again of lamella-type protrusions on the iber suxface
a~ well a~ scarrlng of khe fiber surace. Comparison to the con-
trol samples shown in Figures 23 and 24 again at 100X and 350X
show no similar characteristics.
-21-
~ :~56~28
EXA~IPLE 5.
The characteristics obtainable by the process of the
invention applied to 100 percent polyester woven fabrics made from
a filament warp yarn and a spun filliny yarn were compared. The
starting fabric was woven from a 2/150/34 Danbury-24T Dacron*
5 polyester filament warp yarn (lot number 841). The filling yarn
was a spun 12/1 T-350 Trevira* polyester yarn.
The control sample was prepared by Mezæera treatment,
jet-dyeing with a navy blue dye, and finished by heat setting,
shearing, and decatiny. The finished width was 59.4 inches
10 (inside selvedges) with a weight of 11.5 ounces per yard. The
strength as measured by the Scott Grab Tensile test (ASTM number
D-1682, ~1975)) was 263 lbs. for the warp and 156 lbs. for the
fill.
The above processing sequence for the control sample
15 was modified by surface treatment according to the present invention
prior to Mezzera treatment with the remaining steps in the process
being identical to those set forth above Eor the control sample.
The finished weight and width were the same as for the control
sample. The mechanical surface treatment conditions are set forth
20 in the Table below. After tréatment the Scott Grab Tensile (SGT3
value was Eor the warp 205 lbs. and for the fill 47 lbs.
The above procedure was repeated except that the
mecharllaal surface treatment accordiny to the invention wa5 per-
~o~med after Mezzera treatment and prior to jet-dyeing with the
~5 o-ther processing s~eps being in the same order. The ~lnished
weiyht ancl width were the same. SG~ strenyth ~or the warp was
2~6 lbs. and Eor the fill was 75 lbs~
~ he above process was repeated again exGept that the
mechanical sux~ace ~reatment according to the inventic)n Wcl9 per--
30 formed after jet-dyeing and prior to heat setting with the other
processing steps remaining the same. The Einished weight and
*Registered Trademark
--22--
I 1 5 ~28
fabric width were again the same.
The latter procedure was followed again except that
instead of mechanical surface treatment according to the
present invention prior to heat setting and after dyein~ the
fabric sample was Gessner sanded at this stage in the process.
The finished weight and width were the same. The SGT value
was 259 lbs. for the warp and 93 lbs. for the fill.
The above procedure was repeated again except that
napping was performed on the fabric af~er jet-dyeing but prior
to heat setting. The finished weight and width of the fabric
were the same. The SGT value was 264 lbs. for the warp and
147 lbs. for the fill.
Examination of the samples which were processed
according to the invention be~ore dyeing revealed that a wool--
like hand was achieved. Mechanical surface treatment accordingto the invention after dyeing of the fabric resulted in a fabric
having a cotton-like hand.
Thus, it can be seen that appropriate variation of
the processing steps can be used to achieve two distinct:L~
different products from the same starting material.
Depending upon the processing sequence the samples
treated according to the invention generally had a very attractive,
soPt and pleasant wool or cotton~ e hand, while the fabric
which did not have any sur~ace treatment had the customary hard,
harsh Eeel of polyester ~abric. Sanding by conventional means,
namely with a Gessner sander, resulted in only minor modification
~P the hand of the control sample, although the result dld not
app~oach either the softnes~ or luxuriousne~s oE the surPace fecl
obtained by the present invention. The sample which was napped
resulted in a relatively so~k surEace hand a~ compared to
conventional sanding, but it did not produce either a pleasant
or a soft surface finish as was achieved according to the present
1 ~56028
invention, especially where the surface treatment was performed
prior to dyeing. Also, i-t was noteworthy that napping resulted
in a considerably less uniform and longer cover with a great
deal of "wild hair~' protruding from the fabric surface. Even
ater shearing the finish obtained by the present invention was
both more uniform and more attractive than the finish obtained
according to the conventional techniques.
Fiqures 25 and 26 are SEPMs of the control samples at
lOOX and 350X respectively. Fiyures 27 and 28 are the Gessner-
sanded samples at lOOX and 350X, and Figures 29 and 30 are the
samples which were napped, again depicted at lOOX and 350X.
Figures 31 and 32 are the samples which were finished according
to the present invention by mechanical surface treatment after
dyeing but prior to shearing and decating. Examination of SEPMs
of the sarnples mechanically surface finished prior to Mezzera
treatment and those treated after Mezzera treatment but prior to
dyeing appeared almost identical to Figures 31 and 32 and, there-
fore, need not be shown. As the SEPMs reveal, the fabric samples
treated according to the invention, whether prior to dyeing or
after dyeing; all showed substantial lamella protrusions from
the surface of the fabric as well as a substantial amount of
~carring. Plastic de~ormation of the fibers was also evident.
Conventional Gessner sanding resulted by contrast in only a
limit~d amount of Piber surPace modi~iation with lit~le or no
lamella Pormation and no plastic de~ormation o~ the ~ibers.
Napplng resulted in even less Pibex surPace modiPication, no
plastic deformatlon uf the polymeric ~ibers although a signiPi-
cant amount oP Piber cutting i5 apparerlt.
EX~MPLE 6.
A jersey kni~ was mechanically surface finished
according to the present invention and compared with a non-
finished control sample. The control was prepared ~ro~ 100
-2~-
1 ~56~28
percent Dacron polyester T-56 1/70/34 yarns. The sample was
processed by Mezzera treatment, jet-dyeing a light green color,
slitting and heat setting. The finished weight was 5.75 ounces
per yard with a width of 63 inches. The Mullen Burst strength
was 130 lbs.
Next, the above process was modified by treatment of
the fabric after heat setting according to t:he invention. The
process and conditions were as set forth in the Table. The
Mullen Burst strength after treatment was 123 lbs~
Observation of the finished samples reveals that the
sample treated according to the present invention had a soft,
warm, and luxurious hand; while the untreated control had a
relatively slick surface hand typical of polyester fabrics. The
sample treated according to the invention may be said to have a
5 hand that is comparable to that of fabrics made from spun yarns.
EXAMPLE 7.
Samples of 65/35 polyester cotton blends were treated
according to the present invention and then compared to control
samples. The warp and fill yarns were both 65 percent polyester,
35 percent cotton. The control sample was prepared by s:ingeing
and mercerizing the fabric. The finished weight was 4.86 ounces
per square yard and the finished width was 60.3 inches. A
~eparate sample o~ the fabric was processed in the same manner as
the control sample but was subsequently ~inished by treating
accordiny to the process of the invention. ~he treatiny condi-
tlons are set for~h in the ~ahle. ~or comparison purposes an-
other sample was treated as above by singeing, merceriæin~ and
then ~essner ~anding, ollowed by range dyeing, inishiny and
~an~orixing oE the cloth.
~ vi~ual comparison o the control sample with the
sample treated according to the present invention showed that
the sample of the invention had a substantially softer and moxe
-25-
~ 15~02~
pleasing, cotton-like surface hand than the control without any
significant loss in fabric crispness. By comparison sanding of
the same style fabric by conventional sanding provided vexy
little beneficial effect on the fabric in terms of its hand, or
other characteristics.
Figures 33 and 34 are SEPMs of the control sample at
100X and 350X. Figures 35 and 36 are SEPMs of the sample which
was processed according to the invention, also at 100X and 350X.
Figures 37 and 38 are SEPMs at 100X and 35t)X of the Gessner-
sanded sample. Examination of the SEPMs revealed that the samplewhich was tr~ated according to the process of the invention has
lamella-type protrusions on the fibers at or near the surface of
the fabric. There were also a few cut fibers, scarring and
significant thermoplastic deformation of the polyester fibers.
It was also evident that the yarns immediately at the surface
of the fabric were flattened, apparently in conjunction with
thermoplastic deformation of the polyester fibers. Observation
of the SEP~s of the Gessner sanded samples revealed that the
process resulted in very little modification of the surface
fibers although certain randomly oriented fibers and some cut
Pibers were present on the fabric surface.
_XAMPLE 8~
A sample o~ woven 80/20 polyester cotton having a spun
warp and a filament fill yarn wa~ trea~ed accordlng to the process
~5 o~ th~ inven~ion and compared with a control ~ample. The warp
yarn wa~ a 6S percellt polyester, 35 percen-t cotton ya~n. The
fill yarn was a texturized 100 percent polyester fllament yarn.
The control sample was prepared by the steps of heat
setting, sinyein~ and mercerizlng. The ~inished w~iyht was 4.94
ounce~ per s~uare yard and the finished width was 60.2 inches.
SGT strength of the warp was 133 lbs. and 131 lbs. for the fill.
-26-
~ 156028
A sample of the above ~abric processed in the identical
manner was finished by mechanical surface treatment according to
the process of the invention. The finished weight and width were
both the same as or the control sample. The processing con-
ditions are set forth in the attached Table. The resultiny
SGT strength was 122 lbs. ~or the warp and 101 lbs. for the fill.
A similar fabric having a spun warp yarn of 65 percent
polyester and 35 percent cotton and a fill yarn of textur;zed
100 percent polyes-ter filament yarn was processed by heat setting,
steam treating, mercerizing, and range dyeing to provide a tan
fabric. The fabric was then conventionally Gessner sanded,
finished and sanforized. The finished weight was 5.35 ounces
per square yard, and the finished width was 60.5 inches. The
SGT strength for the warp was 207 lbs. and for the fill was 181
lbs. The tensile strength characteristics of the fabric prior
to treatment were unavailable.
Visual comparison of the sample treated according to
the present invention with the control sample showed that while
the surface appearance of the fabric was not significantly changed,
the surface feel of the fabric treated according to the present
invention was substantially softened as compared to the rather
hard surface feel of -the untreated control sample. The Pabric
crispness Oe the treated samples as compared to the control
sample was substantially retained. By contras-t, little or no
advantageous modiEication was observed when a similar fabric was
subjected to Gessner sanding
Figures 39 and 4~ are SEPMs oE the control sample at
lOOX and 350X. Figures 41 and 42 are SEPMs taken at lOOX and 350X
of a sample which has beqn prepared in the same manner a5 the
3Q control sample and then mechanically surface finished according
to the invention. Figures 43 and 44 are SEPMs of the sample
which has been Gessner sanded and prepared as described above.
1 1S6~2~
Examinat1on of the SEPMs shows that very few of the fibers are
cut in the sample processed according to the present invention.
Rather, the surface of the fibers has been significantly modified
in the process. Some lamella-type protrusions are produced and
scarring was particularly obvious. Some plastic deformation of
the polyester fibers was observed. Also, a flattening of the yarn
surfaces was again observed. With regard to the Gessner-sanded
sample, except for some cutting of the fibers there was little
apparent effect on the fibers of the fabric.
EXAMPLE 9.
An 80/20 polyester/cotton blend fabric was treated
according to the process of the invention using the processing
conditions set forth in the Table before range dyeing. After
range dyeing it was observed that some of the advantageous
characteristics of the fabric treated according to the process
of the invention were apparently lost. This sample, however,
was subsequently brushed with either a nylon brush or a steel
brush, and it was observed that the original beneficial effects
were re-established and actually significantly enhanced, without
any substantial strength loss. In fact, it was determined that
even where the sa~ple was mechanically surface finished according
to the invention after dyeing that the advantageous effect of
brushin~ with either a nylon or a steel brush resulted in a
signi~icant enhancemenk of the beneEicial eEfects of the
mechanical sur~Ace treatmerlt in terms o~ both fabric surface
34~kness, pleasankness and luxuriousne3s Qf feel, again wikhout
any substantial stxengkh loss. A similar sample which was not
mechanically surface finished acco~din~ to the invention was
simply bxushed after dyeing with a nylon hrush and a separate
sample was brushed with a skeel bxush under e~uivalent conditions
and practically no beneficial efect on the samples were observed.
-28-
1 1 56~28
EXAMPLE lO.
A lO0 percent filament embossad woven polyester
napery fabric was treated according to the process of the
invention, and its characteristics were compared to that of an
untreated control sample. The sample treated according to the
invention had a pleasing a~rance resembling ~ t of genuine cotton
~acquard damask fabric and even the depressed embossed areas of
the fabric were beneficially a~Eected. By contrast, the untreated
control sample had a glass-like sheen and a plastic appearance
quite dissirnilar to the subtle and fine appearance of the high
priced jacquard woven damask fabric.
EXAMPLE ll.
A control sarnple of woven lO0 percent polyester
filament warp and fill napery fabric was prepared and its
characteristics were compared to that of a similar sample which
was treated accordin~ to the process of the invention. It was
observed that in addition to the improved surace hand
characteristics, tablecloths or napkins made from the above-
described material and processed according to the invention
could be stacked without the piles of stacked fabric sliding
and falling down. The overall appearance of the fabric was,
however, changed ver~ lit~le and the fabric had a complekely
clear face~ However, the abxic in e~ect clid have a very
advantageou~ cotton-llke hand.
2S E~AMPL~ 12 a
rrhis ~xample illustrates applicat.lon of the process of
the lnvention to a 100 percent nylon nonwoven point-bonded fabxic.
A control ~ample was prepared and a ~epaxate sample was sub-
sequerltly processed accordin~ to the invention. The processing
conditions are set foxth in the Table. The nonwoven nylon fabric
when treated according to the process oE the invention exhibited
a dramatically soter, kinder surface hand than the s1.ick, "glassy"
_~9_
1 1 56~28
starting material. A dense, somewhat longer cover was created
giving the surface of the fabric the touch and surface ~eel of
material made from natural fibers. Little strength loss was
encountered due to the treatment of the fabric. Comparison of
the SEPMs of the sample treated according to the process of the
invention shown in Figures 45 and 46 at 100X and 350X respectivel-
~to the control samples as shown in Figures 47 and 48 at 100X and
350X respectively shows that there has been a significant
generation of lamella-type protrusions on the fiber surface,
fiber surface scarring, and visual observation revealed cut
fibers.
EXAMPLE 13.
A control fabric was prepared of a napped substrate
fabric containing on its surface a coagulation type coating. A
separate sample of the fabric was processed according to the
invention using the processing conditions set forth in the Table.
Observation of the fabric revealed that the original
control fabric had a soft but tacky surface hand while the fabric
which was treated according to the process of the invention had
an even, softer but a tctally non-tacky surface hand. The
appearan~e of the sample treated according to the invention was
also somewha-t smoothqr and more uniform than that of the original
sample. ~e~erence to ths S~P~s shown in ~igure 49 at 350X show~
~hat khere had been a ~ro~s accumulation oE coag-llated polymer
present on the sur~ace oP the untreated control sample, By
contrast -the sample which has been treated according to the
process o~ the invention shown in Figure 5~ at 350X reveals that
while desirable small islands of the polymer coatin~ are still
present, gros~ accumulations have been substantially removed or
hroken up. Furthermore, the sample treated according to the
invention also exhibits the typical lamella-type protrusions and
scarring oE the fiber surfaces.
-30-
1 1$6~28
EXAMPLE 14.
Mechanical surface treatment according to the present
invention was performed on a polyethylene sheet material of 2
mils thickness. The processing conditions are set forth in the
attached table.
Observation of the sheet material which has been
mechanically surface finished revealed that the treatment
resulted in converting a substantially transparent film material
(the control sample) into a translucent film material with a
milky, non-slick surface. SEPMs shown in Figures Sl (the control)
and 52 (the treated sample) reveal that the treated sample
exhibited scratches, striations, lamella-type protrusions and
substantial plastic deformation of the surface. Quite similar
effects were observed when a nylon film was mechanically
surface finished and compared to an untreated nylon film.
Substantially the same results were also observed when a poly-
ester film sample was subject~d to mechanical sur~ace treatment
according to the present invention.
EXAMPLE 15.
In this Example, a heavy duty paper (white, light
cardboard-type) was subjected to mechanical sur~ace treatment
according to the pr~sent invention. Th~ papex had a thickness
o~ 11 to 12 mils. Observation of the pxoduct a~ter treatment
revealed that mechanical surEace treatment oE the paper resulted
in a mat, non-slick sur~ace as aomp~red to ~he untreated control
sample.
-31-
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