Patent Application
20240183089
The present application claims priority to and the benefit of Indian Patent Application Number 201921029368, filed Jul. 21, 2019, the entire contents of which are incorporated by reference herein.
The present disclosure relates to a hydroentangled composite fabric and a method of making such a hydroentangled composite fabric.
Woven fabrics made from cotton yarns or cotton blended yarns are widely used for bedding and other home textile applications due to several properties these particular fabrics possess. Woven fabrics are comfortable, compatible with coloring techniques and design applications, durable and stable when laundered repeatedly, strong, resilient and colorfast. Certain woven fabrics may be made wrinkle-free as well, as is common in sheets and bedding fabrics. Woven fabrics are also receptive to modifications that impart additional desirable properties, such as stain release, anti-microbial properties and moisture wicking, leading to added comfort. Balancing fiber selection, yarn design, fabric design, and process parameters with desired end use properties is difficult in application where comfort is an important decision point for consumers, such as bedding applications. Typical structures used in bedding applications, such as cotton and cotton blended yarns, or cotton/polyester blended fabrics present challenges in achieving the right balance of strength, durability, softness, moisture management, and other properties that are associated with these materials.
Nonwoven fabrics made using techniques such as hydroentanglement have certain advantages over traditional woven fabrics. For example, nonwoven fabrics made by hydroentanglement, where loose fibers are entangled with each other, are more soft and absorbent than woven textile materials, which are composed of yarns made through the tight interlacing of fibers or threads. In certain applications, nonwoven fabrics may be combined with woven fabrics to produce composite fabrics that achieve the benefits of both.
There is a need for composite fabrics that leverage the benefits of both woven and nonwoven fabrics such as high durability, wrinkle-free properties, lightness, moisture management, softness and anti-allergen properties. An embodiment of the present disclosure includes a hydroentangled composite fabric, comprising: a base woven fabric having a plurality of warp yams, a plurality of weft yams interwoven with the plurality of warp yams, and interstitial spaces between the plurality of warp yams and the plurality of weft yams. The hydroentangled composite fabric also includes a web of nonwoven fibers hydroentangled a) within the interstitial spaces, and b) with the plurality of warp yams and the plurality of weft yams, such that the nonwoven fibers are substantially entangled with each other and with fibers of the plurality of warp yams and fibers of the plurality of weft yams. The hydroentangled composite fabric also includes a plurality of pores defined by the web of nonwoven fibers, the plurality of warp yams, and the plurality of weft yams, wherein the plurality of pores have a diameter up to about IO microns, thereby defining the hydroentangled composite fabric.
In accordance with the illustrated embodiment, the hydroentangled composite fabric may have an air permeability of less than six centimeters cubed per centimeters squared per second according to test method ASTM D 737-96. The hydroentangled composite fabric may have a shrinkage that is less than one percent according to test method AATCC 150. The hydroentangled composite fabric may have a durable press rating of at least 3.0 according to test method AATCC 143. The hydroentangled composite fabric may have no detectable formaldehyde content according to BS EN ISO 14184 test methods. The hydroentangled composite fabric may have a wicking distance of at least 13 centimeters during a time period of thirty minutes according to test method AATCC 197. The hydroentangled composite fabric has a tensile strength of at least 80 pounds according to test method ASTM D 5034.
In accordance with another embodiment of the present disclosure, the hydroentangled composite fabric has a basis weight between 80 grams per square meter and 550 grams per square meter. The hydroentangled composite fabric has a thread count between 100 and 1000. The hydroentangled composite fabric, wherein the base woven fabric has a) a warp end density between about 50 warp ends per inch and about 350 warp ends per inch, and b) a weft end density between about 50 weft yams per inch and about 700 weft yams per inch.
In accordance with another embodiment of the present disclosure, the hydroentangled composite fabric includes a plurality of warp yarns that are selected from the group consisting of natural spun yarns, synthetic spun yarns, synthetic filament yarns, and blended yarns. The hydroentangled composite fabric includes a plurality of weft yarns selected from the group consisting of natural spun yarns, synthetic spun yarns, synthetic filament yarns, and blended yarns. The hydroentangled composite fabric comprises a base woven fabric, wherein the base woven fabric comprises pores having a diameter of at least about 40 microns.
An embodiment of the present disclosure includes a method for forming a hydroentangled composite fabric, the method comprising: weaving a plurality of warp yarns with a plurality of weft yarns to define a base woven fabric comprising pores with a diameter of at least about 40 microns. The method also includes combining the base woven fabric with at least one web of nonwoven fibers. The method also includes applying high pressure waterjets to the base woven fabric and the at least one web of nonwoven fibers to generate a hydroentangled composite fabric having pores with a diameter up to about IO microns. The method also includes drying the hydroentangled composite fabric to substantially remove moisture from the hydroentangled composite fabric.
In accordance with the illustrated embodiments, either or both of the warp yarns and the weft yarns comprise synthetic fibers and the method comprises heat setting the hydroentangled composite fabric. The method further includes pre-treating the base woven fabric with high pressure waterjets before the step of applying high pressure waterjets. Applying high pressure waterjets comprises applying high pressure waterjets with an oscillating nozzle. In addition, applying high pressure waterjets comprises applying high pressure waterjets at an angle. In this method, the high pressure waterjets are applied at a pressure of 50 bars to 400 bars.
The foregoing summary, as well as the following detailed description of illustrative embodiments of the present application, will be better understood when read in conjunction with the appended drawings. For purposes of illustrating the present application, the drawings show exemplary embodiments of the present disclosure. It should be understood, however, that the present disclosure is not limited to the precise arrangements and instrumentalities shown in the drawings. In the drawings:
Referring to
The hydroentangled composite fabric 10 further includes a web of nonwoven fibers 60 that are hydroentangled a) within interstitial spaces I, defined by a distance between adjacent warp yarns P measured in the weft direction 6 and a distance between adjacent weft yarns W in the warp direction 4, and b) with the plurality of warp yarns 20 and the plurality of weft yarns 40. The process to make the composite fabric 10 is such that the nonwoven fibers 60 are substantially entangled with each other and with fibers of the plurality of warp yarns 20 and fibers of the plurality of weft yarns 40. In certain embodiments, the combination of the base woven fabric 12 and web of nonwoven fibers define pores having a diameter up to about ten microns, thereby defining an anti-allergen hydroentangled composite fabric. The inventors have surprisingly found that particular fabric, nonwoven fiber constructions, and the process used creates fabrics with high durability, wrinkle-free properties, improved moisture management, softness, strength, and anti-allergen properties. In particular, the web nonwoven fibers 60 are hydroentangled with the base woven fabric 12 through the application of high pressure water jets. A hydroentangled composite fabric 10 as described herein may be suitable for anti-allergen bedding applications, such as sheets, fitted sheets, pillow cases, shams, duvets, blankets, comforters, pillow cases, mattress covers, and/or mattress pads.
Referring to
A number of different woven structures may define the base woven fabric 12 of a hydroentangled composite fabric 10 described herein or woven design repeats. As used herein, a woven design repeat includes at least a first warp yam 20a, a second warp yam 20b, and at least one weft yam 40. For example, a plain weave fabric has a woven design repeat that includes two adjacent warp yams 20 and two adjacent weft yams 40. Depending on the particular design, woven design repeats may repeat along: a) the warp direction 4; b) the weft direction 6; or both the warp direction 4 and weft direction 6. However, the design of the woven fabric is not limited to a plain weave. For example, the woven fabric can have a number of exemplary woven structures, including but not limited to: plain weaves; basket weaves, rib weaves (e.g. 2xl rib weave; 2×2 rib weave; or 3×1 rib weave) twill weaves; oxford weaves; percale weaves, satin weaves (e.g., satin dobby base, satin stripe satin 5/1, satin 4/1 satin; 4/1 satin base strip; 4/1 stain swiss dot; 4/1 downjacquard; 5/1 satins), sateen weaves, or percale weaves. In one example, the woven fabric is a plain weave. In another example, the woven fabric is a basket weave. In another example, the woven fabric is a percale weave. In another example, the woven fabric is a rib weave. In another example, the woven fabric is a twill. In another example, the woven fabric is an oxford weave. In another example, the woven fabric is a satin weave. Furthermore, a number of exemplary satin constructions are possible. For instance, in one satin weave example, the woven fabric is a 4/1 satin. In another example, the woven fabric is a 4/1 satin dobby diamond weave. In another example, the woven fabric is a 4/1 satin dobby stripe. In yet another example, the woven fabric is a 4/1 satin jacquard weave. In another example, the woven fabric is a 5/1 satin. In still another example, the woven fabric may be a 6/1 satin. In another example, the woven fabric is a 7/1 satin. In yet another example, the woven fabric is an 8/1 satin. In another example, the woven fabric is a 9/1 satin. In another example, the woven fabric is a 10/1 satin.
So-called “co-insertion” techniques may be used to insert multiple weft yams 40 along a weft insertion path 19 in a single weft insertion event during weaving, as will be further detailed below. The weft insertion path 19 is in dashed lines in
“Co-insertion” is where multiple picks or weft yams are inserted into the warp shed at one time during weaving. In co-insertion, two pick yams supplied from two different yam packages are inserted at one time through the shed during weaving. Co-insertion may also include inserting three or more yams supplied from the three or more different yam packages into the shed during weaving. In one example, the woven fabric has between one weft yam and 12 weft yams inserted during a single insertion event, i.e., along the weft insertion path 19. By inserting groups of multiple weft yams into the shed during a weft insertion event, it is possible to attain increased weft (or pick or fill) densities and therefore higher thread counts. Thus, a woven fabric as described herein may be constructed to have higher weft yam densities than what is otherwise possible, and thus higher thread counts, yet the woven fabric exhibits desirable fabric quality, softness, hand, and drape suitable for bedding applications. The thread count of the woven fabrics made in accordance with present disclosure is typically greater than about 80 and can be as high as about 1000 (or even higher). The thread count as used herein is the total number of yams in square inch of fabric. The thread count in this context is based on total number of yam ends. In other words, a plied yam is considered one yam for determining thread count.
The warp yams and weft yams are arranged to achieve desired warp and weft end densities, respectively, and thus desired thread count, for bedding applications. In accordance with an embodiment of the present disclosure, the woven fabric has a warp end density between about 50 warp ends per inch and about 350 warp ends per inch. In onc example, the warp end density is between about 50 and 150 warp ends per inch. In another example, the warp end density is between about 150 and 250 warp ends per inch. In another example, the warp end density is between about 250 and 350 warp ends per inch. Furthermore, the weft yarns are arranged to define a weft end density between about 50 weft yarns per inch and about 700 weft yarns per inch (or more). In one example, the weft yarn density is between about 100 and about 700 weft yarns per inch. In one example, the weft yarn density is between about 100 and about 300 weft yarns per inch. In another example, the weft yarn density is between about 300 and about 500 weft yarns per inch. In another example, the weft yarn density is between about 500 and about 700 weft yarns per inch. The weft yarn density as used herein refers to the total number of separate weft yarns along a length of the woven fabric. For example, a weft yarn density of about 50 picks per inch refers the 50 total weft yarns per inch of woven fabric. If the weft yarn groups are inserted during a single weft insertion event and each group includes three weft yarns, then there would be about 16 total weft yarn groups per inch of fabric and 48 picks per inch.
The yarns (warp or weft) can have a range of counts for the different fibers and woven constructions as described herein. The yarn count can range between about 8 Ne (664 denier) to about 120 Ne (44.3 denier). In one example, the yarns can have a count in a range between about 8 Ne (664 denier). In one example, the yarns can have a count in a range between about 20 Ne (266 denier). In one example, the yarns can have a count in a range between about 30 Ne (177 denier). In one example, the yarns can have count in a range between about 40 Ne (133 denier). In another example, the yarns have a count of about 60 Nc (88.6 denier). In another example, the yarns have a count of about 70 Ne (75.9 denier). In another example, the yarns have a count of about 80 Ne (66.4 denier). In another example, the yarns have a count of about 100 Ne (53.1 denier). In another example, the yarns have a count of about 120 Ne (44.3 denier). For hydroentangled woven fabrics, the warp yarn counts may range from 20 Ne (266 denier) to about 100 Ne (53.1 denier). The weft yarn counts may range from 20 Ne (266 denier) to about 120 Ne (44.3.1 denier).
A hydroentangled composite fabric 10 can have a variety yarn constructions for the warp and weft components of the base woven fabric. For instance, the yarns (warp or weft) may be spun staple yarns or filament yarns. In accordance with one embodiment, the woven fabrics include staple yarns formed from natural fibers or a blend of natural and synthetic fibers. In one example, the staple yarns are spun, cotton fiber yarns or blended yarns. While the staple yarn is preferably cotton, in certain alternative embodiments, the staple yarn can include cotton fibers blended with other natural or synthetic fibers. In such an example, the natural fibers could include silk, linen, flax, bamboo, hemp, wool, and the like. The synthetic fibers in this example are those fibers that result in fabric structures with good hand, drape, and softness. Such synthetic fibers include cellulosic fibers, including rayon fibers (e.g., Modal, lyocell) or thermoplastic fibers, such as polyethylene terephthalate (PET) fiber, polylactic acid (PLA) fiber, polypropylene (PP) fibers, polyamide fibers, and microfiber staple fibers.
The staple yarns can be formed using a variety of staple yarn formation systems. For instance, staple yarn formation may include bale opening, carding, combing, drafting, roving, and yarn spinning (yarn spinning processes are not illustrated) to the desired count and twist level. In some cases, the staple yarns can be plied into 2-ply, 3-ply, or 4-ply configurations. After yarn spinning, the staple yarns are wound into the desired yarn packages for weaving. In one example, ring spinning is the preferred spinning system. However, the staple yarns can be formed using open end spinning systems, rotor spun spinning systems, vortex spinning systems, core spinning yarns, jet spinning yarns, or compact spinning systems. Furthermore, the spinning system may include methods used to form Hygrocotton®, disclosed in U.S. Pat. No. 8,833,075, entitled “Hygro Materials for Use In Making Yarns And Fabrics,” (the 075 patent). The 075 patent is incorporated by reference into the present disclosure. Accordingly, the staple yarns can be ring spun yarns, open end yarns, rotor spun yarns, vortex spun yarns, core spun yarns, jet spun yarns, or compact spun yarns. In another embodiment, the warp yarns can be Hygrocotton® yarns marketed by Welspun India Limited. Furthermore, yarns can be formed as disclosed in the 075 patent. Preferably, the staple yarn is a ring spun yarn. The staple yarn, however, may be any type of spun yarn structure.
For spun yarns, twist level is an important parameter in final yarn structure. Twist is imparted during spinning to bind the fibers together into yarn structure. The twist level of the yarn is typically optimized to provide the desired strength to aid in weaving. If the twist level is too high, the forces applied to fibers are high, which may cause in fiber breakage, and yarn break in the weaving process. With increased twist levels, the fibers in the yarn are more compact and softness and absorbency of the yarn is reduced. This can result in less than ideal softness in final woven products. Often this is addressed, to some extent, by adding hand modifiers during the dyeing and finishing process. There are, however, drawbacks, such as costs, increased waste water, energy usage, and other environmental concerns. Due to this tradeoff, there is a certain limitation of woven fabrics in terms of softness and absorbency. The present disclosure addresses this tradeoff by permitting typical high twist yams to be used during manufacturing, while achieving the result of having a low-twist yam in the final fabric construction.
The woven fabric may also include continuous filament yams. In one example, the continuous filament yams are polyethylene terephthalate (PET) filament yams. While the continuous filament yams are primarily formed from PET, in alternative embodiments, the continuous filament, high bulk yam are formed from other synthetic filaments, such as polylactic acid (PLA) fiber, polypropylene (PP) fibers, and polyamide fibers. Embodiments of the present disclosure include the continuous filament yams dyed prior to fabric formation. For example, the continuous filament yams can be a dope-dyed, continuous filament yam. In another example, the continuous filament yams can be dyed using disperse dyes via package dyeing process (not shown). As used herein, a “dyed continuous filament yam” means a yam dyed prior to fabric formation whereby coloring agents are within the morphology of the filaments that form the yams.
A hydroentangled composite fabric IO can use different yam constructions in the warp and weft components of the base woven fabric. In one example, the warp yams are staple spun yams (cotton or any fiber blends) and the weft yams may include staple yams. In one example, the warp yams are continuous filament yams and the weft yams are staple spun yams. In one example, the weft yams are continuous filament yams and the warp yams are staple spun yams. In another example, the warp yams include staple yams and filament yams and the weft yams include staple yams and filament yams.
While the yams are described in relation to the process used to make them, one of skill in the art will appreciate that each staple yam described above has structural differences unique to each yam formation system. Thus, the description of the yams above is also a description of yam structure.
The base woven fabric of the hydroentangled composite fabric IO has a range of basis weights. For instance, the base woven fabric has a basis weight in the range of about 100 grams per square meter to about 330 grams per square meter. In one embodiment, the basis weight of the base woven fabric is in the range of about 150 grams per square meter to about 250 grams per square meter. In another embodiment, the basis weight of the base wove fabric is in the range of about 170 grams per square meter to about 200 grams per square meter. The basis weight of the base woven fabric may fall outside the ranges stated in this paragraph as well. The basis weight referred to herein can be determined according to ISO 9073-1:1989, Textiles—Test methods for nonwovens—Part 1: Determination of mass per unit area.”
The web of nonwoven fibers 60 can be a dry laid fibrous assembly of staple fibers. Details concerning how the web of nonwoven fibers is formed are further discussed below. As used herein, the web of nonwoven fibers includes synthetic or manmade cellulosic fiber and/or natural cellulosic fibers. Manmade cellulosic fibers include but are not limited to: regenerated cellulose; viscose; rayon; lyocell; cellulose nitrate; carboxymethyl cellulose, and the like. Natural cellulosic fibers include but are not limited to: cotton; wood pulp; jute; hemp; sphagnum, and the like. In one embodiment, the web of nonwoven fibers are viscose fibers. For viscose fibers, the staple length can be about 5 mm to about 50 mm. The denier can be about 2 to about 6 and the staple fiber size of from about 15 microns to about 28 microns. In another embodiment, the fibers of the web of nonwoven fibers are cotton fibers. When cotton fibers are used, the cotton fibers have a staple length of about 5 millimeters (mm) to about 30 mm. The cotton fibers can generally have a fiber size of about 150 microns to about 280 microns. The cotton fibers can also be bleached if desired. In a further embodiment, the web of nonwoven fibers includes a blend of viscose and cotton fibers. Other blends are possible. In accordance with one embodiment of the present disclosure, the web of nonwoven fibers may have basis weight in the range of about 100 grams per square meter to about 300 grams per square meter.
Turning now to
Referring to
Continuing with to
Referring still to
The hydroentanglement step 205 forms the structure of the hydroentangled composite fabric. As can be seen
During hydroentanglement, the high pressure waterjets cause the pores of the base woven fabric PI to become blocked by nonwoven fibers. The fabric becomes compacted and the pore sizes are significantly reduced. For example, a base woven fabric of 200TC percale with warp and weft yarns of 75 denier (105″×95″) has pores of 40-50 microns in diameter prior to hydroentanglement, as depicted in
Referring again to
After drying, when thermoplastic fibers are used in the base woven fabric and/or the nonwoven web of fibers, the hydroentangled composite fabric is subjected to a heat set step to stabilize the fibers inside the fabric. Heat setting occurs at 190 to 200 degrees centigrade in a stenter machine with a contact time of 45 to 60 seconds to thermally set the fabric.
The process 200 includes an optional dyeing/printing step 209 and a finishing step after hydroentanglement 205. The dyeing/printing 209 applies color and the finishing step 210 applies one or more functional agents to the fabric. In an embodiment, the hydroentangled composite fabric is dyed with reactive dyes using a pad dry, pad steam, or cold pad batch method. The finishing step 210 may also include applying a composition including one or more of the functional agents to the hydroentangled composite fabric 10. The functional agents may include a softener, antimicrobial agent, etc. Next, excess moisture is removed by advancing the fabric through a heating machine. Heating machines may be heated steam, infrared, hot air, surface rolls, hot oil can, through-air ovens, and like machines. After drying, the woven fabric may be sanforized and calendared to adjust the hand and better control over shrinkage.
Continuing with
The hydroentangled composite fabric 10 has unique properties suitable for barrier and/or anti-allergen applications. It has been surprisingly found the fabrics made in accordance with the present disclosure may possess anti-allergen properties yet are functionally suitable for bedding applications. Typically, woven fabrics are used for sheeting application. Nonwoven materials, on the other hand, can possess good barrier properties but do not possess the comfort and durability that bedding applications require. The hydroentangled composite fabric 10 of the present disclosure is a synergistic result of woven fabric construction and nonwoven processing. In evaluating the fabrics of the present disclosure, various example fabrics were constructed as summarized in
The inventive concepts disclosed herein result in a hydroentangled composite fabric with enhanced anti-allergen properties while retaining excellent strength, durability, colorfastness, moisture management and comfort properties suitable for bedding and other home textile applications.
An embodiment of the present disclosure further comprises a method for forming an anti-allergen hydroentangled composite fabric, comprising: weaving a plurality of warp yams with a plurality of weft yams to define a base woven fabric comprising pores with a diameter of at least about 40 microns; combining the base woven fabric with at least one web of nonwoven fibers; applying high pressure water jets to the base woven fabric and the at least one web of nonwoven fibers to generate a hydroentangled composite having pores with a diameter up to about 10 microns; and drying the hydroentangled composite fabric to substantially remove moisture from the hydroentangled composite fabric. An anti-allergen hydroentangled composite fabric produced by this method may include either or both of the warp yams or the weft yams comprising synthetic fibers, the method comprising heat setting the hydroentangled composite fabric. The method may further comprise pre-treating the base woven fabric with high pressure waterjets before the step of applying high pressure waterjets. The method may comprise applying high pressure waterjets with an oscillating nozzle and may further comprise the high pressure water jets being applied at an angle. The high pressure range may be applied at a range of 50 bars to 400 bars.
It will be appreciated by those skilled in the art that various modifications and alterations of the present disclosure can be made without departing from the broad scope of the appended claims. Some of these have been discussed above and others will be apparent to those skilled in the art. The scope of the present disclosure is limited only by the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 201921029368 | Jul 2019 | IN | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16934594 | Jul 2020 | US |
| Child | 18442691 | US |
