Textured nonwoven fabric

Abstract

The present invention relates to a method of creating a textured nonwoven fabric for apparel and home fashions applications, wherein the nonwoven fabric becomes aesthetically altered upon laundering. Once laundered during manufacture, the nonwoven fabric exhibits a permanent distressed appearance that becomes an integral part of the fabric. Subsequent to laundering, the fabric can be formed into a roll for shipment and storage. The distressed appearance of the nonwoven fabric is best described by comparing the laundered fabric to an elephant's skin.

What is claimed is:  
     
         1 . A process of providing permanently distressed texture to a nonwoven fabric comprising the steps of: 
 a. providing a precursor fibrous nonwoven web;    b. providing a three-dimensional image transfer device;    c. hydroentangling said precursor web on said image transfer device to form a patterned and imaged nonwoven fabric;    d. laundering said formed patterned and imaged nonwoven fabric.    e. said patterned and imaged nonwoven fabric taking on a distressed or wrinkled appearance; and    f. said nonwoven fabric being suitable for use in apparel and home fashions industries.    
     
     
         2 . A process of making a permanently distressed textured nonwoven fabric as in  claim 1 , wherein said precursor web is comprised of synthetic fibers, natural fibers, or blends thereof.  
     
     
         3 . A process of making a permanently distressed textured nonwoven fabric as in  claim 2 , wherein said synthetic fiber is selected from the group consisting of polyamides, polyester, polyolefins, and the combinations thereof.  
     
     
         4 . A process of making a permanently distressed textured nonwoven fabric as in  claim 3 , wherein said synthetic fiber is polyester.  
     
     
         5 . A process of making a permanently distressed textured nonwoven fabric as in  claim 2 , wherein said natural fiber is selected from the group consisting of cotton, wood pulp, rayon and the combinations thereof.  
     
     
         6 . A process of making a permanently distressed textured nonwoven fabric as in  claim 1 , wherein said nonwoven fabric is suitable for use in the apparel industry as a bottom weight or in the home fashions industry as a window covering, bed covering, or furniture cover.  
     
     
         7 . A process of making a permanently distressed textured nonwoven fabric as in  claim 3 , including: 
 forming said nonwoven fabric into a roll subsequent to said laundering step.    
     
     
         8 . A bottom weight garment comprising an imaged nonwoven fabric, said bottom weight garment having a jet dyed finish and a distressed appearance upon laundering, said bottom weight garment having a basis weight of 3.0-8.0 ounces per square yard and a fiber composition of cotton and polyester.  
     
     
         9 . A home fashion articles comprising an imaged nonwoven fabric, said home fashion article having a jet dyed and/or printed finish as well as distressed appearance upon laundering, said home fashion article having a basis weight of 1.0-3.0 ounces per square yard and a fiber composition of polyester and lyocell or rayon fibers.