Physical and mechanical properties of fabrics by hydroentangling

Abstract

Methods for reducing the surface pilling tendency and improving abrasion resistance of a pillable fabric are disclosed. The methods include providing a pillable fabric including fibrils extending from the surfaces thereof, supporting the fabric, and exposing the fabric to a hydroentanglement process that imparts an energy in the range of at least about 4000 to 5000 KJoules/Kg of fabric using pressures of 200 bars or greater. The presence of fibrils on the fabric surface are reduced to an amount wherein the pilling production on the fabric is less than about 20% after 5,000 cycles of abrasion on a Martindale device according to ASTM D4970 testing standard and the fabric remaining mass is at least about 80% to 90% after 50,000 cycles of abrasion on a Martindale device according to ASTM D4966 testing standard.

1 . A method for reducing the surface pilling tendency and improving abrasion resistance of a pillable fabric, the method comprising the steps of: 
 (a) providing a pillable fabric having a top surface, a bottom surface, and side edges and comprising yarns which intersect at crossover points to define interstitial open areas in the fabric, and the fabric further comprising fibrils extending from at least one of the top and bottom surfaces thereof;    (b) supporting the fabric on a support member;    (c) exposing at least one of the surfaces to a hydroentanglement process to cause entanglement of the fibrils into the interstitial open areas of the fabric, wherein the hydroentanglement process includes imparting an energy in the range of at least about 4000 to 5000 KJoules/Kg of fabric using pressures of 200 bars or greater; and    (d) reducing the presence of the fibrils on the at least one fabric surface to an amount wherein the pilling production on the fabric is less than about 20% after 5,000 cycles of abrasion on a Martindale device according to ASTM D4970 testing standard and the fabric remaining mass is at least about 80% to 90% after 50,000 cycles of abrasion on a Martindale device according to ASTM D4966 testing standard.    
     
     
         2 . The method of  claim 1  wherein the fabric is a woven fabric.  
     
     
         3 . The method of  claim 1  wherein the fabric is a knitted fabric.  
     
     
         4 . The method of  claim 3  further comprising the step of restraining the side edges of the knitted fabric to prevent shrinkage during the hydroentanglement process.  
     
     
         5 . The method of  claim 1  wherein the fabric yarns are selected from the group consisting of cotton, polyester, nylon, and blends thereof.  
     
     
         6 . The method of  claim 1  wherein the support member is selected from the group consisting of a belt, a drum, and a belt/drum combination.  
     
     
         7 . The method of  claim 6  wherein the support member includes a pattern of closely spaced fluid pervious open areas to affect fluid passage through the support member.  
     
     
         8 . The method of  claim 1  wherein both surfaces of the fabric are exposed to the hydroentanglement process.  
     
     
         9 . The method of  claim 1  wherein the hydroentanglement process is accomplished by the use of a hydroentanglement system comprising at least one bank of one or more high pressure water jet manifolds.  
     
     
         10 . The method of  claim 9  wherein the hydroentanglement system comprises two banks of high pressure water jet manifolds that apply high pressure water jets to the fabric top and bottom surfaces.  
     
     
         11 . The method of  claim 10  wherein the hydroentanglement system comprises one bank of three manifolds that apply high pressure water jets to the fabric top surface and one bank of two manifolds that apply high pressure water jets to the fabric bottom surface.  
     
     
         12 . The method of  claim 9  wherein the water pressure of the one or more manifolds is between 10 bars and 1000 bars.  
     
     
         13 . The method of  claim 12  wherein each of the one or more manifolds further comprises approximately 1600 to 2000 fluid jet orifices per meter, wherein each orifice has a diameter of approximately 80 to 300 microns.  
     
     
         14 . A fabric produced according to the method of  claim 1 .  
     
     
         15 . A method for reducing the surface pilling tendency and improving abrasion resistance of a pillable cotton knitted fabric, the method comprising the steps of: 
 (a) providing a pillable cotton knitted fabric having a top surface, a bottom surface, and side edges and comprising yarns which intersect at crossover points to define interstitial open areas in the fabric, and the fabric further comprising fibrils extending from at least one of the top and bottom surface thereof;    (b) supporting the fabric on a support member;    (c) restraining the side edges of the knitted fabric;    (d) exposing at least one of the surfaces to a hydroentanglement process system comprising at least one bank of one or more high pressure water jet manifolds to cause entanglement of the fibrils into the interstitial open areas of the fabric, wherein the hydroentanglement process system imparts an energy in the range of at least about 4000 to 5000 KJoules/Kg of fabric using pressures of 200 bars or greater; and    (e) reducing the presence of the fibrils on the at least one fabric surface to an amount wherein the pilling production on the fabric is less than about 20% after 5,000 cycles of abrasion on a Martindale device according to ASTM D4970 testing standard and the fabric remaining mass is at least about 80% to 90% after 50,000 cycles of abrasion on a Martindale device according to ASTM D4966 testing standard.    
     
     
         16 . The method of  claim 15  wherein the support member is selected from the group consisting of a belt, a drum, and a belt/drum combination.  
     
     
         17 . The method of  claim 16  wherein the support member includes a pattern of closely spaced fluid pervious open areas to affect fluid passage through the support member.  
     
     
         18 . The method of  claim 15  wherein both surfaces of the fabric are exposed to the hydroentanglement process system.  
     
     
         19 . The method of  claim 15  wherein the hydroentanglement system comprises two banks of high pressure water jet manifolds that apply high pressure water jets to the fabric top and bottom surfaces.  
     
     
         20 . The method of  claim 19  wherein the hydroentanglement system comprises one bank of three manifolds that apply high pressure water jets to the fabric top surface and one bank of two manifolds that apply high pressure water jets to the fabric bottom surface.  
     
     
         21 . The method of  claim 15  wherein the water pressure of the one or more manifolds is between 10 bars and 1000 bars.  
     
     
         22 . The method of  claim 22  wherein each of the one or more manifolds further comprises approximately 1600 to 2000 fluid jet orifices per meter, wherein each orifice has a diameter of approximately 80 to 300 microns.  
     
     
         23 . A fabric produced according to the method of  claim 15 .  
     
     
         24 . A pill and abrasion resistant fabric comprising: 
 (a) a top surface, a bottom surface, and side edges;    (b) multiple yarns intersecting at crossover points to define interstitial open areas in the fabric;    (c) fibrils extending from at least one of the top and bottom surfaces which have been entangled into the interstitial open areas of the fabric by exposure of at least one of the top and bottom surfaces to a hydroentanglement process including imparting an energy in the range of at least about 4000 to 5000 KJoules/Kg of fabric using pressures of 200 bars or greater; and    (d) wherein the pill and abrasion resistant fabric possesses a reduced pill production potential of less than about 20% after 5,000 cycles of abrasion on a Martindale device according to ASTM D4970 testing standard and possesses an increased abrasion resistance potential wherein the fabric remaining mass is at least about 80% to 90% after 50,000 cycles of abrasion on a Martindale device according to ASTM D4966 testing standard.    
     
     
         25 . The fabric of  claim 24  wherein the fabric is a woven fabric.  
     
     
         26 . The fabric of  claim 24  wherein the fabric is a knitted fabric.  
     
     
         27 . The fabric of  claim 24  wherein the fabric yarns are selected from the group consisting of cotton, polyester, nylon, and blends thereof.  
     
     
         28 . The fabric of  claim 24  wherein both surfaces of the fabric have been exposed to the hydroentanglement process.  
     
     
         29 . A pill and abrasion resistant cotton knitted fabric comprising: 
 (a) a top surface, a bottom surface, and side edges;    (b) multiple yarns intersecting at crossover points to define interstitial open areas in the fabric;    (c) fibrils extending from at least one of the top and bottom surfaces which have been entangled into the interstitial open areas of the fabric by exposure of at least one of the top and bottom surfaces to a hydroentanglement process including imparting an energy in the range of at least about 4000 to 5000 KJoules/Kg of fabric using pressures of 200 bars or greater; and (d) wherein the pill and abrasion resistant fabric possesses a reduced pill production potential of less than about 20% after 5,000 cycles of abrasion on a Martindale device according to ASTM D4970 testing standard and possesses an increased abrasion resistance potential wherein the fabric remaining mass is at least about 80% to 90% after 50,000 cycles of abrasion on a Martindale device according to ASTM D4966 testing standard.    
     
     
         30 . The fabric of  claim 29  wherein both surfaces of the cotton knitted fabric have been exposed to the hydroentanglement process.