Wonder Fabric

Abstract

A novel textile material particularly a wonder fabric comprising of a see-through construction of plurality of yarns intersecting one another at certain angles hydro-laminated thereof with pseudo yarns formed out of staple fibers and mechanical cross linking of yarns on at least one side under specific conditions thereof resulting into a durable and multi functional material suitable for home and apparel textile applications is disclosed herein. A process for production and apparatus thereof are also disclosed.

What is claimed is: 
     
         1 ) A multipurpose fabric comprising:
 a pre-entangled web of fibers and a pre-treated textile substrate comprising fibers,   wherein the web of fibers are entangled among themselves in gaps of a pre-treated textile substrate, wherein the pre-treated textile substrate is a result of hydroentangling a textile substrate under conditions of at least two jet streams, wherein at least one jet stream strikes the textile substrate at a high pressure ranging from at or about 100 bar-at or about 400 bar to form a pre-treated textile substrate;   wherein said web of fibers entangled in gaps of the pre-treated textile substrate are entangled with the pre-treated textile substrate fibers;   wherein the remaining web of fibers, which do not become part of the entanglements in gaps of the pre-treated textile substrate, are entangled with pre-treated textile substrate fibers; wherein entanglements occur on at least one side of the pre-treated textile substrate.   
     
     
         2 . The multipurpose fabric of  claim 1 , wherein the at least two jet streams comprises at least one straight jet head and at least one angled jet head, wherein said angled jet head is at or about 10 degrees-at or about 25 degrees. 
     
     
         3 . The multipurpose fabric according to  claim 1 , wherein the textile substrate is a woven textile substrate. 
     
     
         4 . The multipurpose fabric according to  claim 1 , wherein the textile substrate is a knitted textile substrate. 
     
     
         5 . The multipurpose fabric according to  claim 1 , wherein the textile substrate is made of fibers selected from the group consisting of natural fibers, manmade fibers, and blends of natural and manmade fibers. 
     
     
         6 . The multipurpose fabric according to  claim 1 , wherein the web fibers entangled among themselves in gaps of the pre-treated textile substrate are made of fibers selected from the group consisting of natural fibers, manmade fibers, and blends of natural and manmade fibers. 
     
     
         7 . The multipurpose fabric according to  claim 1 , wherein the textile substrate is constructed with yarn counts in the range of at or about Ne 1 up to at or about Ne 160, wherein the yarns are selected from the group consisting of single yarns and plied yarns. 
     
     
         8 . The multipurpose fabric according to  claim 1 , wherein the textile substrate is constructed with 30 threads/inch up to 300 threads/inch in warp way direction and 12 threads/inch up to 500 threads/inch in weft-way direction, having a weight of 45 g/m 2  to 1,200 g/m 2 , wherein the weave is selected from the group consisting of a plain weave, a twill weave, a satin weave, and a combination weave. 
     
     
         9 . The multipurpose fabric according to  claim 1 , wherein the textile substrate has a weight of 60 g/m 2  to 400 g/m 2  with knitted structure selected from the group consisting of a warp knitted structure and a weft knitted structure. 
     
     
         10 . The multipurpose fabric according to  claim 1 , wherein the fabric has a tensile strength minimum of about 65 pounds (warp) and about 31 pounds (weft). 
     
     
         11 . The multipurpose fabric according to  claim 1 , wherein the fabric has a residual shrinkage after 5 washes of about 3% (warp) and about 0.5% (weft). 
     
     
         12 . The multipurpose fabric according to  claim 1 , wherein the fabric has a minimum seam slippage of about 16 (warp) and about 35 (weft). 
     
     
         13 . An assembly for manufacturing the multipurpose fabric of  claim 1  comprising:
 an opening line for opening and cleaning fibers; 
 a carding machine for carding said fibers to prepare a pre-entangled fiber web; 
 a fabric unwinding, expanding and tensioning device; 
 a fabric combing device including at least one perforated drum having at least one jet stream to prepare a pre-treated textile substrate, wherein the pre-treated textile substrate is a result of hydroentangling a textile substrate under conditions of at least two jet streams, wherein at least one jet stream strikes the textile substrate at a high pressure ranging from about 100 bar-about 400 bar to form a pre-treated textile substrate; 
 a hydro-lamination unit including at least one perforated drum including at least one jet stream for subjecting said pre-entangled fiber web layered on said pre-treated textile substrate to at least one high pressure jet stream ranging from about 100 bar-about 400 bar to form a multipurpose fabric. 
 
     
     
         14 . The assembly of  claim 13 , further comprising:
 a dewatering device for dewatering of said multipurpose fabric;   a dryer for drying of wet fabric;   a winder for winding of dried fabric;   a mercerizer for mercerization, swelling and preparing the fabric for a textile dyeing and finishing process;   an open width continuous bleaching/dyeing range for dyeing of fabric;   a padder including a curing device for padding of chemical agents and fixation;   a machine of a soft flow machine or jet dyeing machine for pretreatment and dyeing of the fabric;   a machine of an open width machine or a soft flow machine for top finishing of the fabric;   a machine of an emerising machine or a raising machine for mechanical surface finishing of fabric;   a sanforisation machine for dimensional stabilization of fabric;   a machine of a knife coater, a padder, a kiss roll arrangement, or a zimmer machine;   a curing device for coating of fabric on at least one side with chemicals of thermoplastic polyolephenes, thermoplastic polyurethane, or   polyurethane/aluminum; and   a lamination device for lamination of fabric on at least one side with a membrane made from polyurethane, thermoplastic polyurethane, thermoplastic polyolephene, a flame retardant material, or a cross linker.   
     
     
         15 . A process for manufacturing a multipurpose fabric of  claim 1 , comprising:
 pre-entangling a web of fibers to increase strength in the web;   supporting the pre-entangled web of fibers on at least one side of a pre-treated textile substrate, wherein the pre-treated textile substrate is a result of hydroentangling a textile substrate under conditions of at least two jet streams, wherein at least one jet stream strikes the textile substrate at a high pressure ranging from about 100 bar-about 400 bar to form a pre-treated textile substrate;   subjecting the web of fibers to at least one oscillating jet stream and at least one angled jet resulting in web disintegration and slipping away of fibers;   rolling the slipped fibers in gaps of the pre-treated textile substrate, wherein the fibers are guided by the textile substrate.   
     
     
         16 . The process according to  claim 15 , wherein pre-entangling a web of fibers comprises:
 opening and cleaning fibers in a fiber opening machine; and   carding the fibers in a carding machine to prepare a web of fibers;   
       wherein pre-treating the textile substrate comprises:
 opening up the textile substrate in an expander roll; 
 tensioning the textile substrate through a fabric tensioner; 
 subjecting the textile substrate to at least two water jets, wherein at least one water jet comprises a high pressure jet stream ranging from about 100 bar-about 400 bar, and at least one water jet strikes the textile substrate at an angle, thereby forming a pre-treated textile substrate; 
 
       and said process further comprising:
 layering the pre-treated textile substrate with the pre-entangled web of fibers entangled among themselves in gaps of the pre-treated textile substrate; 
 subjecting the pre-treated textile substrate and the web fibers entangled among themselves in gaps of the pre-treated textile substrate to hydro-lamination with a at least one stationary water jet or at least one oscillating water jet, wherein the water jet is directed at the pre-treated textile substrate in a direction of a straight strike, an angled strike, or a combination of a straight and angled strike, and at least one water stream is of high pressure ranging from about 100 bar-about 400 bar, thereby forming a multipurpose fabric. 
 
     
     
         17 . The process according to  claim 16 , further comprising:
 dewatering the multipurpose fabric by passing through a dewatering device;   drying the dewatered multipurpose fabric by passing through a dryer;   winding the multipurpose fabric on to bobbins on a winder;   chemically pre-treating the multipurpose fabric with a process of dyeing, printing, top finishing, or a combination thereof; and   treating the multipurpose fabric with a process of coating or laminating, such that the multipurpose fabric has a smooth surface.   
     
     
         18 . The process according to  claim 16 , wherein the at least one water jet strikes at an angle ranging from at or about 10 degrees-at or about 25 degrees. 
     
     
         19 . The process according to  claim 17 , wherein the drying is performed at a temperature such that the dried multipurpose fabric has a residual moisture content equal to a natural moisture content of the fibers.