US20040116021A1 - Flocked fabric - Google Patents

Flocked fabric Download PDF

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Publication number
US20040116021A1
US20040116021A1 US10/316,524 US31652402A US2004116021A1 US 20040116021 A1 US20040116021 A1 US 20040116021A1 US 31652402 A US31652402 A US 31652402A US 2004116021 A1 US2004116021 A1 US 2004116021A1
Authority
US
United States
Prior art keywords
inch
substrate
fabric according
weight
flocked fabric
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/316,524
Inventor
David Smith
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Milliken and Co
Original Assignee
Milliken and Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Milliken and Co filed Critical Milliken and Co
Priority to US10/316,524 priority Critical patent/US20040116021A1/en
Publication of US20040116021A1 publication Critical patent/US20040116021A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00Non-woven pile fabrics
    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/208Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based
    • D03D15/217Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based natural from plants, e.g. cotton
    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/283Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/30Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the fibres or filaments
    • D03D15/33Ultrafine fibres, e.g. microfibres or nanofibres
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06QDECORATING TEXTILES
    • D06Q1/00Decorating textiles
    • D06Q1/12Decorating textiles by transferring a chemical agent or a metallic or non-metallic material in particulate or other form, from a solid temporary carrier to the textile
    • D06Q1/14Decorating textiles by transferring a chemical agent or a metallic or non-metallic material in particulate or other form, from a solid temporary carrier to the textile by transferring fibres, or adhesives for fibres, to the textile
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/01Natural vegetable fibres
    • D10B2201/02Cotton
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00Industrial
    • D10B2505/08Upholstery, mattresses
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/3293Warp and weft are identical and contain at least two chemically different strand materials

Definitions

  • the present invention relates to flocked fabrics and the components forming such fabrics.
  • Flocked fabrics generally comprise a cloth, which has been coated by an adhesive and fine fibers applied over the adhesive. The resultant cloth has a velvet like appearance. These fabrics can be used in many applications, such as for upholstery in home furnishings.
  • the flocking substrate fabric is an osnaburg fabric.
  • An osnaburg fabric is a plain weave that is medium to heavy in weight, and is a coarse fabric often formed partially of waste fiber.
  • the present invention generally relates to flocked fabrics formed from a flocking substrate fabric, which has been coated with an adhesive and subsequently coated with flock.
  • the flocked fabric of the present invention can be used for many applications, such as upholstery for home furnishings.
  • the flocking substrate fabric can be a woven fabric (such as plain, twill, satin, dobby, jacquard, leno, or the like) or a knit fabric (such as weft knit or warp knit).
  • the flocking substrate fabric is formed of spun yarns containing a blend of microdenier polymer fibers and natural fibers. What is meant by microdenier fiber is a fiber of less than one (1) denier per filament. It is believed that the combination of microdenier polymeric fibers and cellulosic fibers provide a less rigid fabric and a better surface for the bonding of the adhesive.
  • the yarns can be open-end spun, ring-spun, air-spun, or any other spinning technology.
  • the microdeiner polymeric fibers are a microdenier staple fiber of polyester.
  • the cellulosic fibers are a cotton, such as pima cotton. Pima cotton is a higher cost material that is not associated in the industry with the lower quality and cost of the materials used in present flocking substrate fabrics.
  • the blend of materials forming the flocking substrate fabric is about 65% microdenier polymeric fibers (such as polyester) with about 35% cellulosic fibers (such as cotton), by weight. In another embodiment, the blend of materials is about 85% microdenier polymeric fibers (such as polyester) with about 15% cellulosic fibers (such as cotton), by weight. It is anticipated that the blend of materials, by weight, can range from about 90% microdenier polymeric fibers (such as polyester) with about 10% cellulosic fibers (such as cotton), to about 50% microdenier polymeric fibers (such as polyester) with about 50% cellulosic fibers (such as cotton).
  • the yarns are typically a yarn with a cotton count of between about 12 and about 25, with about a 15 cotton count being one potentially preferred embodiment.
  • the weave pattern can range from about 28 ends/inch by about 25 picks/inch to about 40 ends/inch by about 32 picks/inch.
  • the weave pattern can range from about 35 ends/inch by 32 picks/inch to about 45 ends/inch by about 42 picks/inch.
  • the weave pattern can range from about 28 ends/inch by about 28 picks/per inch to about 38 ends/inch by about 44 picks/inch, and preferably are about 32 ends/inch by about 28 picks/inch.
  • the weight of the flocking substrate fabric can range from about 2 oz/yd 2 to about 4.5 oz/yd 2 , and in one embodiment is preferably from about 3.0 oz/yd 2 to about 3.8 oz/yd 2 .
  • the adhesive is applied to the flocking substrate fabric prior to applying the flock.
  • the adhesive is a latex adhesive applied to the flocking substrate fabric.
  • the flock is fibers having a denier range from about 0.8 to about 3.0 denier, with an average denier of about 1.1.
  • the flocking fibers can have a length from about 0.025 inches to about 0.07 inches.
  • the flock is applied to the flocking substrate fabric after application of the adhesive.
  • the flock can be applied by mechanical or electrostatic means. The flock will then adhere to the portion of the flocking substrate fabric which has been coated with the adhesive.

Abstract

A flocked fabric having a woven fabric substrate of a blend of microdenier polyester and pima cotton. The fabric substrate is covered with an adhesive, and flock is attached to the fabric substrate by the adhesive.

Description

    BACKGROUND
  • The present invention relates to flocked fabrics and the components forming such fabrics. [0001]
  • Flocked fabrics generally comprise a cloth, which has been coated by an adhesive and fine fibers applied over the adhesive. The resultant cloth has a velvet like appearance. These fabrics can be used in many applications, such as for upholstery in home furnishings. Typically, the flocking substrate fabric is an osnaburg fabric. An osnaburg fabric is a plain weave that is medium to heavy in weight, and is a coarse fabric often formed partially of waste fiber. However, there is a need for improved flocking substrate fabrics, and improved flocked fabrics using such substrates.[0002]
  • DETAILED DESCRIPTION
  • The present invention generally relates to flocked fabrics formed from a flocking substrate fabric, which has been coated with an adhesive and subsequently coated with flock. The flocked fabric of the present invention can be used for many applications, such as upholstery for home furnishings. [0003]
  • The flocking substrate fabric can be a woven fabric (such as plain, twill, satin, dobby, jacquard, leno, or the like) or a knit fabric (such as weft knit or warp knit). In one embodiment, the flocking substrate fabric is formed of spun yarns containing a blend of microdenier polymer fibers and natural fibers. What is meant by microdenier fiber is a fiber of less than one (1) denier per filament. It is believed that the combination of microdenier polymeric fibers and cellulosic fibers provide a less rigid fabric and a better surface for the bonding of the adhesive. The yarns can be open-end spun, ring-spun, air-spun, or any other spinning technology. [0004]
  • In a preferred embodiment of the present invention, the microdeiner polymeric fibers are a microdenier staple fiber of polyester. Also, in one embodiment the cellulosic fibers are a cotton, such as pima cotton. Pima cotton is a higher cost material that is not associated in the industry with the lower quality and cost of the materials used in present flocking substrate fabrics. [0005]
  • In one embodiment, the blend of materials forming the flocking substrate fabric is about 65% microdenier polymeric fibers (such as polyester) with about 35% cellulosic fibers (such as cotton), by weight. In another embodiment, the blend of materials is about 85% microdenier polymeric fibers (such as polyester) with about 15% cellulosic fibers (such as cotton), by weight. It is anticipated that the blend of materials, by weight, can range from about 90% microdenier polymeric fibers (such as polyester) with about 10% cellulosic fibers (such as cotton), to about 50% microdenier polymeric fibers (such as polyester) with about 50% cellulosic fibers (such as cotton). [0006]
  • The yarns are typically a yarn with a cotton count of between about 12 and about 25, with about a 15 cotton count being one potentially preferred embodiment. Where yarns of about a 12 cotton count are used in a plain weave, the weave pattern can range from about 28 ends/inch by about 25 picks/inch to about 40 ends/inch by about 32 picks/inch. Where yarns of about a 25 cotton count are used in a plain weave, the weave pattern can range from about 35 ends/inch by 32 picks/inch to about 45 ends/inch by about 42 picks/inch. Where yarns of about a 15 cotton count are used in a plain weave, the weave pattern can range from about 28 ends/inch by about 28 picks/per inch to about 38 ends/inch by about 44 picks/inch, and preferably are about 32 ends/inch by about 28 picks/inch. The weight of the flocking substrate fabric can range from about 2 oz/yd[0007] 2 to about 4.5 oz/yd2, and in one embodiment is preferably from about 3.0 oz/yd2 to about 3.8 oz/yd2.
  • The adhesive is applied to the flocking substrate fabric prior to applying the flock. In one embodiment, the adhesive is a latex adhesive applied to the flocking substrate fabric. [0008]
  • The flock is fibers having a denier range from about 0.8 to about 3.0 denier, with an average denier of about 1.1. The flocking fibers can have a length from about 0.025 inches to about 0.07 inches. The flock is applied to the flocking substrate fabric after application of the adhesive. The flock can be applied by mechanical or electrostatic means. The flock will then adhere to the portion of the flocking substrate fabric which has been coated with the adhesive. [0009]

Claims (14)

What is claimed is:
1. A flocked fabric including:
a woven fabric substrate comprising from about 50% to about 90% by weight of polymeric microdenier fibers and from about 10% to about 90% by weight of cellulosic fibers, including substrate yarns having a size of from about 12 cotton count to about 25 cotton count, having an end count of from about 28 ends/inch to about 45 ends/inch and a pick count of from about 25 picks/inch to about 42 picks/inch, and having a weight of from about 2 oz/yd2 to about 4.5 oz/yd2;
an adhesive disposed on the fabric substrate; and,
flock adhered to the fabric substrate by the adhesive.
2. The flocked fabric according to claim 1, wherein the cellulosic fibers comprise cotton.
3. The flocked fabric according to claim 1, wherein the cellulosic fibers comprise pima cotton.
4. The flocked fabric according to claim 1, wherein the polymeric microdenier fibers comprise polyester microdenier fibers.
5. The flocked fabric according to claim 4, wherein the cellulosic fibers comprise cotton.
6. The flocked fabric according to claim 5, wherein the fabric substrate comprises about 65% by weight of the polyester microfiber and about 35% by weight of the natural fibers.
7. The flocked fabric according to claim 5, wherein the fabric substrate comprises about 85% by weight of polyester microfiber and about 15% by weight of the natural fiber.
8. The flocked fabric according to claim 1, wherein the substrate yarns further have a size of about 15 cotton count.
9. The flocked fabric according to claim 7, wherein the fabric substrate further includes an end count of from about 28 ends/inch to about 38 ends/inch.
10. The flocked fabric according to claim 7, wherein the fabric substrate further includes a pick count of from about 28 picks/inch to about 44 picks/inch.
11. The flocked fabric according to claim 1, wherein the fabric substrate further comprises a weight of from about 3 oz/yd2 to about 3.8 oz/yd2.
12. The flocked fabric according to claim 1, wherein the substrate yarns are further open-end spun yarns.
13. The flocked fabric according to claim 1, wherein the substrate yarns are further ring spun yarns.
14. The flocked fabric according to claim 1, wherein the substrate yarns are further air spun yarns.
US10/316,524 2002-12-11 2002-12-11 Flocked fabric Abandoned US20040116021A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US10/316,524 US20040116021A1 (en) 2002-12-11 2002-12-11 Flocked fabric

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/316,524 US20040116021A1 (en) 2002-12-11 2002-12-11 Flocked fabric

Publications (1)

Publication Number Publication Date
US20040116021A1 true US20040116021A1 (en) 2004-06-17

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Family Applications (1)

Application Number Title Priority Date Filing Date
US10/316,524 Abandoned US20040116021A1 (en) 2002-12-11 2002-12-11 Flocked fabric

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Country Link
US (1) US20040116021A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090260707A1 (en) * 2008-04-22 2009-10-22 Arun Pal Aneja Woven Textile Fabric with Cotton/Microdenier Filament Bundle Blend

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4034134A (en) * 1975-10-07 1977-07-05 United Merchants And Manufacturers, Inc. Laminates and coated substrates
US4180606A (en) * 1977-07-25 1979-12-25 M. Lowenstein & Sons, Inc. Fabrics having flocked corduroy ribs
US4241122A (en) * 1978-10-31 1980-12-23 Kanebo, Ltd. Artificial leather having chinchilla-like appearance and natural suede-like feeling and a method for producing the same
US4294577A (en) * 1980-03-25 1981-10-13 Pervel Industries, Inc. Dyed flocked fabric and method of making the same
US4438533A (en) * 1980-06-03 1984-03-27 Kufner Textilwerke Kg Interlining for garments and method for the manufacture thereof
US4863633A (en) * 1987-08-07 1989-09-05 The Clorox Company Mitigation of stress-cracking in stacked loads of fragranced bleach-containing bottles
US5487936A (en) * 1994-03-21 1996-01-30 Collier Campbell Ltd. Textile fabrics of differential weave comprising multifilament threads wherein individual filaments have a linear density of one decitex or less
US5756180A (en) * 1994-01-12 1998-05-26 Squires; William J. Flocked fabric suitable as outerwear
US6350504B1 (en) * 1996-04-02 2002-02-26 Microfibres, Inc. Printed flocked pile fabric and method for making same
US6376041B1 (en) * 1996-10-29 2002-04-23 Microfibres, Inc. Embossed fabric
US20030190853A1 (en) * 1999-12-21 2003-10-09 Scott A. Lovingood Chambray fabric having unique characteristics and method of manufacturing same
US20040028873A1 (en) * 2002-08-06 2004-02-12 Corbett Bruce E. Flocked fabric

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4034134A (en) * 1975-10-07 1977-07-05 United Merchants And Manufacturers, Inc. Laminates and coated substrates
US4180606A (en) * 1977-07-25 1979-12-25 M. Lowenstein & Sons, Inc. Fabrics having flocked corduroy ribs
US4241122A (en) * 1978-10-31 1980-12-23 Kanebo, Ltd. Artificial leather having chinchilla-like appearance and natural suede-like feeling and a method for producing the same
US4294577A (en) * 1980-03-25 1981-10-13 Pervel Industries, Inc. Dyed flocked fabric and method of making the same
US4438533A (en) * 1980-06-03 1984-03-27 Kufner Textilwerke Kg Interlining for garments and method for the manufacture thereof
US4863633A (en) * 1987-08-07 1989-09-05 The Clorox Company Mitigation of stress-cracking in stacked loads of fragranced bleach-containing bottles
US5756180A (en) * 1994-01-12 1998-05-26 Squires; William J. Flocked fabric suitable as outerwear
US5487936A (en) * 1994-03-21 1996-01-30 Collier Campbell Ltd. Textile fabrics of differential weave comprising multifilament threads wherein individual filaments have a linear density of one decitex or less
US6350504B1 (en) * 1996-04-02 2002-02-26 Microfibres, Inc. Printed flocked pile fabric and method for making same
US6376041B1 (en) * 1996-10-29 2002-04-23 Microfibres, Inc. Embossed fabric
US20030190853A1 (en) * 1999-12-21 2003-10-09 Scott A. Lovingood Chambray fabric having unique characteristics and method of manufacturing same
US20040028873A1 (en) * 2002-08-06 2004-02-12 Corbett Bruce E. Flocked fabric

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090260707A1 (en) * 2008-04-22 2009-10-22 Arun Pal Aneja Woven Textile Fabric with Cotton/Microdenier Filament Bundle Blend

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