US3403433A - Method of producing pill resistant polyester fiber containing fabrics - Google Patents

Method of producing pill resistant polyester fiber containing fabrics Download PDF

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Publication number
US3403433A
US3403433A US586583A US58658366A US3403433A US 3403433 A US3403433 A US 3403433A US 586583 A US586583 A US 586583A US 58658366 A US58658366 A US 58658366A US 3403433 A US3403433 A US 3403433A
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United States
Prior art keywords
fabric
polyester
cotton
fibers
pilling
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Expired - Lifetime
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US586583A
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English (en)
Inventor
Werner A P Schoeneberg
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Celanese Corp
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Celanese Corp
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Publication date
Priority to BE664663D priority Critical patent/BE664663A/xx
Priority to DE19651460383 priority patent/DE1460383A1/de
Priority to NL6506880A priority patent/NL6506880A/xx
Priority to FR19151A priority patent/FR1455913A/fr
Application filed by Celanese Corp filed Critical Celanese Corp
Priority to US586583A priority patent/US3403433A/en
Application granted granted Critical
Publication of US3403433A publication Critical patent/US3403433A/en
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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/39—Aldehyde resins; Ketone resins; Polyacetals
    • D06M15/423—Amino-aldehyde resins
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/32—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/36—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/38—Oxides or hydroxides of elements of Groups 1 or 11 of the Periodic Table
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/52—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment combined with mechanical treatment
    • D06M13/53—Cooling; Steaming or heating, e.g. in fluidised beds; with molten metals
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process

Definitions

  • United States Patent M ABSTRACT OF THE DISCLOSURE A method of producing pill resistant fabrics from polyester fiber containing blended yarns comprising restraining the fabric and then heating the restrained fabric whereby the polyester fiber components shrink and migrate to the center of the yarns making up the fabric.
  • This invention which is a divisional application of copending application Ser. No. 371,768 filed June 1, 1964, now abandoned, relates to the production of pill-free, soft, brushed polyester/cellulosic and polyester/wool blend fabrics.
  • polyester/cellulosic and polyester/wool blends have been gaining substantial commercial importance, especially such fabrics containing wool or wherein the cellulosic is cotton.
  • the low covering power of typical polyester/ cotton and polyester/wool blend fabrics emphasizes the unevenness of the yarn while all-cotton and all-wool fabrics with yarns of equivalent evenness appear more even due to the surface cover of the cotton or wool fibers.
  • polyester/cellulosic and polyester/wool blend fabrics having a soft brushed surface and good surface cover.
  • polyester fiber in staple form is used in polyester/ cellulosic and polyester/wool blend fabrics
  • a serious problem with regard to pilling of the polyester at the surface of the fabric may be encountered.
  • pilling of course, substantially lessens the desirability of the fabric.
  • the pilling is unpleasing in appearance; at times, large pills will shed from the surface of the fabric, which, of course, is undesirably messy.
  • the cellulosic fibers to be used in the blend often will be in staple form, too. This is because the most common of the cellulosic fibers, cotton, occurs only in staple form and because staple fibers, as compared with continuous filaments, generally have a softer hand, softer surface, warmer feeling and are found by the consumer to be more aesthetically pleasing.
  • any polyester fibers remaining at the surface of the heat-set fabric by the use of singeing.
  • Singeing generally involves the exposure of the surfaces of the fabric to a flame, whereby the polyester fibers remaining near the surface of the fabric are selectively burned away because the polyester fibers have a lower decomposition point than the cellulosic or wool fibers.
  • any other source of sufiicient heat could be used, such as heated rolls or plates past which the fabric would move either near the surface thereof or in contact therewith.
  • the fabric is brushed for the purpose of further raising cellulosic or wool to the surface thereof.
  • a brushing softener is applied to the fabric.
  • the brushing softener may comprise any of the following, alone or in a mixture: anionic, nonionic and cationic stearic compounds, silicone oils, sulfated oils and fats, alkyl quaternaries or solutions, emulsions or suspensions of'any of the preceding substances, mineral oil emulsions and polyethylene emulsions and the like.
  • steam is applied to the fabric during the brushing operation for the purpose of effecting lubrication between the bristle surfaces and fabric surface.
  • a finishing resin may be applied with the softener.
  • Such resins may be applied as a solid, melt, solution, suspension or emulsion and, if thermosetting, the unreacted or partially reacted components of the resin may be so applied and subsequently cured.
  • thermosetting finishing resins or reactant resin components which may be applied are methylol urea, methylated methylol urea, methylol cyclic ethylene urea, methylol melamine, methylated methylol melamine, polyesters, phenolic formaldehyde, acetone formaldehyde, epoxy resins, melamine resin acid colloid, dirnethylolpropyleneurea, dimethylol-uron-dimethylether and methylol triazone.
  • thermoplastic resins which may be applied are butadiene/styrene and butadiene/acrylonitrile copolymers and polymers and copolymers of acrylate esters, vinyl acetate, vinyl alcohol, vinyl butyral, vinyl chloride, vinylidene chloride, styrene, ethylene, propylene, linear ester condensates, linear amide condensates, natural rubber and the like.
  • calendering is preferred to calender after singeing and brushing because calendering before brushing flattens the fabric and hinders good pile formation in brushing.
  • results achieved in terms of pile formation and pilling performance if the calendering is performed before brushing can be improved by low pressure calendering (e.g., silk calendering) subsequent to the initial calendering and before the brushing.
  • Silk calendering is generally performed by passing the fabric in sequence between the two nips of a three-bowl calender, the top and bottom bowl (roll) surfaces of which are 3 usually paper and the center bowl (roll) surface of which is usually metal.
  • the resin finish is then cured.
  • a conventional loop dryer is particularly suitable.
  • any other type oven or dryer which would provide adequate dwell time e.g., a conventional roller curing oven
  • Temperature and dwell time are, of course, dependent on the particular resin finish.
  • conventional resin finishes are used, conventional curing times and temperatures for these resins are well known in the art.
  • the fabric may be conventionally pressed and/ or decated or semi-decated.
  • the above referred to restrained heat setting is carried out at from about 325 to about 425 F., preferably from about 350 to 415 F., for a duration of from about 300 to 5 seconds, preferably from about 60 to about seconds (temperature and time being correlated inversely).
  • the above referred to singeing preferably is carried out at a flame temperature of about 2000 to about 4000 F. for a duration of from about 0.02 second to 0.08 second (temperature and time being correlated inversely).
  • Hinneken boil off and prescouring are conventional and may be performed at conventional temperatures and durations, which, of course depend upon the specific fabric treated.
  • the extent of drying of the fabric, subsequent to padding is preferably to a moisture content of from about 1 to preferably from about 2 to about 10%, whereby, the fabric is suitably soft for the subsequent brushing.
  • the curing of the finish on the fabric and the decating are performed under conventional conditions.
  • polyester refers to polyesters of glycols and dibasic acids, particularly glycols of the series HO(CH ),,OH where n is an integer within the range of 2-10, and the dibasic acid is one or more of terephthalic acid, isophthalic acid, adipic acid, sebacic acid, dibenzoic acid and the like.
  • cellulosic includes cotton, regenerated cellulose, cross-linked regenerated cellulose derivatives, sisal, hemp, jute, linen, ramie, tampico and the like.
  • EXAMPLE I A sample of viyella flannel made of 26/1s (i.e., yarn made from one end having a cotton count of 26) (19 turns/inch S-twist) of 65% 1.5 denier x 1 /2" polyethylene terephthalate staple fibers and 35% combed Pima cotton both in the Warp and in the filling and having a loom count of 74 ends/inch x 70 picks/inch, the reed width being 50.5" with 37 reed dents per inch and 2 ends per dent and the weave being a 2 x 2 twill, is treated as follows:
  • Aerotex resin M3 (melamine formaldehyde condensate resin) 50
  • Catalyst MX magnesium chloride
  • Ahcovel G cationic softener-fatty carbamide
  • Triton X-lOO ethoxylated nonylphenol 1 (H) Drying of the fabric on a tenter clip frame with hot air at 250 F., leaving approximately 5% moisture content;
  • EXAMPLE III A sample of lawn made of 70/ ls of 65% polyethylene terephthalate staple and 35% cotton both in the warp and in the filling and having a greige construction of 88 ends/inch x 76 picks/inch, the greige width being 40" is treated as follows:
  • Treatment of the fabric with hot strong caustic solution may be used as an additional and independent anti-pilling measure.
  • Such treatment tends to decrease pilling by partly degrading the polyester yarn whereby the polyester is weakened so that polyester fibers at the yarn surfaces, when rubbed, gradually break away from the surfaces rather than form bunches or balls of tangled fibers on the surfaces (which bunches or balls are commonly known as pills)
  • incorporating a caustic treatment into the present selective coring processes gives only a marginal improvement with regard to the brush and sponge pilling test (ASTM Dl37559*T Method C), results which generally cannot justify the concomitant strength loss; also, excellent random tumble pilling test (ASTM 1375) results, comparable to those achieved by the use of caustic treatment with the present selective coring processes, are achieved without the use of caustic and concomitant strength loss.
  • Random tumble pilling test (15/30/60 minuteS (ASTM-D1375) 515/ 5/515 Brush and sponge pilling test (ASTM-D- 137559T method C) 2 2-3 Samples of all fabrics to be treated by the processes of the present invention may be cross dyed (e.g., cotton 1 to 3% in excess of the pre-heat set dimension during heat setting.
  • the lateral restraining may be within the same range as the lateral restraining used for normally shrinkable polyester, but more latitude of choice is permissible: specifically, the fabric may be allowed to shrink up to about 10% below its pre-heat setting lateral dimension during heat setting while being laterally restrained against further shrinkage; thus, even under such conditions, it is properly said that the fabric is laterally restrained against shrinkage.
  • the lateral restraint during heat setting preferably is such that the percentage to which the lateral dimension of the fabric during heat-setting is maintained above or allowed to decrease below the pre-heat setting lateral dimension is within the range of from about 3% above to about 5% below the pre-heat setting lateral dimension.
  • Table I shows the influence of heat setting with minor stretching, after dyeing (experiment Numbers 1 to 5) and before dyeing (experiment Number 6), followed by singeing alone or with other process steps in sequence, as listed, in accordance with the present invention, upon the pilling resistant properties of polyester/ cotton blend yarns:
  • restrained heat setting means heat setting of the fabric while it is laterally restrained against shrinkage. Restraining may be accomplished by use of a tenter frame (pin or clip or any other type), pinch rolls or any other conventional means for laterally restraining fabric.
  • the lateral restraining during heat setting constitute maintaining the fabric at its initial (i.e., pre-heat setting) lateral dimension or at lateral dimension of up to about 5% in excess thereof; preferably, the lateral dimension of the fabric is maintained at about It is thus apparent that a highly shrinkable polyestercontaining blend will tend to demonstrate greater pilling resistance than an identically processed normally shrinkable polyester-containing blend.
  • Highly shrinkable polyester means polyester filaments which have not been conventionally heat set during their manufacture and thus will shrink in boiling water substantially more than the 10-l2% which is typical of conventionally heat set, i.e., normally shrinkable, polyester.
  • Table II shows the effect of shrink-proofing ("Sanforize process) preceded or not by mercerization on pilling performance.
  • the fabrics tested in each of these experiments are oxfords each having a warp of 88 ends/inch of 50/ ls of 30 turns/inch Z-twist 35/ polyethylene terephthalate/cotton yarn.
  • px. means picks/inch
  • P/ C means polyester/ cotton blend yarn.
  • B & S means 12 minute duration Brush & Sponge Test and RT means 30 minute duration Random Tumble test.
  • the headings Original” and Washed mean, respectively, that the fabric was not washed after being processed and before being tested and that the fabric was so washed.
  • the fabric processing steps are, of course, listed inchronological order.
  • each fabric in each experiment was heat set while laterally restrained against shrinkage at 415 F. for 20 seconds. Each singeing and resingeing was performed at an Industrial Heat Engineering Singer Setting of Flame 6, Speed 10.
  • Table III shows the effect of mercerization on pilling performance.
  • the mercerization consisted of caustic impregnation (4852 TW. concentration) of the fabric on a pad, removal of excess caustic by squeezing, holding the fabric under filling tension on a tenter clip frame and partially washing out the caustic from the fabric while under tension, and completing of washing of the fabric in a 6-box open width washer with neutralization of the fabric in the last box.
  • each fabric was heat set at 400 F. for seconds while laterally restrained against shrinkage, brushed two times on each side with a soft steel bristle brush roll and singed at an Industrial Heat Engineering Singer Setting of Flame 6, Speed 10.
  • the fabric tested is a gabardine having a warp of 132 ends/inch and a fill of 72 picks/inch each of ls of Z-twisted 65/ polyethylene terephthalate/ cotton yarn.
  • Table IV sets forth pilling and strength data for the fabric produced in each of the Examples I to IV, above.
  • Method of producing soft, pilling-resistant fabric of blend yarn comprising polyester staple fibers and fibers selected from the group consisting of cellulosics. and wool comprising the steps of restraining the fabric and heating said restrained fabric whereby the polyester staple fibers shrink and migrate to the center of the yarn.
  • Method of producing soft, pilling resistant fabric of blend yarn comprising polyester fibers and fibers selected from the group consisting of cellulosics and wool comprising the steps of restraining the fabric, heating said restrained fabric whereby the polyester staple fibers shrink and migrate to the center of the yarn, applying an aqueous composition to said fabric, drying said aqueous composition containing fabric to a moisture content of from about 1 to about 10% based on the weight of the dry fabric, applying lubricant to said dried fabric thereby to facilitate the subsequent raising of the selected fibers, and brushing said lubricant-containing fabric thereby to raise additional selected fibers to the surface thereof.
  • aqueous composition comprises finishing resin and brushing softener.
  • heating step is at a temperature of from about 325 to about 425 F.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Treatment Of Fiber Materials (AREA)
US586583A 1964-06-01 1966-08-10 Method of producing pill resistant polyester fiber containing fabrics Expired - Lifetime US3403433A (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
BE664663D BE664663A (en)) 1964-06-01 1965-05-28
DE19651460383 DE1460383A1 (de) 1964-06-01 1965-05-29 Verfahren zur Herstellung verbesserter Textilgewebe
NL6506880A NL6506880A (en)) 1964-06-01 1965-05-31
FR19151A FR1455913A (fr) 1964-06-01 1965-06-01 Perfectionnements aux étoffes textiles
US586583A US3403433A (en) 1964-06-01 1966-08-10 Method of producing pill resistant polyester fiber containing fabrics

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US37176864A 1964-06-01 1964-06-01
US586583A US3403433A (en) 1964-06-01 1966-08-10 Method of producing pill resistant polyester fiber containing fabrics

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US3403433A true US3403433A (en) 1968-10-01

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BE (1) BE664663A (en))
DE (1) DE1460383A1 (en))
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NL (1) NL6506880A (en))

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3676906A (en) * 1967-09-13 1972-07-18 Ici Ltd Process for making a patterned fabric by using differential shrinkage yarns
US4485535A (en) * 1979-05-04 1984-12-04 Toray Industries, Inc. Methods of manufacturing pile fabric
US6221488B1 (en) 1997-10-14 2001-04-24 Wellman, Inc. Modified polyester with high intrinsic viscosity at moderate strength
US20130255048A1 (en) * 2012-03-30 2013-10-03 Deckers Outdoor Corporation Natural wool pile fabric and method for making wool pile fabric
US20140013555A1 (en) * 2012-07-12 2014-01-16 Michael Xu Method of manufacturing velvet plush and article thereof
US20150259843A1 (en) * 2014-03-11 2015-09-17 Welspun India Limited Natural finish fabric
US10801139B2 (en) 2017-01-27 2020-10-13 Deckers Outdoor Corporation Sheared wool fleece and method for making sheared wool fleece utilizing yarn knitting
US11591748B2 (en) 2020-01-14 2023-02-28 Shadow Works, Llc Heat treated multilayer knitted textile of liquid crystal polymer fibers and modified polyacrylonitrile fibers, and process for making same
US11713524B2 (en) 2017-01-27 2023-08-01 Deckers Outdoor Corporation Sheared wool fleece and method for making sheared wool fleece utilizing yarn knitting

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA466070A (en) * 1950-06-20 Bamber Speakman John Treatment of textile materials
US2897042A (en) * 1955-06-30 1959-07-28 Du Pont Method for increasing pill resistance and density of blended staple polyethylene terephthalate and cellulosic fabrics by applying specific chemical shrinking agents for the polyethylene terephthalate
US3006055A (en) * 1958-02-21 1961-10-31 Du Pont Process for fulling textile fabrics
US3060551A (en) * 1959-08-11 1962-10-30 Bogaty Herman Mixed fabric with wool surface
US3279163A (en) * 1964-01-06 1966-10-18 Du Pont Pill-resistant yarns

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA466070A (en) * 1950-06-20 Bamber Speakman John Treatment of textile materials
US2897042A (en) * 1955-06-30 1959-07-28 Du Pont Method for increasing pill resistance and density of blended staple polyethylene terephthalate and cellulosic fabrics by applying specific chemical shrinking agents for the polyethylene terephthalate
US3006055A (en) * 1958-02-21 1961-10-31 Du Pont Process for fulling textile fabrics
US3060551A (en) * 1959-08-11 1962-10-30 Bogaty Herman Mixed fabric with wool surface
US3279163A (en) * 1964-01-06 1966-10-18 Du Pont Pill-resistant yarns

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3676906A (en) * 1967-09-13 1972-07-18 Ici Ltd Process for making a patterned fabric by using differential shrinkage yarns
US4485535A (en) * 1979-05-04 1984-12-04 Toray Industries, Inc. Methods of manufacturing pile fabric
US6221488B1 (en) 1997-10-14 2001-04-24 Wellman, Inc. Modified polyester with high intrinsic viscosity at moderate strength
US10287720B2 (en) 2012-03-30 2019-05-14 Deckers Outdoor Corporation Natural wool pile fabric and method for making wool pile fabric
US9212440B2 (en) * 2012-03-30 2015-12-15 Deckers Outdoor Corporation Natural wool pile fabric and method for making wool pile fabric
US20130255048A1 (en) * 2012-03-30 2013-10-03 Deckers Outdoor Corporation Natural wool pile fabric and method for making wool pile fabric
US20140013555A1 (en) * 2012-07-12 2014-01-16 Michael Xu Method of manufacturing velvet plush and article thereof
US9181646B2 (en) * 2012-07-12 2015-11-10 Chen Feng Method of manufacturing velvet plush and article thereof
USRE49640E1 (en) * 2012-07-12 2023-09-05 Chen Feng Method of manufacturing velvet plush and article thereof
US20150259843A1 (en) * 2014-03-11 2015-09-17 Welspun India Limited Natural finish fabric
US9732455B2 (en) * 2014-03-11 2017-08-15 Welspun India Limited Natural finish fabric
US10801139B2 (en) 2017-01-27 2020-10-13 Deckers Outdoor Corporation Sheared wool fleece and method for making sheared wool fleece utilizing yarn knitting
US11713524B2 (en) 2017-01-27 2023-08-01 Deckers Outdoor Corporation Sheared wool fleece and method for making sheared wool fleece utilizing yarn knitting
US11591748B2 (en) 2020-01-14 2023-02-28 Shadow Works, Llc Heat treated multilayer knitted textile of liquid crystal polymer fibers and modified polyacrylonitrile fibers, and process for making same

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Publication number Publication date
FR1455913A (fr) 1966-10-21
DE1460383A1 (de) 1969-01-30
NL6506880A (en)) 1965-12-02
BE664663A (en)) 1965-11-29

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