US3567548A - Production of permanently sculptured pile fabrics - Google Patents

Production of permanently sculptured pile fabrics Download PDF

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Publication number
US3567548A
US3567548A US639927A US3567548DA US3567548A US 3567548 A US3567548 A US 3567548A US 639927 A US639927 A US 639927A US 3567548D A US3567548D A US 3567548DA US 3567548 A US3567548 A US 3567548A
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United States
Prior art keywords
pile
fabric
adhesive
solution
solvent
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Expired - Lifetime
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US639927A
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English (en)
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Phillip Miller
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Individual
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06Q—DECORATING TEXTILES
    • D06Q1/00—Decorating textiles
    • D06Q1/06—Decorating textiles by local treatment of pile fabrics with chemical means
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C23/00—Making patterns or designs on fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C2700/00—Finishing or decoration of textile materials, except for bleaching, dyeing, printing, mercerising, washing or fulling
    • D06C2700/31—Methods for making patterns on fabrics, e.g. by application of powder dye, moiréing, embossing
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23986—With coating, impregnation, or bond
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23993—Composition of pile or adhesive

Definitions

  • Pile fabrics have achieved a Wide degree of public acceptance due in particular to their luxurious hand, appearance and Warmth.
  • An important factor which has however inhibited even greater demand for pile fabrics has been the lack of a wide selection of designs, particularly in multicolored patterns, as compared to the variety available in other fabric constructions.
  • the art has experienced great difficulty in producing interesting, deep, clearly delineated and reproducible designs in an inexpensive manner.
  • low-cost pile fabrics have tended to be esthetically monotonous.
  • This process broadly comprises (1) directly depositing in a predetermined pattern a solution having a viscosity of about 500 to 1000 cps. and containing a solvent for at least one of the major constituent fibers of said pile, said deposition being at a depth of about to 30% of the average pile height and in sufficient amount and under sufficient pressure as to cause the solution to penetrate substantially to the base of the pile with essentially no lateral flow, (2) heating said solvent-containing pile fabric to remove at least 75% of the solvent, (3) compacting said pile and (4) relofting the pile elements. If desired, metallic particles can be included in the deposited solution.
  • the sculptured effect as thereby produced is truly permanent since part of the pile itself has actually been dissolved.
  • ornamentation is achieved and maintained by chemical etching and not merely by adhesive action.
  • dry-cleaning or any other deleterious conditions cannot destroy the pattern definition.
  • Suitable solvents for the practice of this invention are dimethyl formamide, dimethyl acetaniide, tetramethylene sulfone, dimethyl sulfoxide and similar highly polar solvents.
  • the viscosity of the solution can be increased to within the range of 500 to 1000 cps. by the addition of silica thickening agents or similar thickening materials well known to the skilled chemist. 'If the viscosity is significantly lower than 500 cps, the solution tends to laterally flow thus resulting in a smudged unesthetic design. On the other hand, if the viscosity is significantly above 1000 cps. the solution cannot easily penetrate to the base of the fiber with the result that the sculpture will be of only limited depth. Within the aforesaid critical range, the optimum viscosity is a function of the speed of operation, the drying time and the specific materials and apparatus employed.
  • the amount of solution deposited and the pressure of deposition should be correlated so that the solution penetrates substantially to the base of the pile with essentially no lateral flow. These optimum absolute values will vary with the specific apparatus, solution and fabric employed. With most pile fabrics the amount deposited should be within the range of O.82 gallons/ sq. yards of printed space and the pressure should be within the range of about 40 to 100 p.s.i.
  • the solution is deposited by means of an engraved roll as distinct from a heated embossing roll.
  • the engraving need only be on the order of 0.010 to 0.040 inch deep.
  • the pile fabric contains a high percentage of fibers which are readily soluble in the chosen polar solvent, one need heat the solvent-treated fabric only to the degree necessary to remove the solvent.
  • the pile can then be cold compacted and relofted.
  • Exemplary of such piles are those containing acrylics and cellulose acetate.
  • the compacting can be effected in a heated zone such as a hot nip.
  • Pile fabrics which contain only fibers such as polyester which are not readily soluble at room temperature in such polar solvents should be compacted in a heated zone such as a hot nip at a temperature above which the fibers become soluble in the solvent.
  • the solvent solution may also contain a compatible adhesive material soluble in said solvent which is curable and which can be rendered partially heat settable.
  • a compatible adhesive material soluble in said solvent which is curable and which can be rendered partially heat settable.
  • adhesive formulations based on polyurethanes Other curable adhesive formulations based on urea-formaldehyde, phenolics, acrylics, curable epoxy resins and others well known to those skilled in the adhesive art are also utilizable and aid in maintaining pattern definition during dry-cleaning. Par-- ticularly with suitable plasticizers well known in the art, such added adhesives increase the flexibility and elasticity of the decorated pile fabric.
  • the adhesive should be one that has sufficient tack and cohesiveness to hold the insoluble fibers in a matted condition as it exits from the squeeze rolls.
  • the pile fabric is fed through a printing apparatus containing one or more engraved rolls inked with the adhesive-solvent solution which can be colored or colorless.
  • the solution is deposited thereon beneath the pile surface in accordance with the engraved design.
  • the engraved roll itself penetrates the pile only to a depth of about 10 to 30% of the average pile height.
  • the printed pile fabric is then rendered at least partially .settable by any suitable means, as for example, heating to about F.
  • the fabric is then sent to a pressure device to compress the entire pile.
  • the compacted pile fabric is then cured by any of a variety of means and then subjected to finishing treatment which relofts the pile.
  • the resulting fabric has a controlled, sharply defined permanent pattern in three dimensions while retaining the flexibility and other desirous properties of a pile fabric.
  • the ornamentation is not affected by commercial dry-cleaning.
  • the setting operation may involve cross-linking for retention of the adhesive during dry-cleaning but it is not critical to this invention that the adhesive be cross-linked.
  • Cross-linking can be accomplished in numerous Ways Well known in the adhesive art, the choices being largely de pendent on the nature of the adhesive.
  • chemical cross-linking can be accomplished by the passage of time, chemical treatment, radiation, application of heat or pressure or the like depending on the chemistry of the adhesive.
  • FIG. 1 is a diagrammatic showing of the apparatus utilized according to the specific embodiment.
  • Example I A pile fabric, a A inch deep polyester pile having a cotton backing, is decorated in a four color pattern in the following manner.
  • the pile fabric 2 is fed from a supply roller '1 on through the four nips between engraved rolls 3, 4, 5 and 6 and back-up rolls 7, 8, 9 and 10, respectively.
  • Each engraved roll is 5 inches in diameter with a Width of 60 inches and the engravings are .035 inch deep.
  • the printing pressure on each cylinder is provided by two air cylinders (not shown) having 6 inch diameters supplying 80 to 100 lbs. of pressure per square inch.
  • Each cylinder drives one' end of the engraved roll against the corresponding rubber back-up roll.
  • En'graved roll 3 is inked by a colored adhesive solution 11 picked up from color box 12 applied by a doctor blade 13.
  • the other engraved rolls are similarly inked with different colors (not numbered).
  • the colored solutions contain suitable dyes dissolved in dimethylformamide.
  • Enough Cab-O-Sil (a colloidal silica preparation-Cabot) is added to increase the viscosity to 750 cps.
  • Each engraved roll then prints its portion of the total design of the pile fabric.
  • the engraving rolls are synchronized and adjustable to ensure perfect register so that there is no color mixing on the pile fabric.
  • Hot air ducts 14, 1'5 and 16 partially dry the fabric between the rolls to prevent marking off onto the next roll. No back gray cloth is necessary as the pile backing serves sufficiently as a cushion to produce sharp designs.
  • the printed pile fabric then passes up over guide roll 17 and onto a conveyer belt 18 moved along by a series of idle rolls 21 into a heated tunnel 19.
  • the oven 20 heats the tunnel and fabric to a temperature of about 150 F. to 300 F., removing about 80% of the solvent from the printed colored solution. Heated air is continuously supplied to the oven at 22 and exhausted at 23 carrying away the vaporized solvent.
  • the fabric then exits from the tunnel and is passed to a pair of hot squeeze rolls 24 and 25 having a nip therebetween small enough to cause all the pile projections to mat down firmly against the backing.
  • the surface temperature on the pressure roll 24 should be about 212 F.
  • the pressure rolls should preferably be covered with Teflon or other release agents to minimize sticking.
  • the fabric After the fabric emerges from hot roll 24 and rubber roll 25, it passes through the cold nip between roll 25 and roll 26 to cold set the decoration.
  • the fabric is then passed to wind-up mechanism 28 over conveyer 27 and thereafter can be subjected to a normal finishing treatment.
  • the pile fabric can be subjected to the .4 action of steam jets and mechanical brushing in the conventional manner or with hot air and heat.
  • the full loft returns to the unprinted areas of the pile fabric while the printed areas remain depressed according to the predetermined design.
  • the overall effect is a luxurious, permanent three-dimensional multicolored design.
  • Example II The same pile fabric as in Example I is processed in the same manner.
  • the printing solution contains an adhesive and plasticizer and has the following composition in addition to the various pigments:
  • the printing solution has the following composition:
  • multiple level effects can be achieved by using several engraved rolls varying in the depth of their engravings.
  • a pile fabric having a surface rose print with a deeply incised outline can be produced by the method of this invention.
  • a variable height effect can also be achieved herein by the selection of the design so that as the straight pile tips are folded over in going through the various nips they essentially cause the pile to lay flat. For example, if one selects a design in which the lines are inch apart and the pile is about the same length, much of the fiber length will be held in a plane position. That part of the design which is greater will permit the full length of the pile to become erect.
  • the color in the printing compositions can be imparted by conventional dyes, inks, pigments, lacquers and combinations thereof, and in general, any suitable colorant which is compatible with the adhesive composition.
  • the instant invention has the further advantage over general embossing methods which employ heated cameo type pressure embossing rolls in that the latter are considerably more expensive, on the order of ten times as much, as photoengraved printing rolls.
  • the relief on the hot pressure embossing roll, which'is hot enough to soften the fiber, must be deeper than the pile to avoid melting the fiber.
  • the method of this invention much shallower engravings are possible since the solution is made to penetrate the pile by pressure or capillary flow.
  • the pile fabric can move around a cylinder instead of an a belt with the printing rolls disposed along the cylinder circumference.
  • additives can be incorporated into the printing composition to impart other desired properties, said additives being so chosen of course, as not to adversely affect the printing step or the adhesive action.
  • conventional fire-retardant, anti-static, bacteriostatic, ultraviolet stabilizer and similar additives can be applied to the pile fabric in accordance with the method of this invention without requiring additional processing steps.
  • metallic particles of appropriate size in the printing solution to product glitter effects can be used.
  • a process for sculpturing a pile fabric comprising the steps of (1) directly depositing in a predetermined pattern on the surface of said pile a solution having a viscosity of about 500 to 1000 cps. and containing a solvent for at least one of the major constituent fibers of said pile, said deposition being at a depth of about to 30% of the average pile height and in sufi'icient amount and under suflicient pressure to penetrate the pile substantially to the base of the fabric, (2) heating said solvent-containing pile fabric to remove at least 75% of said solvent to form in situ an adhesive mixture comprising the dissolved major constituent fibers of said pile, (3) compacting said pile with said adhesive mixture present and (4) relofting the pile elements.
  • one of the major constituent fibers of said pile is selected from the group consisting of acrylic and cellulose acetate fibers.
  • step (3) 4. A process according to claim 1 wherein step (3);
  • a process according to claim 1 wherein said solvent is selected from the group consisting of dimethyl formamide and dimethyl sulfoxide.
  • step (1) is conducted sequentially with a multiplicity of said solutions.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Coloring (AREA)
US639927A 1967-05-10 1967-05-12 Production of permanently sculptured pile fabrics Expired - Lifetime US3567548A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US63870467A 1967-05-10 1967-05-10
US63992767A 1967-05-12 1967-05-12

Publications (1)

Publication Number Publication Date
US3567548A true US3567548A (en) 1971-03-02

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Application Number Title Priority Date Filing Date
US639927A Expired - Lifetime US3567548A (en) 1967-05-10 1967-05-12 Production of permanently sculptured pile fabrics

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US (1) US3567548A (enrdf_load_stackoverflow)
AT (1) AT303664B (enrdf_load_stackoverflow)
BE (1) BE714960A (enrdf_load_stackoverflow)
BR (1) BR6898993D0 (enrdf_load_stackoverflow)
CH (2) CH523382A (enrdf_load_stackoverflow)
DE (1) DE1760376A1 (enrdf_load_stackoverflow)
ES (1) ES353719A1 (enrdf_load_stackoverflow)
FI (1) FI48208C (enrdf_load_stackoverflow)
FR (1) FR1566904A (enrdf_load_stackoverflow)
GB (1) GB1227381A (enrdf_load_stackoverflow)
IL (1) IL29955A (enrdf_load_stackoverflow)
NL (1) NL152034B (enrdf_load_stackoverflow)
NO (1) NO125238B (enrdf_load_stackoverflow)
SE (1) SE356773B (enrdf_load_stackoverflow)

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3830683A (en) * 1970-06-30 1974-08-20 Armstrong Cork Co Steam-etched solvent embossed tufted carpet
US3849158A (en) * 1973-08-06 1974-11-19 Congoleum Ind Inc Carpet embossing in register with print
US3849157A (en) * 1973-08-06 1974-11-19 Congoleum Ind Inc Carpet embossing in register with print
US3849159A (en) * 1973-08-06 1974-11-19 Congoleum Ind Inc Carpet embossing in register with print
USB460388I5 (enrdf_load_stackoverflow) * 1974-04-12 1976-01-27
US3969551A (en) * 1974-07-05 1976-07-13 American Cyanamid Company Chemically sculpturing fabrics
US3996404A (en) * 1974-07-30 1976-12-07 Japan Vilene Company Ltd. Conjugate polycarbonate fibers and fibrous sheets made thereof
JPS5314899A (en) * 1976-07-23 1978-02-09 Toray Industries Imparting method of three dimentional pattern to plush cloth
US4084026A (en) * 1975-02-06 1978-04-11 Colortex, S.A. Method of embossing textile material
US4189336A (en) * 1976-10-07 1980-02-19 Imperial Chemical Industries Limited Method of forming pile products by tack-spinning and heat treatment therefore
US4260390A (en) * 1979-12-10 1981-04-07 Armstrong Cork Company Additive-solvent process to form embossed product
DE3115523A1 (de) * 1980-04-17 1982-02-04 Milliken Research Corp., 29304 Spartanburg, S.C. Verfahren zur erzeugung eines reliefmusters auf florware
US4340381A (en) * 1975-09-24 1982-07-20 Congoleum Corporation Textured pile fabrics
JPS584888A (ja) * 1982-03-15 1983-01-12 東レ株式会社 ポリエステル立毛布帛の後処理方法
DE3247690A1 (de) * 1982-12-23 1984-07-05 Mechanische Gardinenweberei Ge Dekorationsstoff, insbesondere gardinenstoff, und verfahren zu seiner herstellung
US4500319A (en) * 1979-02-26 1985-02-19 Congoleum Corporation Textured pile fabrics
AU656916B2 (en) * 1990-08-27 1995-02-23 Wool Research Organisation Of New Zealand Inc. Process for the development of a textural effect on products
WO2005057487A2 (en) 2003-11-12 2005-06-23 Milliken & Company Sculptured and etched textile having shade contrast corresponding to surface etched regions

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3324666C2 (de) * 1983-07-08 1986-09-11 J.H. Benecke Gmbh, 3000 Hannover Verfahren zur Erzeugung von Mustern in der Struktur von Faserstoffen sowie Vorrichtung zur Durchführung des Verfahrens
EP0823506A3 (en) * 1996-08-05 1998-07-08 William J. Squires Flocked fabric with laid down fibers
CN108657747A (zh) * 2018-07-06 2018-10-16 山东鼎泰盛食品工业装备股份有限公司 整理输送装置、整理输送机构及清洗装置

Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3830683A (en) * 1970-06-30 1974-08-20 Armstrong Cork Co Steam-etched solvent embossed tufted carpet
US3849158A (en) * 1973-08-06 1974-11-19 Congoleum Ind Inc Carpet embossing in register with print
US3849157A (en) * 1973-08-06 1974-11-19 Congoleum Ind Inc Carpet embossing in register with print
US3849159A (en) * 1973-08-06 1974-11-19 Congoleum Ind Inc Carpet embossing in register with print
USB460388I5 (enrdf_load_stackoverflow) * 1974-04-12 1976-01-27
US3989448A (en) * 1974-04-12 1976-11-02 Armstrong Cork Company Overprint of solvent on total solvent coating
US3969551A (en) * 1974-07-05 1976-07-13 American Cyanamid Company Chemically sculpturing fabrics
US3996404A (en) * 1974-07-30 1976-12-07 Japan Vilene Company Ltd. Conjugate polycarbonate fibers and fibrous sheets made thereof
US4084026A (en) * 1975-02-06 1978-04-11 Colortex, S.A. Method of embossing textile material
US4340381A (en) * 1975-09-24 1982-07-20 Congoleum Corporation Textured pile fabrics
JPS5314899A (en) * 1976-07-23 1978-02-09 Toray Industries Imparting method of three dimentional pattern to plush cloth
US4189336A (en) * 1976-10-07 1980-02-19 Imperial Chemical Industries Limited Method of forming pile products by tack-spinning and heat treatment therefore
US4500319A (en) * 1979-02-26 1985-02-19 Congoleum Corporation Textured pile fabrics
US4260390A (en) * 1979-12-10 1981-04-07 Armstrong Cork Company Additive-solvent process to form embossed product
DE3115523A1 (de) * 1980-04-17 1982-02-04 Milliken Research Corp., 29304 Spartanburg, S.C. Verfahren zur erzeugung eines reliefmusters auf florware
US4353706A (en) * 1980-04-17 1982-10-12 Milliken Research Corporation Process for producing sculptured pile fabric
JPS584888A (ja) * 1982-03-15 1983-01-12 東レ株式会社 ポリエステル立毛布帛の後処理方法
DE3247690A1 (de) * 1982-12-23 1984-07-05 Mechanische Gardinenweberei Ge Dekorationsstoff, insbesondere gardinenstoff, und verfahren zu seiner herstellung
AU656916B2 (en) * 1990-08-27 1995-02-23 Wool Research Organisation Of New Zealand Inc. Process for the development of a textural effect on products
WO2005057487A2 (en) 2003-11-12 2005-06-23 Milliken & Company Sculptured and etched textile having shade contrast corresponding to surface etched regions
EP1684974A4 (en) * 2003-11-12 2008-06-25 Milliken & Co MODELED AND APPLIED TEXTILE WITH SURFACE AREAS ACCORDING TO SHADING CONTRAST

Also Published As

Publication number Publication date
FI48208B (enrdf_load_stackoverflow) 1974-04-01
NL152034B (nl) 1977-01-17
GB1227381A (enrdf_load_stackoverflow) 1971-04-07
BR6898993D0 (pt) 1973-02-20
NO125238B (enrdf_load_stackoverflow) 1972-08-07
BE714960A (enrdf_load_stackoverflow) 1968-11-12
FI48208C (fi) 1974-07-10
IL29955A (en) 1971-12-29
IL29955A0 (en) 1968-07-25
CH523382A (fr) 1972-02-15
AT303664B (de) 1972-12-11
ES353719A1 (es) 1970-02-16
FR1566904A (enrdf_load_stackoverflow) 1969-05-09
CH699368A4 (enrdf_load_stackoverflow) 1972-02-15
NL6806673A (enrdf_load_stackoverflow) 1968-11-11
SE356773B (enrdf_load_stackoverflow) 1973-06-04
DE1760376A1 (de) 1971-12-23

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