US3622372A - Process for manufacturing bulky fabrics - Google Patents

Process for manufacturing bulky fabrics Download PDF

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US3622372A
US3622372A US787237A US3622372DA US3622372A US 3622372 A US3622372 A US 3622372A US 787237 A US787237 A US 787237A US 3622372D A US3622372D A US 3622372DA US 3622372 A US3622372 A US 3622372A
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fabric
metal salts
expanded
water
temperature
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Haruo Ishida
Kiyoshi Otaka
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Daiwa Chemical Industries Ltd
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    • 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
    • D06M11/51—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 sulfur, selenium, tellurium, polonium or compounds thereof
    • D06M11/55—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 sulfur, selenium, tellurium, polonium or compounds thereof with sulfur trioxide; with sulfuric acid or thiosulfuric acid or their salts
    • 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
    • D06M11/07—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 halogens; with halogen acids or salts thereof; with oxides or oxyacids of halogens or salts thereof
    • D06M11/11—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 halogens; with halogen acids or salts thereof; with oxides or oxyacids of halogens or salts thereof with halogen acids or salts thereof
    • D06M11/155—Halides of elements of Groups 2 or 12 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
    • 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
    • D06M11/51—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 sulfur, selenium, tellurium, polonium or compounds thereof
    • D06M11/55—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 sulfur, selenium, tellurium, polonium or compounds thereof with sulfur trioxide; with sulfuric acid or thiosulfuric acid or their salts
    • D06M11/57—Sulfates or thiosulfates of elements of Groups 3 or 13 of the Periodic Table, e.g. alums
    • 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
    • D06M11/77—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 silicon or compounds thereof
    • D06M11/79—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 silicon or compounds thereof with silicon dioxide, silicic acids or their salts
    • 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
    • D06M11/80—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 boron or compounds thereof, e.g. borides
    • D06M11/82—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 boron or compounds thereof, e.g. borides with boron oxides; with boric, meta- or perboric acids or their salts, e.g. with borax
    • 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
    • D06M15/53—Polyethers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0043—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers
    • D06N3/0052—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers obtained by leaching out of a compound, e.g. water soluble salts, fibres or fillers; obtained by freezing or sublimation; obtained by eliminating drops of sublimable fluid
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2352—Coating or impregnation functions to soften the feel of or improve the "hand" of the fabric
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2369—Coating or impregnation improves elasticity, bendability, resiliency, flexibility, or shape retention of the fabric
    • Y10T442/2385—Improves shrink resistance
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2369—Coating or impregnation improves elasticity, bendability, resiliency, flexibility, or shape retention of the fabric
    • Y10T442/2393—Coating or impregnation provides crease-resistance or wash and wear characteristics

Definitions

  • PROCESS FOR MANUFACTURING BULKY FABRICS This invention relates to bulky fabrics such as bulky woven and knitted fabrics and the manufacture thereof. More particularly, the invention pertains to a novel process for manufacturing bulky fabrics and a novel intermediate fabrics for preparing bulky fabrics.
  • bulky fabrics are prepared in the prior art by weaving bulky yams into a textile fabric and heat-setting it. ln the heat-setting process temperatures higher than second order transition temperature of the fibers constituting the fabric are usually applied to heat-set the fabric.
  • fabrics of synthetic fibers which are heat-shrinkable are heated at such high temperatures, however, undesirable shrinkage of the fabrics occurs to the extreme degree, making it difficult to produce fabrics having excellent bulkiness, softness, hand the the like characteristics.
  • lengthwise and widthwise shrinkage of the fabric can be prevented to some extent by using a tenter or other mechanical means, it is inevitable that the extreme shrinkage occurs in thickness of the fabric, reducing the thickness of the fabric and resulting in the product hard to the touch.
  • the creases produced in the fabric during dyeing and finishing steps have so far been removed by ironing, pressing or tentering, but in such a case some shrinkage of the fibers is unavoidable.
  • special machines such as beam dyeing machine, jet dyeing machine, open-soaper, etc., but the equipment as above calls for enormous expenditure for installation and operation.
  • An object of the invention is to provide bulky fabrics having excellent bulkiness, softness, hand, shrink-proof property, crease-proof property, pleating property and draping property.
  • Another object of the invention is to provide a process for manufacturing bulky fabrics having above characteristics free from the drawbacks of the conventional processes.
  • a further object of the invention is to provide expanded fabrics resistant to heat applied in the heat-setting step and capable of producing bulky fabrics having above characteristics free from undesired shrinkage.
  • the fabrics used in the invention include woven fabrics and knitted fabrics prepared from at least one of synthetic fibers which are heat-shrinkable.
  • synthetic fibers are polyester, polyamide, polyacrylonitrile, polyurethane, polyvinyl chloride, polypropylene and the like fibers.
  • the fabrics made of mixed yarn of said synthetic fibers and natural or semisynthetic fibers, and the fabrics in which the yarn of said synthetic fibers and that of natural or semisynthetic fibers are combined can also be used in the invention.
  • the bound water-containing metal salts used in the invention should have properties expandable by the emission of their own bound water when heated at a temperature of from 100 C. to below a second order transition temperature of the fibers constituting the fabric to produce the expanded metal salt soluble in water but not melting or decomposing at an elevated temperature applied in the heat-setting step, i.e., a temperature of a second order transition temperature to below a decomposing temperature of the fibers.
  • various metal salts having above properties can be used, which include organic metal salts, inorganic metal salts, double salts and complex salts.
  • Typical examples of such metal salts are hydrous calcium chloride (CaCl 'l-l o or CaCl '6H-, 0), hydrous sodium tetraborate (Na B,Q 'l0H O), hydrous sodium acetate (CH -,COONa-3H,O), hydrous aluminum sulfate [Al (SO l8H O], hydrous aluminum potassium sulfate [KAI (SO 'l2H O], hydrous magnesium chloride -(MgCl 6I-l O), hydrous sodium potassium tartrate (K- NaC H4OO6 41-1 0), hydrous sodium thiosulfate (Na i S 0 SH O), hydrous sodium silicate (Na2O XSiO2'yH20), ydrous sotmlrn metasilicate (l l a S i Q 5l-l O) etc.
  • these metal salts When these metal salts are heated at a temperature of higher than C., they are first dissolved in their own bound water and emit the water in a gaseous state to produce pumicelike expanded solids of the metal salts which are soluble in water but can not be melted nor decomposed at an elevated temperature to be applied in the setting step of the fabric.
  • the expanded volume of the metal salts may vary depending on the kind of the metal salts used and the heat conditions to decompose the metal salts. Preferable heat conditions are represe nte d in the Table 1 below, in which expanded volume is determined by the following equation.
  • the metal salts can be used alone or in mixture and in the form of solution, suspension, paste or powder, and various additives may be added thereto, as required.
  • various additives may be added thereto, as required.
  • the conventional blowing agents which will emit carbon dioxide gas, ammonium gas, nitrogen gas, etc., by the decomposition thereof when heated.
  • fillers such as metal salts containing no bound water, clay, bentonite, etc., may be added.
  • dyestuffs may also be added to make it possible to dye the fabric simultaneously.
  • fabrics are first impregnated with the metal salts by various means according to the forms of metal salts used, for example, by dipping, padding, coating, spraying, printing, sprinkling, etc.
  • the entire part of the fabrics may be uniformly impregnated with the metal salts, while to obtain bulky fabrics having bulky spots and other bulky patterns the fabrics may be partly impregnated with the metal salts in accordance with the patterns desired.
  • the amount of the metal salts infused into the fabric may be in the range of 2 to 200 weight percent, preferably 20 to 60 weight percent, based on the weight of the fabric.
  • weight of the fabric is intended to mean the weight of the fibers constituting the impregnated part of the fabric. Lesser amount of the impregnation results in poorer effect and higher amount brings no increase in the effect. rendering the process uneconomical.
  • the bulkiness of the final bulky fabric may vary depending on the amount of the impregnation, so that by suitably selecting such amount the bulky fabric having desired bulkiness is obtainable.
  • the fabrics thus impregnated with metal salts are then subjected to heating step to expand the metal salt after squeezing and/or drying, as required.
  • heating step for expanding the metal salts is carried out at a temperature not lower than I C. but below second order transition temperatures of the fibers constituting the fabric.
  • Preferable temperatures to be applied may vary in accordance with the kind of the metal salts and fabrics used, and temperatures preferable for the respective metal salts are shown in the foregoing table I.
  • the time required for the expansion of the metal salts may vary depending in the temperature applied and metal salts used. but usually a period of 0.1 to minutes is sufficient for the purpose.
  • the resultant fabric contains expanded metal salts interposed in the intervals between fibers of the fabric and easily soluble in water but not melting or decomposing by the heat applied in the subsequent heat-setting process.
  • the fabric thus obtained is in expanded form.
  • the respective fibers constituting the fabric are elongated irregularly by the expansion of the metal salts and locked in such conditions by the expanded metal salts. Accordingly, when the expanded fabric is heated at a temperature higher than a second order transition temperature of the fibers the fabric is heat-set without the shrinkage of the fibers locked with the expanded metal salts.
  • the amount of the expanded metal salts interposed in the fabric may be in the range of l to I00 weight percent. preferably 10 to 30 weight percent. based on the weight of the fabric.
  • the bulky fabrics of the invention are prepared by heatsetting the expanded fabric and washing the heat-set fabric with water to remove the expanded metal salts therefrom.
  • the heat-setting treatment is carried out in the conventional manner. for example, by heating the expanded fabric at temperatures of second order transition temperatures to below decomposing temperatures of the fibers constituting the fabric.
  • the preferable temperatures may vary in accordance with the kind of the fibers. but temperatures of not higher than 50 C. above the second order transition temperature of the fibers may usually be applied.
  • the time required for the heatsetting is usually ().l to 10 minutes. in this step the fabric shows no shrinkage as the fibers are locked with expanded metal salts.
  • the fabric thus heat-set is washed with water to remove the expanded metal salts. whereby the bulky fabric having excellent bulkiness. softness. hand, shrink-proof property. creaseproof property. pleating property and draping property is obtained.
  • the heating step for expanding metal salts and heatsetting step are carried out in a single heating apparatus.
  • a single heating apparatus such as air oven and the like.
  • the fabric impregnated with metal salts is introduced into an air oven through which air heated at a temperature of higher than a second order transition temperature of the fibers is passed.
  • the metal salts have expanded, and when the temperature of the fabric reaches the second transition temperature or higher. the fabric is heat-set. in a continuous manner the fabric impregnated with the metal salts is continuously passed through the air oven. and at the inlet portion of the oven the metal salts are expanded. and then the fabric is heat-set.
  • EXAMPLE 1 A woven fabric of polyester yarn in which creases occurred during carrier dyeing process using a dispersed dye was immersed in the following composition and squeezed with a mangle to weight percent impregnation with the composition. based on the weight of the fabric.
  • EXAMPLE 2 A woven fabric of polyamide yarn was impregnated with the following composition in the order of 50 weight percent impregnation and dried at room temperature.
  • EXAMPLE 3 A woven fabric of bulky polyester yarn was immersed in the following composition, squeezed with a mangle to 80 weight percent impregnation and dried at 60 C.
  • EXAMPLE 4 A textile fabric of high-bulky polyacrylonitrile yarn, in which creases were created during dyeing process was immersed in the following composition, squeezed with a mangle 4 to 80 weight percent impregnation and dried at 60 C.
  • EXAMPLE 5 A textile fabric of polyester yarn in which creases occurred during dyeing step was immersed in the following composition 5 and squeezed with a mangle to I00 weight percent impregnatron.
  • Hydrous sodium metasilicate powder was uniformly sprinkled on a woven fabric of bulky polyester yarn in the order of 40 weight percent based on the weight of the fabric and placed in an air oven heated at I80 C. for 5 minutes.
  • EXAMPLE 7 A woven fabric of polyester fiber dyed by carrier dyeing was immersed in the following composition prior to heat-treatment for removing carrier, squeezed to 80 weight percent impregnation and dried at C.
  • Hydrous calcium chloride 30 parts Hydrous magnesium chloride 20 parts Polyethylencglycol nonylphenyl ether 0.5 parts Water 49 5 parts
  • the fabric thus treated was placed in an air oven heated at C. for 3 minutes. in the first one minute the hydrous calcium chloride and hydrous magnesium chloride expanded, generating water vapor and in the last two minutes the fabric was heat-set. The fabric was then washed with water to remove the expanded metal salts and dried at 60 C. Thus, the bulky fabric having the following properties shown in table 7 was obtained.
  • EXAMPLE 8 A woven fabric of polyester yarn was immersed in the following composition, squeezed to 70 weight percent impregnation and dried at 80 C.
  • Hydrous sodium tetraborutc 40 parts Polycthyleneglycul nonylphenyl ether 0.5 parts Starch 8 parts Water 5 LS parts
  • the fabric thus treated was tentered on a frame with pins and placed in an air oven heated at 180 C. for 3 minutes. In the first 1 minute the hydrous sodium tetraborate expanded. generating water vapor and in the last 2 minutes the fabric was heat-set. The fabric was then washed with water to remove the expanded metal salts and dried at 80 C. Thus, the bulky fabric soft to the touch was obtained.
  • An expanded synthetic fabric resistant to heat-shrinkage for producing a bulky fabric which comprises a fabric and 10 to 30 weight percent, based on the weight of the fabric, of expanded metal salts interposed in the intervals between fibers of the fabric and water-soluble but not melting or decomposing at a temperature of between a second transition temperature and below a decomposing temperature of the fabrics.
  • said metal salts being at least one species selected from the group consisting of calcium chloride, sodium tetraborate, sodium acetate, aluminum sulfate, aluminum potassium sulfate, magnesium chloride, sodium potassium tartrate. sodium thiosulfate, sodium silicate and sodium metasilicate.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)

Abstract

A process for producing a bulky fabric which comprises impregnating a fabric with a bound water-containing metal salt, heating the impregnated fabric to expand said metal salt contained in the fabric, heat-setting the resultant fabric and washing with water the resultant fabric to remove the expanded metal salt; said bound water-containing metal salt being expandable by the emission of its own bound water when heated at a temperature of from 100* C. to a second order transition temperature of the fiber to produce the expanded metal salt soluble in water but not melting or decomposing at a temperature applied in said heat-setting step.

Description

United States Patent Inventors Haruo lshida Hirakata-shl; Kiyoshi Otaka, Hyogo-ken, both of Japan Appl. No. 787,237 Filed Dec. 26, 1968 Patented Nov. 23, 1971 Assignee Daiwa Chemical Industries Ltd.
Osaka-shi, Japan Priority Dec. 29, 1967 Japan 42/84829 PROCESS FOR MANUFACTURING BULKY FABRICS 2 Claims, No Drawin U.S. Cl. 117/62, 1 17/ 1 39.5 CE
Int. Cl 844d l/44 Field of Search 1 17/62,
1 [56] References Cited UNlTED STATES PATENTS 758,311 4/1904 Goldman 106/150 Primary Examiner-William D. Martin Assistant Examiner-M. Sofocleous An0rney--Larson, Taylor and Hinds ABSTRACT: A process for producing a bulky fabric which comprises impregnating a fabric with a bound water-containing metal salt, heating the impregnated fabric to expand said metal salt contained in the fabric, heat-setting the resultant fabric and washing with water the resultant fabric to remove the expanded metal salt; said bound water-containing metal salt being expandable by the emission of its own bound water when heated at a temperature of from 100 C. to a second order transition temperature of the fiber to produce the expanded metal salt soluble in water but not melting or decomposing at a temperature applied in said heat-setting step.
PROCESS FOR MANUFACTURING BULKY FABRICS This invention relates to bulky fabrics such as bulky woven and knitted fabrics and the manufacture thereof. More particularly, the invention pertains to a novel process for manufacturing bulky fabrics and a novel intermediate fabrics for preparing bulky fabrics.
In general, bulky fabrics are prepared in the prior art by weaving bulky yams into a textile fabric and heat-setting it. ln the heat-setting process temperatures higher than second order transition temperature of the fibers constituting the fabric are usually applied to heat-set the fabric. When fabrics of synthetic fibers which are heat-shrinkable are heated at such high temperatures, however, undesirable shrinkage of the fabrics occurs to the extreme degree, making it difficult to produce fabrics having excellent bulkiness, softness, hand the the like characteristics. While lengthwise and widthwise shrinkage of the fabric can be prevented to some extent by using a tenter or other mechanical means, it is inevitable that the extreme shrinkage occurs in thickness of the fabric, reducing the thickness of the fabric and resulting in the product hard to the touch.
Further, the creases produced in the fabric during dyeing and finishing steps have so far been removed by ironing, pressing or tentering, but in such a case some shrinkage of the fibers is unavoidable. To prevent the creation of the creases dyeing and finishing of bulky fabrics havebeen done in the prior art using special machines such as beam dyeing machine, jet dyeing machine, open-soaper, etc., but the equipment as above calls for enormous expenditure for installation and operation.
An object of the invention is to provide bulky fabrics having excellent bulkiness, softness, hand, shrink-proof property, crease-proof property, pleating property and draping property.
Another object of the invention is to provide a process for manufacturing bulky fabrics having above characteristics free from the drawbacks of the conventional processes.
A further object of the invention is to provide expanded fabrics resistant to heat applied in the heat-setting step and capable of producing bulky fabrics having above characteristics free from undesired shrinkage.
The above and other objects and advantages of the invention will be apparent from the following description.
According to the researches of the present inventors, it has been found that when a woven or knitted fabric is impregnated with a certain kind of bound water-containing metal salts and heated at a temperature not lower than l C. to expand the metal salts, a unique expanded fabric containing expanded metal salts interposed in the intervals between fibers of the fabric can be obtained and that when such an expanded fabric is subjected to a heat-setting step, such fabric is set in the expanded form without showing any shrinkage and a bulky fabric having excellent properties is produced after the removal of the expanded metal salts contained therein.
The fabrics used in the invention include woven fabrics and knitted fabrics prepared from at least one of synthetic fibers which are heat-shrinkable. Examples of the synthetic fibers are polyester, polyamide, polyacrylonitrile, polyurethane, polyvinyl chloride, polypropylene and the like fibers. Further, the fabrics made of mixed yarn of said synthetic fibers and natural or semisynthetic fibers, and the fabrics in which the yarn of said synthetic fibers and that of natural or semisynthetic fibers are combined can also be used in the invention.
The bound water-containing metal salts used in the invention should have properties expandable by the emission of their own bound water when heated at a temperature of from 100 C. to below a second order transition temperature of the fibers constituting the fabric to produce the expanded metal salt soluble in water but not melting or decomposing at an elevated temperature applied in the heat-setting step, i.e., a temperature of a second order transition temperature to below a decomposing temperature of the fibers. In the invention various metal salts having above properties can be used, which include organic metal salts, inorganic metal salts, double salts and complex salts. Typical examples of such metal salts are hydrous calcium chloride (CaCl 'l-l o or CaCl '6H-, 0), hydrous sodium tetraborate (Na B,Q 'l0H O), hydrous sodium acetate (CH -,COONa-3H,O), hydrous aluminum sulfate [Al (SO l8H O], hydrous aluminum potassium sulfate [KAI (SO 'l2H O], hydrous magnesium chloride -(MgCl 6I-l O), hydrous sodium potassium tartrate (K- NaC H4OO6 41-1 0), hydrous sodium thiosulfate (Na i S 0 SH O), hydrous sodium silicate (Na2O XSiO2'yH20), ydrous sotmlrn metasilicate (l l a S i Q 5l-l O) etc. V 7
When these metal salts are heated at a temperature of higher than C., they are first dissolved in their own bound water and emit the water in a gaseous state to produce pumicelike expanded solids of the metal salts which are soluble in water but can not be melted nor decomposed at an elevated temperature to be applied in the setting step of the fabric. The expanded volume of the metal salts may vary depending on the kind of the metal salts used and the heat conditions to decompose the metal salts. Preferable heat conditions are represe nte d in the Table 1 below, in which expanded volume is determined by the following equation.
Volume of metal salt expanded Expanded volume 100 containing inetal salt used A The metal salts can be used alone or in mixture and in the form of solution, suspension, paste or powder, and various additives may be added thereto, as required. For example, to adjust the blowing temperature, expanded volume and mechanical strength of the expanded solids, there may be added the conventional blowing agents which will emit carbon dioxide gas, ammonium gas, nitrogen gas, etc., by the decomposition thereof when heated. For the same purposes as above fillers, such as metal salts containing no bound water, clay, bentonite, etc., may be added. To improve the stability of the resultant foam surface active agents or starch paste may be added thereto. Further, dyestuffs may also be added to make it possible to dye the fabric simultaneously.
According to the invention fabrics are first impregnated with the metal salts by various means according to the forms of metal salts used, for example, by dipping, padding, coating, spraying, printing, sprinkling, etc. To obtain bulky fabrics having uniform bulkiness throughout the fabric the entire part of the fabrics may be uniformly impregnated with the metal salts, while to obtain bulky fabrics having bulky spots and other bulky patterns the fabrics may be partly impregnated with the metal salts in accordance with the patterns desired. The amount of the metal salts infused into the fabric may be in the range of 2 to 200 weight percent, preferably 20 to 60 weight percent, based on the weight of the fabric. Throughout the specification and claims the expression weight of the fabric" is intended to mean the weight of the fibers constituting the impregnated part of the fabric. Lesser amount of the impregnation results in poorer effect and higher amount brings no increase in the effect. rendering the process uneconomical. The bulkiness of the final bulky fabric may vary depending on the amount of the impregnation, so that by suitably selecting such amount the bulky fabric having desired bulkiness is obtainable.
The fabrics thus impregnated with metal salts are then subjected to heating step to expand the metal salt after squeezing and/or drying, as required. When dyestuff is used in combination with the metal salts it is preferable to dry the impregnated fabric prior to the heating step to prevent the migration of the dye. The heating step for expanding the metal salts is carried out at a temperature not lower than I C. but below second order transition temperatures of the fibers constituting the fabric. Preferable temperatures to be applied may vary in accordance with the kind of the metal salts and fabrics used, and temperatures preferable for the respective metal salts are shown in the foregoing table I. The time required for the expansion of the metal salts may vary depending in the temperature applied and metal salts used. but usually a period of 0.1 to minutes is sufficient for the purpose.
The resultant fabric contains expanded metal salts interposed in the intervals between fibers of the fabric and easily soluble in water but not melting or decomposing by the heat applied in the subsequent heat-setting process. By the presence of the expanded metal salts the fabric thus obtained is in expanded form. in more detail the respective fibers constituting the fabric are elongated irregularly by the expansion of the metal salts and locked in such conditions by the expanded metal salts. Accordingly, when the expanded fabric is heated at a temperature higher than a second order transition temperature of the fibers the fabric is heat-set without the shrinkage of the fibers locked with the expanded metal salts. The amount of the expanded metal salts interposed in the fabric may be in the range of l to I00 weight percent. preferably 10 to 30 weight percent. based on the weight of the fabric.
The bulky fabrics of the invention are prepared by heatsetting the expanded fabric and washing the heat-set fabric with water to remove the expanded metal salts therefrom. The heat-setting treatment is carried out in the conventional manner. for example, by heating the expanded fabric at temperatures of second order transition temperatures to below decomposing temperatures of the fibers constituting the fabric. The preferable temperatures may vary in accordance with the kind of the fibers. but temperatures of not higher than 50 C. above the second order transition temperature of the fibers may usually be applied. The time required for the heatsetting is usually ().l to 10 minutes. in this step the fabric shows no shrinkage as the fibers are locked with expanded metal salts.
The fabric thus heat-set is washed with water to remove the expanded metal salts. whereby the bulky fabric having excellent bulkiness. softness. hand, shrink-proof property. creaseproof property. pleating property and draping property is obtained.
In the preferred embodiment of the process of the invention. the heating step for expanding metal salts and heatsetting step are carried out in a single heating apparatus. such as air oven and the like. For example. the fabric impregnated with metal salts is introduced into an air oven through which air heated at a temperature of higher than a second order transition temperature of the fibers is passed. At the initial stage. while the fabric has not been heated yet to a second order transition temperature or higher. the metal salts have expanded, and when the temperature of the fabric reaches the second transition temperature or higher. the fabric is heat-set. in a continuous manner the fabric impregnated with the metal salts is continuously passed through the air oven. and at the inlet portion of the oven the metal salts are expanded. and then the fabric is heat-set.
For better understanding of the invention examples are given below in which all parts are in parts by weight.
EXAMPLE 1 A woven fabric of polyester yarn in which creases occurred during carrier dyeing process using a dispersed dye was immersed in the following composition and squeezed with a mangle to weight percent impregnation with the composition. based on the weight of the fabric.
"Kciso N0. 3"
(Hydrous sodium silicate containing 60 weight percent of water. specified in JlS K-MOK I966) 50 parts Polyethylcneglycol nonylphenyl other 0.5 parts Water 49.5 parts Then the fabric was tentered on a frame with pins to accurate lengthwise and widthwise measurements and placed in an air oven heated at C. for 3 minutes. in the first one minute the sodium silicate expanded. generating water vapor and in the last two minutes the fabric was heat-set. Thereafter the fabric was washed with water to remove the expanded metal salts and dried at 80 C. Thus the bulky fabric having the properties shown in table 2 below was obtained.
For comparison. the same treatment was performed using the composition same as above but not containing hydrous sodium silicate. The results are shown in Table 2 below.
TABLE 2 Changes in thick- Changes in hand ness Greases Fabric finished Softrtess and Nil Completely accordmg to the hand improved. removed. method of the invention.
Comparative iabric Hand hardened Decrease Originally creased and feature of of 30%. portions redrapery lost. mained as depressions.
EXAMPLE 2 A woven fabric of polyamide yarn was impregnated with the following composition in the order of 50 weight percent impregnation and dried at room temperature.
Hydmus aluminum potassium sulfate 40 parts Bentonilc (water content. Xi) uuighl percent) 10 arts Water 50 parts TABLE 3 Changes in thick- Changes in hand ness Pleat Fabric finished softness and Nil Excellent pleats.
by method of the hand improved. invention.
Comparison Hand hardened... Decrease Pleated portions of 40%. thinned and sharpened and partly shrunk.
EXAMPLE 3 A woven fabric of bulky polyester yarn was immersed in the following composition, squeezed with a mangle to 80 weight percent impregnation and dried at 60 C.
"Foron Blue BL" (Trade Mark. Sandoz Ltd., Switzerland) 4 parts Hydrous potassium tartarate 30 parts Carboxymethyl cellulose l parts Sodium metanitrotuluenc sulfonat: 1 parts Polyethyleneglycol l nonylphenyl other 0.5 parts Water 63.5 parts The fabric thus treated was tentered on a frame with pins and placed in an air oven heated at 180 C. for minutes. in the first 1.5 minutes the hydrous sodium potassium tartarate expanded, generating water vapor and in the last 3.5 minutes the fabric was heat-set. The removal of the expanded metal salts by washing with water gave the bulky fabric having the properties shown in table 4 below. 5
For comparison the same treatment was performed using the same composition as above but not containing hydrous sodium potassium tartarate. The results are shown in table 4 below.
TABLE 4 Changes Changes in in hand Dyeing property thickness Sample treated 50- softness Excellent Nil.
cording to the and hand method of invenimproved. tion.
Comparison Hand Excellent. Sli htly Decrease of hardened. derkerin co our 32%.
due to shrinkage of fibers.
EXAMPLE 4 A textile fabric of high-bulky polyacrylonitrile yarn, in which creases were created during dyeing process was immersed in the following composition, squeezed with a mangle 4 to 80 weight percent impregnation and dried at 60 C.
Hydrous sodium acetate 30 parts Hydrous sodium formate parts Polyethyleneglycol nonylphcnyl ether 0.5 parts Water 49.5 parts TABLE 5 Change Changes in in hand thickness Crease ;Samp1e finished acsoftness Nil Completely cording to the and hand removed. method of the improved. invention.
Comparison Hand Decrease of 35%"... Originally hardened creased 1 and feaportions ture of remained drapery as depresdecressed. sions.
EXAMPLE 5 A textile fabric of polyester yarn in which creases occurred during dyeing step was immersed in the following composition 5 and squeezed with a mangle to I00 weight percent impregnatron.
Hydrous aluminum sulfate 25 parts Hydrous sodium thiosulfate 25 parts Polyethylcncglycul nonylphenyl ether 0.5 parts Water 49.5 parts The fabric thus treated was tentered on a frame with pins and placed in an air oven heated at l C. for 3 minutes. In
5 the first one minute the metal salts expanded, generating water vapor and in the last two minutes the fabric was heatset. The removal of the expanded metal salts gave the bulky fabric having the properties shown in table 6 below.
For comparison. the same treatment was performed using the same composition as above but not containing hydrous aluminum sulfate and hydrous sodium thiosulfate. The results are shown in table 6 below.
TABLE 6 Change Change in in hand thickness Crcasos Bulky fabric of the softness Increase (omplctoly removed.
invention. and hand of 5%.
improved.
Comparison H Decrease of Originally creased portions remained and hardened. 20%.
as depressions.
EXAMPLE 6 Hydrous sodium metasilicate powder was uniformly sprinkled on a woven fabric of bulky polyester yarn in the order of 40 weight percent based on the weight of the fabric and placed in an air oven heated at I80 C. for 5 minutes.
in the first l.5 minutes the hydrous sodium metasilicate was melted, infused into the fabric and then expanded. generating water vapor, and in the last 3.5 minutes the fabric was heatset.
Thereafter the fabric was washed with water to remove the 50 expanded metal salts and dried, whereby the bulky fabric soft to the touch was obtained.
EXAMPLE 7 A woven fabric of polyester fiber dyed by carrier dyeing was immersed in the following composition prior to heat-treatment for removing carrier, squeezed to 80 weight percent impregnation and dried at C.
Hydrous calcium chloride 30 parts Hydrous magnesium chloride 20 parts Polyethylencglycol nonylphenyl ether 0.5 parts Water 49 5 parts The fabric thus treated was placed in an air oven heated at C. for 3 minutes. in the first one minute the hydrous calcium chloride and hydrous magnesium chloride expanded, generating water vapor and in the last two minutes the fabric was heat-set. The fabric was then washed with water to remove the expanded metal salts and dried at 60 C. Thus, the bulky fabric having the following properties shown in table 7 was obtained.
For comparison. the same treatment was performed using the same composition as above but not containing hydrous calcium chloride and hydrous magnesium chloride. The hydrous sodium potassium tartrate, hydrous sodium resultsare shown in table7below. thiosulfate, hydrous sodium silicate and hydrous sodium TABLE 7 Changes in Changes in Removal of hand thickness Greases carriers Fabric of the softness Nil Nil Carrier completely invention. and hand removed.
improved. Comparison Han Decrease of Originally Carrier slightly hardened. 25%. creased remainlng.
portions remained as depressions.
EXAMPLE 8 A woven fabric of polyester yarn was immersed in the following composition, squeezed to 70 weight percent impregnation and dried at 80 C.
Hydrous sodium tetraborutc 40 parts Polycthyleneglycul nonylphenyl ether 0.5 parts Starch 8 parts Water 5 LS parts The fabric thus treated was tentered on a frame with pins and placed in an air oven heated at 180 C. for 3 minutes. In the first 1 minute the hydrous sodium tetraborate expanded. generating water vapor and in the last 2 minutes the fabric was heat-set. The fabric was then washed with water to remove the expanded metal salts and dried at 80 C. Thus, the bulky fabric soft to the touch was obtained.
What we claim is:
metasilicate, heating the impregnated fabric to a temperature of from l00 C. to below a second order transition temperature of the fibers constituting the fabric to expand said metal salt contained in the fabric, heat-setting the resultant fabric at a temperature ranging from a second order transition temperature to below a decomposing temperature of the fibers and washing with water the resultant fabric to remove the expanded metal salt; said bound water-containing metal salt being first dissolved in its own bound water and emitting the water in a gaseous state when heated at a temperature of from C. to a second order transition temperature of the fibers to produce pumicelike expanded solid of the metal salt soluble in water but not melting or decomposing at a temperature applied in said heat-setting step 2. An expanded synthetic fabric resistant to heat-shrinkage for producing a bulky fabric which comprises a fabric and 10 to 30 weight percent, based on the weight of the fabric, of expanded metal salts interposed in the intervals between fibers of the fabric and water-soluble but not melting or decomposing at a temperature of between a second transition temperature and below a decomposing temperature of the fabrics. said metal salts being at least one species selected from the group consisting of calcium chloride, sodium tetraborate, sodium acetate, aluminum sulfate, aluminum potassium sulfate, magnesium chloride, sodium potassium tartrate. sodium thiosulfate, sodium silicate and sodium metasilicate.

Claims (1)

  1. 2. An expanded synthetic fabric resistant to heat-shrinkage for producing a bulky fabric which comprises a fabric and 10 to 30 weight percent, based on the weight of the fabric, of expanded metal salts interposed in the intervals between fibers of the fabric and water-soluble but not melting or decomposing at a temperature of between a second transition temperature and below a decomposing temperature of the fabrics, said metal salts being at least one species selected from the group consisting of calcium chloride, sodium tetraborate, sodium acetate, aluminum sulfate, aluminum potassium sulfate, magnesium chloride, sodium potassium tartrate, sodium thiosulfate, sodium silicate and sodium metasilicate.
US787237A 1967-12-29 1968-12-26 Process for manufacturing bulky fabrics Expired - Lifetime US3622372A (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4101270A (en) * 1975-06-20 1978-07-18 Vepa Aktiengesellschaft Process and apparatus for the continuous dyeing or printing of endless lengths of materials
US20010048984A1 (en) * 2000-01-12 2001-12-06 Legare David J. Fire protection containers incorporating novel low free-water insulation materials

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US758311A (en) * 1903-08-29 1904-04-26 Gustav Goldman Method of felting or matting fibers together.

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US758311A (en) * 1903-08-29 1904-04-26 Gustav Goldman Method of felting or matting fibers together.

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4101270A (en) * 1975-06-20 1978-07-18 Vepa Aktiengesellschaft Process and apparatus for the continuous dyeing or printing of endless lengths of materials
US20010048984A1 (en) * 2000-01-12 2001-12-06 Legare David J. Fire protection containers incorporating novel low free-water insulation materials
US6841209B2 (en) * 2000-01-12 2005-01-11 Fireking International, Inc. Fire protection containers incorporating novel low free-water insulation materials

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