Napped fabric and process

Abstract

A fabric having at least one hydraulically napped surface comprised of tangled fibers is disclosed. Because the fiber tangles are created from intact, undamaged fibers, fabric strength is not adversely affected by treatment. In addition, laundering enhances entanglement and the aesthetic qualities attributed to this fabric property: surface texture (hand), resistance to pilling, drapeability, and the like. These subjective characteristics have been quantified using values from the Kawabata Evaluation System. A process for creating such fabrics has also been disclosed. The fabric passes through one or two treatment zones in which high pressure fluids (e.g., water) are directed at the fabric surface as the fabric moves away from a support member. IN the case of dual treatment zones, a substantially lower pressure is used in the second treatment zone.

We claim:  
     
         1 . A fabric having a hydraulically napped surface comprised of a plurality of fiber tangles, said fiber tangles being comprised of fibers that are substantially intact and undamaged, said fabric having a Kawabata System MIU value greater than 0.20.  
     
     
         2 . A fabric having a hydraulically napped surface comprised of a plurality of fiber tangles, said fiber tangles being comprised of fibers that are substantially intact and undamaged, said fabric having a Kawabata System LC value greater than 0.375 and an MIU value greater than 0.195.  
     
     
         3 . The fabric of  claim 2  wherein said fabric has a Kawabata System LC value greater than 0.390 and an MIU value greater than 0.21.  
     
     
         4 . The fabric of  claim 2  or  3  wherein said fabric is a woven fabric having warp yarns and fill yarns and said napped surface is comprised of fibers from said warp yarns.  
     
     
         5 . The fabric of  claim 4 , wherein said warp yarns are comprised of synthetic fibers.  
     
     
         6 . The fabric of  claim 4  wherein said warp yarns are comprised of spun polyester yarns.  
     
     
         7 . The fabric of  claim 4 , wherein the majority of said fibers comprising said fiber tangles are from said warp yarns.  
     
     
         8 . The fabric of  claim 5  wherein said fabric has a nap index that increases with repeated launderings.  
     
     
         9 . A fabric having a hydraulically napped surface comprised of a plurality of fiber tangles, said fiber tangles being comprised of fibers that are substantially intact and undamaged, said fabric having a Kawabata System DEN 50  value less than 0.40 and an MIU value greater than 0.195.  
     
     
         10 . The fabric of  claim 7  wherein said fabric has a Kawabata System DENS value less than 0.39 and an MIU value greater than 0.21.  
     
     
         11 . The fabric of  claim 8  or  9  wherein said fabric is a woven fabric having warp yarns and fill yarns and said napped surface is comprised of fibers from said warp yarns.  
     
     
         12 . The fabric of  claim 10 , wherein said warp yarns are comprised of synthetic fibers.  
     
     
         13 . The fabric of  claim 10  wherein said warp yarns are comprised of spun polyester yarns.  
     
     
         14 . The fabric of  claim 10  wherein the majority of said fibers comprising said fiber tangles are from said warp yarns.  
     
     
         15 . The fabric of  claim 12  wherein said fabric has a nap index that increases with repeated launderings.  
     
     
         16 . A fabric having a hydraulically napped surface comprised of a plurality of fiber tangles, said fiber tangles being comprised of fibers that are substantially intact and undamaged, said fabric having a Kawabata System 2HB value less than 0.130 and an MIU value greater than 0.195.  
     
     
         17 . The fabric of  claim 16  wherein said fabric has a Kawabata System 2HB value less than 0.130 and an MIU value greater than 0.21.  
     
     
         18 . The fabric of  claim 16  or  17  wherein said fabric is a woven fabric having warp yarns and fill yarns and said napped surface is comprised of fibers from said warp yarns.  
     
     
         19 . The fabric of  claim 18 , wherein said warp yarns are comprised of synthetic fibers.  
     
     
         20 . The fabric of  claim 18  wherein said warp yarns are comprised of spun polyester yarns.  
     
     
         21 . The fabric of  claim 18 , wherein the majority of said fibers comprising said fiber tangles are from said warp yarns.  
     
     
         22 . The fabric of  claim 19  wherein said fabric has a nap index that increases with repeated launderings.  
     
     
         23 . A fabric having a hydraulically napped surface comprised of a plurality of fiber tangles, said fiber tangles being comprised of fibers that are substantially intact and undamaged, said fabric having a Kawabata System 2HB value less than 0.130 and a COMP value greater than 42.5.  
     
     
         24 . The fabric of  claim 23  wherein said fabric has a Kawabata System 2HB value less than 0.130 and a COMP value greater than 44.0.  
     
     
         25 . The fabric of  claim 23  or  24  wherein said fabric is a woven fabric having warp yarns and fill yarns and said napped surface is comprised of fibers from said warp yarns.  
     
     
         26 . The fabric of  claim 25  wherein said warp yarns are comprised of synthetic fibers.  
     
     
         27 . The fabric of  claim 25  wherein said warp yarns are comprised of spun polyester yarns.  
     
     
         28 . The fabric of  claim 25 , wherein the majority of said fibers comprising said fiber tangles are from said warp yarns.  
     
     
         29 . The fabric of  claim 26  wherein said fabric has a nap index that increases with repeated launderings.  
     
     
         30 . A woven napery fabric comprised of spun warp yarns and filament fill yarns and having a hydraulically napped surface, said warp yarns and said fill yarns consisting essentially of intact, undamaged fibers, said napped surface being comprised of a plurality of fiber tangles from said warp yarns.  
     
     
         31 . The napery fabric of  claim 30  wherein said filament fill yarns are low shrinkage yarns.  
     
     
         32 . The napery fabric of  claim 30  wherein said spun warp yarns are comprised of synthetic fibers.  
     
     
         33 . The napery fabric of  claim 30  wherein said spun yarns are comprised of polyester fibers.  
     
     
         34 . The napery fabric of  claim 30  wherein said spun yarns consist of polyester fibers and wherein said fabric has a nap index that increases with repeated launderings.  
     
     
         35 . A process for forming a napped fabric wherein said fabric passes through a treatment zone in which a plurality of individual streams of high pressure fluid is directed onto said fabric, said process comprising the steps of (a) directing said fabric against a support member having a support surface as said fabric enters said treatment zone, (b) directing said fabric away from said support surface as said fabric moves through said treatment zone, and (c) directing said plurality of individual streams onto said fabric as said fabric is leaving said treatment zone and is moving away from said support surface, thereby forming on said fabric a napped surface, said surface being adjacent to said support surface.  
     
     
         36 . A process for forming a napped surface on both a first and a second side of a woven fabric, said fabric being comprised of yarns containing staple fibers, said process comprising the steps of moving said fabric along a path in which said fabric passes through a first treatment zone wherein a plurality of individual streams of high pressure fluid is directed onto said first side of said fabric, whereby said fluid streams arrange said staple fibers to form a napped surface comprised of fiber tangles on said second side of said fabric, and then moving said fabric along said path wherein said fabric passes through a second treatment zone wherein a plurality of individual streams of high pressure fluid is directed onto said second side of said fabric, whereby said fluid streams partially redistribute said fiber tangles from said second side of said fabric to said first side of said fabric, wherein said fluid streams in said second treatment zone directed at said second side have a pressure that is substantially less than the pressure of said fluid streams in said first treatment zone directed at said first side.  
     
     
         37 . The process of  claim 36  wherein the pressure of said fluid streams in said second treatment zone is less than the pressure of said fluid jets in said first treatment zone by a factor that is greater than about 0.2 and less than about 0.8.  
     
     
         38 . The process of  claim 36  wherein the pressure of said fluid streams in said second treatment zone is less than the pressure of said fluid streams in said first treatment zone by a factor that is greater than about 0.4 and less than about 0.6.  
     
     
         39 . The process of  claim 36  wherein said path directs said fabric against a support member having a support surface as said fabric enters one of said treatment zones, and then directs said fabric away from said support surface within said one of said treatment zones.  
     
     
         40 . The process of  claim 36  wherein said path directs said fabric against a support member having a support surface as said fabric enters each of said treatment zones, and then directs said fabric away from said support surface within said each of said treatment zones.  
     
     
         41 . The process of  claim 36  wherein said napped surface formed by said fiber tangles is substantially uniform on both said first side and said second side.