Process for face finishing fabrics, fabrics having good strength and aesthetic characteristics, and items of napery having good pick and snag resistance

Abstract

A process for face finishing fabrics, and in particular fabrics containing filaments, to provide them with good aesthetic characteristics is described. In addition, fabrics made from filaments having aesthetic characteristics and surface effects similar to those of fabrics made from spun yarns are described. Also, items of napery made from filaments and having good surface effects and low pick and snag performance are described. The process involves pre-abrading a fabric, such as one made from filaments, and then subjecting it to a high energy fluid treatment process.

We claim:  
     
         1 . A process for enhancing the surface of a fabric comprising the steps of: 
 providing a textile fabric formed from a plurality of fibers;    pre-abrading said textile fabric and    treating said textile fabric with a high energy fluid, to thereby form a surface effect on the textile fabric.    
     
     
         2 . A process according to  claim 1 , wherein said fabric contains filaments.  
     
     
         3 . A process according to  claim 1 , wherein said steps of pre-abrading and treating result in cut fiber ends, and said cut fiber ends have a length of about 1.5 float lengths or less.  
     
     
         4 . A process according to  claim 1 , wherein said step of pre-abrading comprises a process selected from the group consisting of sanding, brushing, napping, wet sueding, and dry sueding.  
     
     
         5 . A process according to  claim 1 , wherein said step of treating the fabric with a high energy fluid comprises a process selected from the group consisting of high pressure gas treatment, and high pressure liquid treatment.  
     
     
         6 . A process according to  claim 1 , wherein said step of pre-abrading is performed on only one surface of the fabric.  
     
     
         7 . A process according to  claim 1 , wherein said step of treating the fabric with a high energy fluid is performed on only one surface of the fabric.  
     
     
         8 . A process according to  claim 1 , wherein said step of treating the fabric with a high energy fluid is performed by way of a plurality of treatment stages.  
     
     
         9 . A process according to  claim 1 , wherein said step of treating the fabric with a high energy fluid is performed by way of a single treatment stage.  
     
     
         10 . A process according to  claim 1 , wherein said step of treating the fabric with a high energy fluid comprises a high pressure hydraulic treatment.  
     
     
         11 . A fabric made by the process of  claim 1 .  
     
     
         12 . A process according to  claim 1 , wherein said step of treating the fabric with a high energy fluid is performed to apply at least about 0.0295 horsepower-hr/lb of energy to the fabric.  
     
     
         13 . A process for enhancing the aesthetic characteristics of a filament containing textile fabric comprising the steps of: 
 providing a woven textile fabric comprising filaments in each of the warp and filling directions;    pre-abrading said textile fabric to raise some fibers from each of the warp and filling; and    treating the fabric with a high energy fluid, such that a surface effect is formed on at least one surface of said fabric and fibers from adjacent yarns are entangled with each other.    
     
     
         14 . A process according to  claim 13 , wherein the surface effect is formed from short fibers having a length of about 1.5 float lengths or less.  
     
     
         15 . A fabric made by the process of  claim 13 .  
     
     
         16 . A process according to  claim 13 , wherein said step of treating the fabric with high energy fluid is performed to apply at least about 0.0295 horsepower-hr/lb of energy to the fabric.  
     
     
         17 . A fabric comprising a plurality of associated yarns comprising a plurality of filaments, wherein said fabric comprises a surface effect on at least one fabric surface, said surface effect comprising a plurality of cut fiber ends, and wherein fiber ends from at least some of said yarns are entangled with fiber ends of associated yarns.  
     
     
         18 . A fabric according to  claim 17 , wherein said fabric is selected from the group consisting of woven, knit and nonwoven fabrics.  
     
     
         19 . A fabric according to  claim 17 , wherein said fabric consists essentially of filaments.  
     
     
         20 . A fabric according to  claim 17 , wherein said fabric comprises a woven fabric consisting essentially of filaments.  
     
     
         21 . A fabric according to  claim 20 , wherein said fabric is in the form of an article of napery.  
     
     
         22 . A fabric according to  claim 20 , wherein said fabric is in a plain weave construction.  
     
     
         23 . A fabric according to  claim 20 , wherein said fabric has a Pick and Snag rating of greater than 3 after one wash when tested according to ASTM D5362-97a.  
     
     
         24 . A fabric according to  claim 20 , wherein said fabric has a Pick and Snag rating of greater than 2 after 50 washes when tested according to ASTM D5362-97a.  
     
     
         25 . A fabric according to  claim 20 , wherein said fabric has a Pick and Snag rating of about 3 or greater after 50 washes when tested according to ASTM D5362-97a.  
     
     
         26 . A fabric according to  claim 20 , wherein said fabric has a Pick and Snag rating of greater than 3.5 after 50 washes when tested according to ASTM D5362-97a.  
     
     
         27 . A fabric according to  claim 20 , wherein said fabric has a Pick and Snag rating of greater than 1 after 125 washes when tested according to ASTM D5362-97a.  
     
     
         28 . A fabric according to  claim 20 , wherein said fabric has a Pick and Snag rating of greater than 2 after 125 washes when tested according to ASTM D5362-97a.  
     
     
         29 . A fabric according to  claim 20 , wherein said fabric has a Pick and Snag rating of greater than 3 after 125 washes when tested according to ASTM D5362-97a.  
     
     
         30 . A fabric according to  claim 17 , wherein said fabric is a woven fabric and said fiber ends have a length of about 1.5 float lengths or less.  
     
     
         31 . A fabric according to  claim 17 , wherein said fabric has a Kawabata System COMP05 value of about 45% or greater.  
     
     
         32 . A fabric according to  claim 31 , wherein said fabric has a Kawabata System COMP value of about 50% or greater.  
     
     
         33 . A fabric according to  claim 17 , wherein said fabric has a Kawabata System MIU value of about 0.15 or greater in each of the lengthwise and crosswise directions.  
     
     
         34 . A fabric according to  claim 33 , wherein said fabric has a Kawabata System MIU value of about 0.21 or greater in each of the lengthwise and crosswise directions.  
     
     
         35 . A fabric comprising a plurality of associated yarns comprising a plurality of filaments, said fabric defining first and second fabric surfaces, wherein at least some of the filaments positioned along said first fabric surface fabric define a plurality of cut fiber ends, and at least some of said cut fiber ends extend through the dimension of the fabric and outwardly from said second fabric surface.  
     
     
         36 . A fabric according to  claim 35 , wherein said fabric is a woven fabric and said cut fiber ends extend outwardly from said first and second fabric surfaces a distance of 1.5 float lengths or less.  
     
     
         37 . A fabric comprising spun yarns, said fabric having first and second exterior fabric surfaces defining a fabric interior therebetween, wherein portions of said spun yarns adjacent said first exterior surface have a greater number of cut fiber ends than portions of said spun yarns adjacent the fabric interior, and wherein at least some of said cut fiber ends originating from the spun yarns at the first exterior surface of the fabric extend through the interior of the fabric to the second exterior fabric surface.  
     
     
         38 . The fabric according to  claim 37 , wherein said fabric is a woven fabric, and said cut fiber ends extend outwardly from said first and second exterior fabric surfaces a distance of 1.5 float lengths or less.  
     
     
         39 . A napery article comprising substantially all filament fibers, wherein said fabric has a Pick and Snag Rating of greater than 3 when tested according to ASTM D5362-97a, a filling tear strength of about 2.5 or greater when tested according to ASTM D2261-96, and a Kawabata System Comp05 value of about 45% or greater.  
     
     
         40 . A napery article according to  claim 39 , wherein said fabric comprises substantially all polyester.  
     
     
         41 . A napery article comprising substantially all filament fibers, wherein said fabric has a Pick and Snag Rating of greater than 3 when tested according to ASTM D5362-97a, a filling tear strength of about 2.5 or greater when tested according to ASTM D2261-96, and a Kawabata System MIU value of about 0.15 or greater in each of the lengthwise and crosswise directions.  
     
     
         42 . A napery article according to  claim 41 , wherein said fabric comprises substantially all polyester.  
     
     
         43 . A napery article comprising substantially all filament fibers woven in a plain weave construction, wherein said fabric has a filling tear strength of about 2.5 or greater when tested according to ASTM D2261-96, and a Kawabata System Comp05 value of about 45% or greater.  
     
     
         44 . A napery article according to  claim 43 , wherein said fabric comprises substantially all polyester.  
     
     
         45 . A napery article comprising substantially all filament fibers woven in a plain weave construction, wherein said fabric has a filling tear strength of about 2.5 or greater when tested according to ASTM D2261-96, and a Kawabata System MIU value of about 0.15 or greater in each of the warp and filling directions.  
     
     
         46 . A napery article according to  claim 45 , wherein said fabric comprises substantially all polyester.