Continuous wash & plush laminate

Abstract

A method for producing an improved washed and plushed upholstery fabric in a continuous process includes the provision of a soft, dimensionally stable, nonwoven fabric backing. After the chemical application of an anti-migrant and softener, the fabric is washed in a rope form, opened and de-twisted. After the fabric is rewound and further coatings are applied, an adhesive is applied to hold a nonwoven web to the previously prepared fabric in a rewinding process. The fabric is then subjected to a steam flow process to enhance the fabric texture and reduce the width of the fabric.

1 . A method for producing a washed and plushed upholstery fabric in a continuous process comprising the steps of: 
 a. Spraying a base fabric with an anti-migrant and/or softener in open width.    b. Subjecting the fabric to a continuous wash in a rope form.    c. Opening the rope form, wherein the fabric is de-twisted back to its full width.    d. Rewinding the fabric to its open width.    e. Applying further coatings at a low coating weight.    f. Applying an adhesive, while maintaining the width of the fabric by a pin frame.    g. Unwinding and applying in a rewinding process a nonwoven web.    h. Subjecting the fabric to a steam flow process while transporting the fabric on a belt without substantial tension.    
     
     
         2 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1  wherein the rate of spraying of step a is at a rate of application of between 50 and 300 ml/min.  
     
     
         3 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 2  wherein the fabric is rayon and the rate of application is approximately 300 ml/min.  
     
     
         4 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 2  wherein the fabric is an acrylic and the rate of application is approximately 100 ml/min.  
     
     
         5 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1 , wherein step c is performed under the control of a load cell that controls the rate of operation of the process step.  
     
     
         6 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1 , wherein the fabric is highly textured and during step e tension on the fabric is maintained at a low value to prevent the loss of texture.  
     
     
         7 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1 , wherein the adhesive is a powder.  
     
     
         8 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 7 , wherein the adhesive powder is applied at a speed of 15-20 yards per minute.  
     
     
         9 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1  wherein the fabric is highly textured and the adhesive is applied below the amount of about 1 oz/lin. yd.  
     
     
         10 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1  wherein the fabric is a light weight fabric and the adhesive is applied above the amount of about 4 oz/lin. yd.  
     
     
         11 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1 , wherein the nonwoven web is a polypropylene plastic.  
     
     
         12 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 11 , wherein the weight range of the nonwoven web is 0.25 to 5 ounces per square yard.  
     
     
         13 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1 , wherein the nonwoven web is a polyester.  
     
     
         14 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 13 , wherein the weight range of the nonwoven web is 0.25 to 5 ounces per square yard.  
     
     
         15 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1 , wherein the nonwoven web is a blend of polyester and polypropylene.  
     
     
         16 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 15 , wherein the weight range of the nonwoven web is 0.25 to 5 ounces per square yard.  
     
     
         17 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1 , wherein the steam flow process is operated at a rate of about 26 yards per minute.  
     
     
         18 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1 , wherein the steam flow process reduces the width of the fabric to between 55 and 110 inches.  
     
     
         19 . The method for producing a washed and plushed upholstery fabric in a continuous process of  claim 1 , further comprising the step of flat folding the fabric in open width.  
     
     
         20 . A method for producing a washed and plushed upholstery fabric in a continuous process comprising the steps of: 
 a. Spraying a base fabric with an anti-migrant and/or softener upon a rayon or an acrylic fabric in open width, wherein for rayon the rate of application is about 300 ml/min, whereas for acrylic the rate of application is about 100 ml/min is optimal.    b. Subjecting the fabric to a continuous wash in a rope form.    c. Opening the rope form under the control of a load cell, which controls the rate of operation, wherein the fabric is de-twisted back to its full width.    d. Rewinding the fabric to its open width.    e. Applying further coatings at a low coating weight, wherein the material is highly textured, and the tension is maintained at a low value to prevent the loss of texture.    f. Applying an adhesive powder at a speed of 15-20 yards per minute, wherein for highly textured fabrics the amount of powder is kept below about 1 oz/lin. yd and for light weigh materials the amount of powder is kept at about 4 oz/lin. yd while maintaining the width of the fabric, by a pin frame.    g. Unwinding and applying in a rewinding process a polypropylene, polyester or blended nonwoven web in the weight range of 0.25 to 5 ounces per square yard.    h. Subjecting the fabric to a steam flow process at a rate of about 26 yards per minute, wherein the fabric width is reduced to between 55 and 110 inches, while transporting the fabric on a belt without substantial tension.