Process for creating fabrics with branched fibrils and such fibrillated fabrics

Abstract

The present process involves applying a plasticizer- or solvent-containing solution to a subject fabric, preferably under heated conditions, and then mechanically abrading the treated fabric. The process results in the rearrangement of the fabric structure, as a plurality of branched fibrils are created along the length of the yarn filaments. Thus, the molecular weight of the fabric's yarns and, therefore, the strength of the polymer chains are maintained. Fabrics made from this process, which exhibit a silk-like hand that results from the presence of multiple integral fibrils and branched fibrils, are also provided.

1 . A process for creating a fibrillated fabric, said fabric comprising a plurality of yarns, said process comprising the steps of: 
 (a) providing a fabric;    (b) applying a fiber-specific chemical agent to said fabric; and    (c) abrading said fabric to which the fiber-specific chemical agent has been applied, such that at least some of said yarns of said fabric have fibers from which multiple integral fibrils and multiple branched fibrils protrude.    
   
   
       2 . The process of  claim 1  wherein said fabric is selected from the group consisting of woven fabrics, knit fabrics, nonwoven fabrics, braided fabrics, pile fabrics, scrims, and composites containing at least one of these fabrics.  
   
   
       3 . The process of  claim 2  wherein said fabric is a woven fabric.  
   
   
       4 . The process of  claim 2  wherein said fabric is a knit fabric.  
   
   
       5 . The process of  claim 1  wherein said yarns are selected from the group consisting of polyesters, polyamides, polypropylenes, olefins, polyolefins, polyurethanes, aramids, acrylics, modacrylics, blends of any of these fibers with one or more other fibers, and blends of any of these fiber types with natural fibers.  
   
   
       6 . The process of  claim 5  wherein said yarns are polyester.  
   
   
       7 . The process of  claim 6  wherein said fiber-specific chemical agent is a plasticizer selected from the group consisting of phenolic compounds, chlorinated aromatic compounds, aromatic hydrocarbons and ethers, aromatic esters, and phthalates.  
   
   
       8 . The process of  claim 7  wherein said plasticizer is present in an amount of between about 0.1% to about 10% of the weight of an aqueous solution into which said fabric is immersed.  
   
   
       9 . The process of  claim 6  wherein said fiber-specific chemical agent is a solvent selected from the group consisting of n-methyl-2-pyrrolidone, propylene glycol n-butyl ether, propylene glycol n-phenyl ether, dipropylene glycol methyl ether, di-basic esters, and imidazole-containing solvents.  
   
   
       10 . The process of  claim 1  wherein said fabric to which the fiber-specific chemical agent has been applied is heated.  
   
   
       11 . The process of  claim 10  wherein said fabric to which the fiber-specific chemical agent has been applied is simultaneous with step (c).  
   
   
       12 . The process of  claim 10  wherein said fabric is heated to temperatures of between 40° C. and 100° C.  
   
   
       13 . The process of  claim 1  wherein said abrading is accomplished by a technique selected from the group consisting of needling; napping; napping with diamond-coated napping wire; gritless sanding; patterned sanding against an embossed surface; shot-peening; sand-blasting; particle bombardment; ice-blasting; tumbling; brushing; impregnated brush rolls; ultrasonic agitation; stone-washing; sueding; engraved roll abrasion; patterned roll abrasion; constricting through a jet orifice; and impacting against or with another material, said other material being selected from the group consisting of the same fabric, a different fabric, abrasive substrates, steel wool, diamond grit rolls, tungsten carbide rolls, etched rolls, scarred rolls, and sandpaper rolls.  
   
   
       14 . The process of  claim 13  wherein said abrading is accomplished by impacting said fabric against or with another material.  
   
   
       15 . The process of  claim 1  wherein said fabric is dyed after step (c).  
   
   
       16 . The process of  claim 1  wherein said fabric is printed after step (c).  
   
   
       17 . A textile fabric comprised of a plurality of yarns, each of said yarns comprising a plurality of filaments, characterized in that multiple fibrils and branched fibrils extend from at least the length of some of said filaments.  
   
   
       18 . The textile fabric of  claim 17  wherein each of said fibrils are attached to said filaments on at least one end of said fibrils.  
   
   
       19 . The textile fabric of  claim 18  wherein said fibrils are attached to said filaments on both ends of said fibrils.  
   
   
       20 . The textile fabric of  claim 17  wherein said fabric is selected from the group consisting of woven fabrics, knit fabrics, nonwoven fabrics, braided fabrics, pile fabrics, and scrims.  
   
   
       21 . The textile fabric of  claim 20  wherein said fabric is a woven fabric.  
   
   
       22 . The textile fabric of  claim 17  wherein said yarns comprise fibers that are selected from the group consisting of polyesters, polyamides, polypropylenes, olefins, polyolefins, polyurethanes, aramids, acrylics, modacrylics, blends of any one of these fibers with one or more of these fibers, and blends of any one of these fibers with natural fibers.  
   
   
       23 . The textile fabric of  claim 22  wherein said yarns are polyester.  
   
   
       24 . The textile fabric of  claim 17  wherein a plurality of said filaments is broken and said fibrils extend from end portions of said broken filaments.  
   
   
       25 . The textile fabric of  claim 17  wherein said multiple fibrils and said branched fibrils are present on a face side and a back side of said fabric.