Apparatus and method for hydroenhancing fabric

Abstract

An apparatus 10 and related process for enhancement of woven and knit fabrics through use of dynamic fluids which entangle and bloom fabric yarns. A two stage enhancement process is employed in which top and bottom sides of the fabric are respectively supported on members 22, 34 and impacted with a fluid curtain including high pressure jet streams. Controlled process energies and use of support members 22, 34 having open areas 26, 36 which are aligned in offset relation to the process line produces fabrics having a uniform finish and improved characteristics including, edge fray, drape, stability, abrasion resistance, fabric weight and thickness.

1. A method for enhancing textile fabrics over the fabrics before treatment and for finishing textile fabrics, the fabrics including either or both of spun and/or  and spun filament yarns which intersect at cross-over points, and first and second sides, the fabric including yarn fibers having deniers and lengths in the range of 0.3 to 16.0 and 0.5 to 8 inches, respectively, and yarn counts in the range of 0.5s to 80s , the method comprising the steps of:
 supporting the fabric on a first support member, the fabric including yarn fibers having deniers and lengths in the range of  0 . 3  to  16 . 0  and  0 . 5  to  8  inches, respectively, and yarn counts in the range of  0 . 5 s to  80 s, and  
 traversing the first side of said fabric with a first continuous curtain of non- compressible  fluid for sufficient duration to effect entanglement of said yarns at the cross-over points, thereby enhancing fabric cover and quality,  
 said curtain of fluid impacting the fabric with an  a cumulative energy in the range of  0.1 and  to  2.0 hp-hr/lb.  
 
     
     
       2. The method of  claim 1 , wherein said fluid curtain is provided by columnar fluid jet  jets having orifices having a diameter of approximately 0.005 inches, center-to-center spacing of approximately 0.017 inches, and spacing from said first support member of approximately 0.5 inches, said fluid jets impinging the fabric with fluids at a pressure of approximately 1500 psi. 
     
     
       3. The method of  claim 2 , wherein said support member includes a pattern of closely spaced fluid pervious open areas aligned in a first direction to effect fluid passage through said support member. 
     
     
       4. The method of  claim 3 , wherein said open areas occupy approximately 17 to 40% of said support member. 
     
     
       5. The method of  claim 1 , comprising the further steps of:
 supporting said enhanced fabric on a second support member, and  
 traversing the second side of said enhanced fabric in a second enhancement stage with a second continuous fluid  curtain of non- compressible fluid  for sufficient duration to further enhance fabric cover and provide a uniform fabric finish,  
 said second enhancement stage  fluid curtain impacting the fabric with an  a cumulating energy in the range of 0.1 and  to 2.0 hp-hr/lb.  
 
     
     
       6. The method of  claim 5 , wherein:  said first and second  fluid curtains are provided by columnar fluid jets, each having a diameter of approximately 0.005 inches and center-to-center spacing of approximately 0.017 inches,
 said fluid curtains are spaced  originate approximately 0.5 inches from said first and second members, and said fluid jets  impinge approximately the fabric with fluids at a pressure of approximately 1500 psi, and  
 said first and second support members each include a pattern of closely spaced fluid pervious open areas, respectively aligned in first and second directions, said open areas being dimensioned to effect fluid passage through said support members without imparting a patterned effect to the fabric.  
 
     
     
       7. The method of  claim 6 , wherein said open areas occupy approximately 17 to 40% of each of said first and second support members. 
     
     
       8. The method of  claim 7 , wherein said first and second support members respectively have flat and drum configurations. 
     
     
       9. The method of  claim 8 , wherein said first and second directions are offset approximately 45°. 
     
     
       10. The method of  claim 7 , wherein said first and second support members have drum configurations. 
     
     
       11. The method of  claim 10 , wherein said first and second directions are offset approximately 45°. 
     
     
       12. The method of  claim 6 , comprising the further  subsequent step, following said further enhancement  of drying the enhanced  fabric to a specified width under tension. 
     
     
       13. An enhanced textile fabric enhanced over the fabric before treatment and made by the method of  claim 6 ,the fabric including yarn fibers having deniers and lengths in the range of 0.3 to 16 and 0.5 to 8 inches, respectively, and thread counts in the range of 0.5s to 80s, the yarn cross-over points in the fabric weave define interstitial open areas,  wherein the process  method effects enhancement  blooming of the yarns in the  interstitial open areas defined by the cross- over points in the fabric weave , thereby enhancing fabric cover and quality. 
     
     
       14. An  The enhanced textile fabric made by the method  of claim  6    13 , wherein the fabric including  includes yarn fibers having deniers and lengths in the range of 0.5 to 6 and 0.5 to 8 inches, respectively, and thread counts in the range of 0.5s to 50s, the yarn cross-over points in the fabric weave define interstitial open areas, wherein the process effects enhancement of the yarns in the interstitial open areas, thereby enhancing fabric cover, and yields  and demonstrates a reduction in fabric air permeability in the range of 10 to 90% after finishing. 
     
     
       15. An enhanced woven polyester fabric enhanced over the fabric before treatment and made by the method of  claim 6 , wherein the fabric includes 2 denier, 1.9 inch polyester fiber, open-end cotton spun yarn having a yarn number of 17s and count of 49×23 per inch, and the process yields an approximate 48% reduction in air permeability in the fabric. 
     
     
       16. An enhanced woven acrylic fabric enhanced over the fabric before treatment and made by the method of  claim 6 , wherein the fabric includes 3 denier, 1.5 inch fiber, open-end cotton warp yarn having a yarn number of 9s, 28 ends per inch, and a 3 denier, 3 inch acrylic fiber open-end wool spun fill yarn having a number of 4s, 16 picks per inch, and the process yields an approximate 36% reduction in air permeability in the fabric. 
     
     
       17. An enhanced acrylic wrap spun fabric enhanced over the fabric before treatment and made by the method of  claim 6 , wherein the fabric includes 3 denier, 3.0 inch acrylic fiber, wrap spun with 100 denier textured polyester yarn having a yarn number of 4s and count of 14×16 per inch, and the process yields an approximate 65% reduction in air permeability in the fabric. 
     
     
       18. An enhanced woven acrylic fabric enhanced over the fabric before treatment and made by the method of  claim 6 , wherein the fabric includes 3 denier, 1.5 inch acrylic fiber, open-end cotton spun warp yarn having a yarn number of 9s, 28 ends per inch, and a 3 denier, 3 inch acrylic fiber, hollow wrap spun fill yarn, 6 twists per inch having a number of 4s, 16 picks per inch, and the process yields an approximate 48% reduction in air permeability in the fabric. 
     
     
       19. An enhanced woven acrylic fabric enhanced over the fabric before treatment and made by the method of  claim 6 , wherein the fabric includes 3 denier, 1.5 inch acrylic fiber, open-end wool spun warp yarn having a yarn number of 4s, 14 ends per inch, and a 3 denier, 3 inch acrylic fiber, open-end wool spun fill yarn having a yarn number of 2.6s, 16 picks per inch, and the process yields an approximate 48% reduction in air permeability in the fabric. 
     
     
       20. An enhanced woven fabric enhanced over the fabric before treatment and made by the method of  claim 6 , wherein the fabric includes 80% wool/20% nylon in a 2×1 twill weave, and the process yields an approximate 49.5% reduction in air permeability in the fabric. 
     
     
       21. An enhanced 53% polyester/47% cotton fabric enhanced over the fabric before treatment and made by the method of  claim 6 , wherein the fabric includes a 3×1 twill weave, a thread count of 120 ends×38 picks, and the process yields an approximate 50.6% reduction in air permeability in the fabric. 
     
     
       22. An enhanced 50% polyester/50% cotton doubleknit fabric enhanced over the fabric before treatment and made by the method of  claim 6 , wherein the fabric includes wrap spun yarn with 100 denier polyester wrap, and the process yields an approximate 16% reduction in air permeability in the fabric. 
     
     
       23. An enhanced  A uniformly finished woven or knit textile fabric which comprises:  comprising either or both of spun and/or  and  spun filament yarns which intersect at cross-over points to define interstitial open areas, said yarns defining a top and bottom surface, 
 said yarns including fibers having deniers and lengths in the range of 0.3 to 16.0 and 0.5 to 8 inches, respectively,  
 wherein said fiber of said yarns are fluid entangled in said interstitial open areas, at least in a plane between said surfaces of said fabric, by application of a continuous curtain of non- compressible  fluid energy in the range of 0.1 to 2.0 hp-hr/lb.  
 
     
     
       24. An enhanced woven or knit textile fabric according to  claim 23 , wherein the yarn is cotton spun. 
     
     
       25. An enhanced woven or knit textile fabric according to  claim 23 , wherein the yarn is wrap spun. 
     
     
       26. An enhanced woven or knit textile fabric according to  claim 23 , wherein the yarn is wool spun. 
     
     
       27. A method for hydrobonding woven or knit fabric materials to form a composite textile fabric, the fabric including either or both of spun and/or  and spun filament yarns in a structured pattern including yarns which intersect at cross-over points, the method comprising the steps of:
 napping first and second surfaces of the fabric to raise surface fibers thereof,  
 arranging said first and second surfaces in opposing and overlying layered relation,  
 supporting the layered fabric on a support member, and  
 traversing one side of said layered fabric with a first continuous curtain of fluid for sufficient duration to effect entanglement of said raised surface fibers in said first and second surfaces, said curtain of fluid impacting the fabric with an energy in the range of  0.1 and  to  2.0 hp-hr/lb.  
 
     
     
       28. The method of  claim 27 , wherein said fluid curtain is provided by columnar fluid jet orifices having a diameter of approximately 0.005 inches and center-to-center spacing of approximately 0.017 inches, said fluid curtain impinging the fabric with fluids at pressure of approximately 1500 psi. 
     
     
       29. The method of  claim 28 , wherein said support member includes a pattern of closely spaced fluid pervious open areas aligned in a first direction to effect fluid passage through said support member. 
     
     
       30. The method of  claim 29  wherein said open areas occupy approximately 17 to 40% of said support member. 
     
     
       31. The method of  claim 27 , comprising the further steps of:
 supporting said layered fabric on a second support member, and  
 traversing the other side of said layered fabric in a second entanglement stage with a second continuous fluid curtain to effect a uniform composite fabric bond and finish,  
 said second entanglement stage impacting the layered fabric with an energy in the range of  0.1 and  to  2.0 hp-hr/lb.  
 
     
     
       32. The method of  claim 31 , wherein:
 said first and second fluid curtains are provided by columnar fluid jets having a diameter of approximately 0.005 inches and center-to-center spacing of approximately 0.017 inches, said fluid jets impinging the fabric with fluids at pressure of approximately 1500 psi,  
 said first and second support members each include a pattern of closely spaced fluid pervious open areas, respectively aligned in first and second directions, said open areas being dimensioned to effect fluid passage through said support members without imparting a patterned effect to the fabric.  
 
     
     
       33. An enhanced composite woven or knit textile fabric which comprises  which is enhanced by the bonding together of at least two fabric layers, the fabric comprising:
 at least two fabric layers which each include either or both of spun and/or  and spun filament yarns in a structured pattern of yarns which intersect at cross-over points, said fabric layers including first and second napped surfaces which have raised surface fibers, said napped surfaces being arranged in overlying and opposed relation and bonded together by dynamic fluid energy through entanglement of said raised surface fibers in said first and second surfaces.  
 
     
     
       34. An apparatus for enhancing woven and knit fabric over the fabric before treatment and for finishing woven and knit fabric, the fabric including either or both of spun and/or  and spun filament yarn, by impacting the fabric with pressurized fluid jets, the fabric including yarns which intersect at cross-over points, and first and second sides, the apparatus comprising:
 conveyor means for conveying the fabric in a machine direction (“MD”) through a production line including a first enhancing station, said conveying means supporting a first support member which underlies the fabric in said enhancing station;  
 curtain means spaced from said first support member for directing a continuous curtain of non- compressible  fluid onto the  a first side of the fabric, said curtain means including a plurality of densely spaced jet orifices which eject high pressure fluid jets ;  
 said curtain means coacting with said first support member, and impacting the fabric with a cumulative energy in the range of  0 . 1  to  2 . 0  hp- hr/lb,  to entangle fabric yarns at the  their cross-over points, enhancing  enhance fabric cover and imparting  impart a uniform finish to the fabric.  
 
     
     
       35. An apparatus as set forth in  claim 34 , wherein said fluid orifices have a columnar configuration, a diameter of approximately 0.005 inches and center-to-center spacing of approximately 0.17 inches, and impart energy to the fabric of approximately 0.1 to 2.0 hp-hr/lb. 
     
     
       36. An apparatus as set forth in  claim 35 , wherein said fluid jets have a spray pressure of approximately 1500 psi. 
     
     
       37. An apparatus as set forth in  claim 34 , further comprising a second enhancing station, a second support member which underlies the fabric and is supported for movement on the production line by said conveyor means, and a second curtain means spaced from said second support member for directing a continuous curtain of non- compressible  fluid onto the second side of the fabric, said second curtain means including a second plurality of densely spaced jet orifices which eject high pressure fluid jets , thereby further enhancing the fabric. 
     
     
       38. An apparatus as set forth in  claim 37 , wherein said first and second fluid curtains respectively impart energy to the fabric of approximately 0.1 to 2.0 hp-hr/lb. 
     
     
       39. An apparatus as set forth in claim  38    37 , wherein said first and second support member is  members are fluid pervious and has  have open areas aligned on a bias relative to the machine direction of the line. 
     
     
       40. An apparatus as set forth in  claim 39 , wherein said first and second curtain means are spaced approximately 0.5 inches from said first and second support members, said fluid jets have a spray pressure of approximately 1500 psi, and conveyor means speed is approximately 100 fpm. 
     
     
       41. An apparatus as set forth in  claim 40 , wherein said first and second support members respectively have generally flat and cylindrical configurations. 
     
     
       42. A method for uniformly finishing woven or knitted textile fabrics including either or both of spun and spun filament yarns which intersect at cross- over points, and first and second sides, the method comprising the steps of:  
   supporting the fabric on a support member, the fabric including yarn fibers having deniers and lengths in the range of  0 . 3  to  16 . 0  and  0 . 5  to  8  inches, respectively, and yarn counts in the range of  0 . 5 s to  80 s;    
   conveying the supported fabric in a machine direction;    
   traversing the conveyed fabric on at least a first side with a proximate stationary array of closely and uniformly spaced liquid jets aligned in a cross - direction relative to the machine direction and emanating from orifices, each having an axis substantially perpendicular to the fabric;    
   selecting conveying speed, jet pressure, and the diameter and center - to - center spacing of the orifices, as a function of fabric type and weight, to impact the fabric with a cumulative energy of  0 . 1  to  2 . 0  hp-hr/lb in order to effect entanglement of yarns at cross - over points and to provide a uniformly finished fabric; and    
   drying the fabric.    
 
     
     
       43. A method according to  claim 42 , wherein conveying speed is approximately  100  fpm, jet pressure is approximately  1500  psi, and the jets are columnar and have diameters and center- to - center spacings of approximately  0 . 005  inches and approximately  0 . 034  inches respectively.    
     
     
       44. A method according to  claim 43 , wherein the jets are approximately  0 . 5  inches from the support member.  
     
     
       45. A method according to  claim 42 , wherein the support member is liquid pervious and includes open areas of  17 - 40 %  and has a fine mesh pattern which permits fluid passage without imparting a patterned effect to the fabric.    
     
     
       46. A method according to  claim 45 , wherein the support includes a fine mesh screen arranged in offset relation to the machine direction.  
     
     
       47. A method according to any of claims  42 - 46 , wherein the fabric is treated on both sides.  
     
     
       48. A method according to any of claims  42 - 46 , wherein the array of jets is provided by a plurality of parallel manifolds spaced approximately  8  inches apart.  
     
     
       49. A method according to  claim 42 , wherein the pressure is approximately  1500  psi, the jet diameter is approximately  0 . 005  inches, the center- to - center spacing of the jets provides approximately  60  jets per inch, and the fabric is impacted with a cumulative energy of approximately  0 . 46  hp - hr/lb.    
     
     
       50. A method according to any of claims  42 - 46 , wherein the fabric includes low denier, short length fibers and loosely twisted yarns.  
     
     
       51. An apparatus for uniformly enhancing and finishing woven or knitted textile fabrics of either or both of spun and spun filament yarns by impacting the fabric with pressurized fluid jets, the fabric including yarns which intersect at cross- over points, and first and second sides, the apparatus comprising:      a fabric support member underlying the fabric;        means for conveying the supported fabric in a machine direction through a production line including a first enhancing station;        means for impacting the conveyed fabric on at least one side thereof with a proximate stationary array of closely and uniformly linearly spaced high pressure liquid jets aligned in a cross - direction relative to the machine direction and emanating from orifices, each having an axis substantially perpendicular to the fabric forming a curtain, the liquid jets spaced from the support member;        wherein the conveying speed, jet pressure, and the diameter and center - to - center spacing of the jet orifices are selected as a function of fabric type and weight, to impact the fabric with a cumulative energy of  0 . 1  to  2 . 0  hp - hr/lb through coaction with the support member to entangle fabric yarns at cross - over points, enhance fabric cover, and impart an enhanced and uniform finish to the fabric.      
     
     
       52. An apparatus according to  claim 51 , wherein the conveyor speed is approximately  100  fpm, jet pressure is approximately  1500  psi, and the jets are columnar and have diameters and center- to - center spacings of approximately  0 . 005  inches and approximately  0 . 017  inches respectively.    
     
     
       53. An apparatus according to  claim 52 , wherein the jets are approximately  0 . 5  inches from the support member.  
     
     
       54. An apparatus according to  claim 51 , wherein the support member is liquid pervious and includes open areas of  17 - 40 %  and has a fine mesh pattern which permits fluid passage without imparting a patterned effect to the fabric.    
     
     
       55. An apparatus according to  claim 54 , wherein the support includes a fine mesh screen arranged in offset relation to the machine direction.  
     
     
       56. An apparatus according to any of claims  51 - 55 , wherein the fabric is treated on both sides.  
     
     
       57. An apparatus according to any of claims  51 - 55 , wherein the array of jets is provided by a plurality of parallel manifolds spaced approximately  8  inches apart.  
     
     
       58. An apparatus according to  claim 51 , wherein the pressure is approximately  1500  psi, the jet diameter is approximately  0 . 005  inches, the center- to - center spacing of the jets provides approximately  60  jets per inch, and the fabric is impacted with a cumulative energy of approximately  0 . 46  hp - hr/lb.    
     
     
       59. An apparatus according to any of claims  51 - 55 , wherein the fabric includes low denier, short length fibers and loosely twisted yarns.  
     
     
       60. An apparatus for uniformly enhancing and finishing woven or knitted textile fabrics of either or both of spun and spun filament yarns by impacting the fabrics with pressurized fluid jets, the fabric including yarns which intersect at cross- over points, and first and second sides, the apparatus comprising:      a fabric support member underlying the fabric;        a conveyor for moving the supported fabric in a machine direction through a production line including a first enhancing station;        a plurality of stationary parallel manifolds aligned in a cross - direction relative to the machine direction, each of said plurality of stationary parallel manifolds having a plurality of densely spaced high pressure liquid jets spaced from and directed substantially perpendicular to the fabric for forming a curtain;        wherein conveyor speed, and the pressure, diameter and center - to - center spacing of the manifold jets are selected as a function of fabric type and weight, to impact one side of the fabric with a cumulative energy of  0 . 1  to  2 . 0  hp - hr/lb through coaction with the support member to entangle fabric yarns at cross - over points, enhance fabric cover, and impart an enhanced and uniform finish to the fabric.      
     
     
       61. An apparatus according to  claim 60 , wherein the conveyor speed is approximately  100  fpm, jet pressure is approximately  1500  psi, and the jets are columnar and have diameters and center- to - center spacings of approximately  0 . 005  inches and approximately  0 . 017  inches respectively.    
     
     
       62. An apparatus according to  claim 61 , wherein the jets are approximately  0 . 5  inches from the support member.  
     
     
       63. An apparatus according to  claim 60 , wherein the support member is liquid pervious and includes open areas of  17 - 40 %  and has a fine mesh pattern which permits fluid passage without imparting a patterned effect to the fabric.    
     
     
       64. An apparatus according to  claim 63 , wherein the support includes a fine mesh screen arranged in offset relation to the machine direction.  
     
     
       65. An apparatus according to any of claims  60 - 64 , wherein the fabric is treated on both sides.  
     
     
       66. An apparatus according to  claim 60 , wherein the pressure is approximately  1500  psi, the jets are columnar and have a diameter of approximately  0 . 005  inches, with center-to-center spacing which provides approximately  60  jets per inch, and wherein the fabric is impacted with a cumulative energy of approximately  0 . 46  hp-hr/lb. 
     
     
       67. An apparatus according to any of claims  60 - 64 , wherein the fabric includes low denier, short length fibers and loosely twisted yarns.  
     
     
       68. A uniformly enhanced woven or knitted textile fabric made according to  claim 42 , wherein the fabric yarns are bloomed and entangled at cross-over points defined by intersecting warp and fill yarns of the fabric, thereby filling interstitial open areas between adjacent yarns.  
     
     
       69. A uniformly enhanced fabric according to  claim 68 , wherein the fabric includes low denier, short length fibers and loosely twisted yarns.  
     
     
       70. A uniformly enhanced woven or knit textile fabric comprising
   either or both of spun and spun filament yarns which intersect at cross-over points to define interstitial open areas,        the yarns including fibers having deniers and lengths in the range of  0 . 3  to  16 . 0  and  0 . 5  to  8  inches, respectively, wherein        the yarns are uniformly bulked, entangled in the interstitial open areas, and bloomed by an array of densely packed liquid jets which deliver from  0 . 1  to  2 . 0  hp-hr/lb of energy,        and the enhanced fabric demonstrates a substantial improvement in at least two of air permeability, abrasion resistance, tensile strength, edge fray, seam slippage, wrinkle recovery, torque resistance, and fabric weight.      
     
     
       71. A uniformly enhanced fabric according to  claim 70 , made from loosely twisted yarns.