Bleaching and dyeing; fluid treatment and chemical modification – Coating or sizing with dyeing process or product
Reexamination Certificate
2002-02-08
2004-01-06
Einsmann, Margaret (Department: 1751)
Bleaching and dyeing; fluid treatment and chemical modification
Coating or sizing with dyeing process or product
C008S115510, C008S115700, C427S393400, C442S093000, C442S094000, C442S109000, C252S008620, C252S008610
Reexamination Certificate
active
06673125
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to a process for chemically modifying nonwoven textile articles to impart pilling resistance and soil release properties to the article without compromising the strength and abrasion resistance of the article.
Nonwoven textile articles have historically possessed many attributes that led to their use for many items of commerce, such as air filters, furniture lining, and vehicle floorcovering, side panel and molded trunk linings. Among these attributes are lightweightness of the products, low cost and simplicity of the manufacturing process, and various other advantages. More recently, technological advances in the field of nonwovens, in areas such as abrasion resistance, fabric drape, fabric softness, and wash durability, have created new markets for nonwoven materials. For example, U. S. Pat. Nos. 5,899,785 and 5,970,583, both assigned to Freudenberg, describe a nonwoven lap of very fine continuous filament and the process for making such nonwoven lap using traditional nonwoven manufacturing techniques. The raw material for this process is a spun-bonded composite, or multi-component, fiber that is splittable along its length by mechanical or chemical action. As an example, after a nonwoven lap is formed, it may be subjected to high-pressure water jets which cause the composite fibers to partially separate along their length and become entangled with one another thereby imparting strength and microfiber-like softness to the final product. One such product manufactured and made available by Freudenberg according to these processes is known as Evolon®, and it is available in standard or point bonded variations. These manufacturing techniques allow for the efficient and inexpensive production of nonwoven fabrics having characteristics, such as strength, softness, and drapeability, equal to those of woven or knitted fabrics, which have end uses in products such as apparel, cleaning cloths, and artificial leather.
With the emergence of nonwovens into these new markets and increased consumer interest in such products, there has been a desire to produce fabrics with other characteristics, in addition to strength, similar to those of woven or knitted fabrics. Some of these characteristics include pilling resistance and soil release. Pilling typically results from fibers being pulled out of the fiber bundle and becoming entangled into a “ball” due to mechanical action, such as rubbing that, for example, fabrics encounter during normal use. These “pill balls” are a detriment to the appearance and comfort of textile articles. Reducing or eliminating the pilling propensity of textile articles would typically extend the useful life of the end-use product, such as a garment, by retaining its original appearance and comfort. Furthermore, soil release properties have obvious considerable importance for end-use products such as children's clothing, napery, and cleaning cloths since it is desirable to maintain the original appearance of these products for aesthetic reasons. Thus, it is an important attribute for nonwoven articles to possess pilling resistance and soil release characteristics without compromising strength and abrasion resistance of the articles for their emergence into these new markets.
SUMMARY OF THE INVENTION
In light of the foregoing discussion, it is one object of the current invention to achieve a nonwoven textile article which has been chemically modified to possess pilling resistance, soil release, and acceptable strength characteristics. Textile articles include fabrics, films, and combinations thereof. By pilling resistant, it is meant that the article achieves a minimum “B” rating after 18,000 cycles under a 9 kPa weight when tested for Martindale Pilling according to ASTM D4970 and using the Marks & Spencer Test Method P17 and rating the article on the Marks & Spencer Holoscope. Soil release is determined according to test method AATCC Method 130-2000 and is found to be acceptable for articles that achieve a minimum 3.0 rating after one wash cycle. The amount of strength that will generally be considered to be “acceptable” is the strength required for the treated article to function within its anticipated end product for a minimum number of use or wear cycles, which will generally also include intermittent cleaning cycles as well. The strength that is considered to be acceptable for a given article will therefore vary depending on the type of treated article, how it will be used in an end product, the type of end product, etc. By way of example, acceptable strength for an article intended for use as apparel is achieved with a minimum 2000 cycles when tested for Flex Abrasion according to ASTM D 3885. More specifically, by experience it has been determined that a certain nonwoven fabric comprised of spun-bonded continuous multi-component splittable fibers, wherein the fibers are 65% polyester and 35% nylon 6 or nylon 6, 6, to be used in shirting should achieve a minimum of 2000 cycles when tested according to ASTM D 3885. Other standard methods for evaluating the pilling resistance, soil release, and abrasion resistance of fabrics may be used and are known and available to those skilled in the art.
A second object of the current invention is to achieve a nonwoven textile article, which has been chemically modified, that maintains its aesthetic appearance and comfort properties due to its resistance to pilling. The formation of “pill balls” leads to an unsightly appearance of the article. In addition, these “pill balls,” when found in a garment, for example, generally result in a loss of garment comfort due to the abrasive nature of these protrusions against the skin. Therefore, reducing or eliminating the formation of “pill balls” allows for the extension of the useful life of textile articles, such as apparel, made from nonwoven fabric.
A further object of the current invention is to achieve a nonwoven textile article, which has been chemically modified, that maintains its aesthetic appearance due to its soil release characteristics. For example, garments or napery articles having food or soil stains are typically detracting to the appearance of those items. Thus, treating nonwoven textile articles with soil release chemicals would generally preserve the appearance of those articles and thereby extend the useful of those articles.
It is also an object of the current invention to achieve a method for chemically modifying nonwoven textile articles to impart pilling resistance and soil release properties to the articles while at the same time maintaining acceptable strength and abrasion resistance characteristics.
A further object of the current invention is to achieve a composition of matter for chemically modifying a nonwoven textile article to achieve pilling resistance, soil release, strength and abrasion resistance comprising a hydrophilic silicone, a soil release agent, an abrasion resistance agent, water, and optionally, a wetting agent and a defoaming agent.
Other objects, advantages, and features of the current invention will occur to those skilled in the art. Thus, while the invention will be described and disclosed in connection with certain preferred embodiments and procedures, such embodiments and procedures are not intended to limit the scope of the current invention. Rather, it is intended that all such alternative embodiments, procedures, and modifications are included within the scope and spirit of the disclosed invention and limited only by the appended claims and their equivalents.
DETAILED DESCRIPTION OF THE INVENTION
A nonwoven textile article is provided that has been chemically modified to achieve a useful change in certain of its properties. U.S. Pat. Nos. 5,899,785 and 5,970,583, both incorporated herein by reference, describe the composition and process for manufacturing the nonwoven lap that is the basis for the nonwoven textile article that is chemically modified by the current invention. Typically, the nonwoven article is a fabric comprised of spun-bonded continuous multi-component fil
Miller Brian C.
Sturm Raymond C.
Einsmann Margaret
Milliken & Company
Moyer Terry T.
Wentz Brenda D.
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