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  Process for creating fabrics with branched fibrils and such fibrillated fabricsUSPTO Application #: 20060166578Title: 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. (end of abstract) Agent: Charlotte C. Wilson Legal Department, M-495 - Spartanburg, SC, US Inventors: Kasey R. Myers, Franklin Sadler Love, Kirkland W. Vogt USPTO Applicaton #: 20060166578 - Class: 442001000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Scrim (e.g., Open Net Or Mesh, Gauze, Loose Or Open Weave Or Knit, Etc.) The Patent Description & Claims data below is from USPTO Patent Application 20060166578. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD [0001] The present disclosure relates to a process for creating fine-scale multiple fibrils and branched fibrils that are integrally connected to the filaments from which they protrude. The process involves mechanically abrading, preferably under heated conditions, a fabric to which a plasticizer- or solvent-containing solution has been applied. The fabric containing such a fibrillated structure is also disclosed. BACKGROUND [0002] All patents described herein are hereby incorporated by reference. [0003] There have been numerous attempts to modify synthetic fabrics (particularly polyester) to improve their hand and/or appearance. Conventionally, sanding or napping of the fabric has been used to soften the hand and, in the case of continuous filament polyester fabric, to deluster the fabric. Sanding alone, however, typically results in large numbers of broken yarn ends, in which the broken ends have substantially the same diameter as the originating yarns, thereby yielding a fabric with a somewhat harsh hand and whitened and blurred surface. [0004] Efforts to modify the surface of synthetic-containing fabric with specialized finishing equipment have also been used with some degree of success. Various abrading mechanisms have been employed, including abrasion with sandpaper, diamond grit, and the like, as described in U.S. Pat. No. 5,058,329 and U.S. Pat. No. 5,109,630, both to Love et al.; U.S. Pat. No. 5,815,896 to Dischler; and U.S. Pat. No. 5,819,816 to Dischler. Further, subject fabrics have also been modified by treatment with high-pressure streams of air or water, as described in U.S. Pat. No. 4,918,795 to Dischler; U.S. Pat. No. 5,033,143 to Love, III; and U.S. Pat. No. 6,546,605 to Emery et al. The success of these efforts has been largely dependent on the starting fabric and the desired results. However, these approaches failed to create the multiple and branched fibrillated structure that is characteristic of the present process and product. [0005] Others have attempted to create fibrillated, scale-like textile structures through the use of chemical application combined with face-finishing techniques. U.S. Pat. Nos. 4,421,513 and 4,331,724 to Su describe a process for fibrillating polyester materials, which involves lowering the molecular weight of the polyester, treating it with a 100% concentrated swelling agent, and abrading the fabric. The result of this process is a fabric that has scale-like fibrils projecting away from the convex portion of the filament curvature (that is, the fibrils are produced only on one side of the fabric at places along the filament that are exposed to abrasion). The fabric is also weakened because of the process used to reduce the molecular weight of the polyester. These references do not contemplate a dual-sided treatment of the fabric or a method to enhance fibrillation to create multiple fibrils and fibrils with multiple splitting. [0006] An apparatus and process are described in U.S. Pat. Nos. 5,058,329 and 5,109,630 to Love et al. to implement the art described in the Su patents. The process abrades fabric against a roll covered with rounded tungsten-carbide particles, after saturating the fabric with 100% methylene chloride at room temperature. The teachings of Love et al. fail to disclose a fabric having multiple fibrils and branched fibrils that are integrally connected to the filaments from which they protrude. [0007] Yet another method of modifying fabrics is described in U.S. Pat. No. 4,259,393 to Marco. Marco teaches treating a fabric containing texturized polyester filaments with an alkaline solution in a jet-dyeing machine in order to chemically break a substantial number of the filaments. When the fibers break, the broken ends split into multiple filaments as a result of their exposure to the alkaline solution at preferred temperatures of between 45.degree. C. and 55.degree. C. Marco suggests that smaller filaments should project from each broken end. Like the Su and Love et al. references discussed above, Marco does not present a method for creating the multiple fibrils or branched fibrils that are characteristic of the present product. SUMMARY [0008] 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. [0009] Benefits of the present process and product include, in one preferred embodiment, the use of relatively inexpensive yarns made entirely of single-component polymers (as opposed to the use of multi-component filaments that are commonly described as being easily splittable or "island-in-the-sea"-type filaments). Fabrics made from the present process retain their surface sharpness or clarify, making it possible to create fibrillated fabrics with fine-gauge stylized appearances. Further, fabrics made from this process exhibit a silk-like hand that results from the presence of multiple integral fibrils and branched fibrils. In fact, the process achieves a microdenier-like soft hand without the limitations of using microdenier fibers, which include poor abrasion resistance, difficulty in and a relatively higher expense of dyeing, and poor lightfastness. DESCRIPTION OF THE DRAWINGS [0010] FIG. 1 is a flow-chart of the process of making a fibrillated fabric; and [0011] FIGS. 2 through 6 are photomicrographs of fibrillated fabrics of the present disclosure, taken with an AMRAY scanning electron microscope, Model 1845 FE (1991). DETAILED DESCRIPTION [0012] As used herein, "fiber" is defined as a unit of matter, either natural or manufactured, that forms the basic element of fabrics and other textile structures. A fiber is characterized by having a length at least 100 times its diameter or width. [0013] "Fibrillation" is defined as the act or process of forming fibrils, such as by breaking up a fiber into the minute fibrous elements from which the main structure is formed. [0014] "Fibril" is defined as a tiny, threadlike element of a natural or synthetic fiber that is still integrally attached to its parent filament at one or both ends. A "branched fibril" is a threadlike element of a natural or synthetic fiber that is split into multiple smaller elements, all of the smaller elements originating from and being integrally attached to the parent filament. [0015] Fibrillation results in a fabric with finer filaments, as a plurality of fibrils is formed from a portion of the filaments that is moved away from the main body of the filaments. Thus, fibrillation is not an additive or subtractive process, but rather a fiber rearrangement process. The advantage of this approach is that the fabric's overall weight is essentially unchanged. [0016] Turning now to the drawings, FIG. 1 provides a flowchart of the preferred present process for creating integral, branched fibrils on a subject fabric. Step 10 is to provide a fabric for modification. Fabrics contemplated for use with the present process include woven fabrics, knit fabrics, nonwoven fabrics, braided fabrics, pile fabrics, scrims, composites, spacer fabrics, and other fabric constructions as may be conventionally processed through a sander. [0017] The fabrics may be made of yarns containing fiber types such as polyesters, polyamides, polypropylenes, olefins and polyolefins, polyurethanes, aramids (such as Kevlar), 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 (such as cotton). The presence of natural fibers will not inhibit the effects of the present process on the synthetic components of the fabric and may enhance certain characteristics of the natural fibers (e.g., hand). Preferably, the yarns are continuous filament yarns, although the process may be applied to spun yarns as well. Most preferably, the yarns are polyester. [0018] Before being subjected to the present process, the fabric may be dyed; calendered; embossed; coated; sheared; screen patterned; digitally patterned by hot air, water, lasers, or the like; combined into a composite; or printed. In one embodiment as will be discussed herein, the fabric is in its greige state when processed. [0019] Step 20 involves the application of a chemical agent (specifically, a fiber-specific plasticizer- or solvent-containing solution) to the fabric. Suitable application techniques include dipping, spraying, foam coating, and other methods that may be known to those of skill in the art. Preferably, the plasticizer or solvent is part of an aqueous solution. Suitable amounts of plasticizing agent range from about 0.1% to about 100% of the weight of the solution and, preferably, are from about 0.1% to about 10% of the weight of the solution. Continue reading... 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