Classifications

• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
  • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F1/00—General methods for the manufacture of artificial filaments or the like
  • D01F1/02—Addition of substances to the spinning solution or to the melt
  • D01F1/04—Pigments

Definitions

• This invention relates generally to fabrics, and more particularly, is directed to a white blackout drapery fabric.
• a fabric is backed with a first coat of white acrylic foam, followed by a second coat of an acrylic foam having an opaque color, and finally, by a third coat of white acrylic foam.
• a thin vinyl or polyester sheeting having a white color is laminated to the fabric, followed by a second thin vinyl or polyester sheeting having an opaque color which is laminated thereto, and finally, by a third thin vinyl or polyester sheeting having a white color that is also laminated thereto.
• blackout fabrics created by these known methods present numerous disadvantages. Specifically, such blackout fabrics are bulky and stiff. In addition, such blackout fabrics drape poorly and are difficult to launder. Still further, such blackout fabrics have a tendency to come apart or delaminate. It is also difficult to make such blackout fabrics fire retardant. Further, it is difficult to stitch such fabrics, and there is a high cost of production of such blackout fabrics.
• a blackout fabric without the aforementioned drawbacks can be made from yarns comprised of core and sheath components in which the core components have a black color and the sheath components have a white color.
• the black core components tend to show through, producing a black or gray appearance, thereby rendering the blackout fabric unsatisfactory from an aesthetic viewpoint.
• the use of sheath and core components is taught generally in U.S. Patent No. 3,616,167 to Gosden; U.S. Patent No. 3,700,544 to Matsui; U.S. Patent No. 4,075,378 to Anton et al; U.S. Patent No. 3,316,336 to Smith; U.S. Patent No. 2,932,079 to Horn et al; and U.S. Patent No. 4,059,949 to Lee.
• core components containing carbon black function to discharge static electricity build-up, and have particular utility in certain textile products, such as carpets.
• a large amount of carbon black is required to achieve the desired electrical properties so that the fabric will sufficiently discharge static electricity. Accordingly, such fibers tend to be too dark, and therefore, the final product tends to be unsatisfactory from an aesthetic viewpoint.
• the static discharging fibers are used in blends with regular white fibers to minimize their blackness, i.e., are usually in a quantity of 1% or less.
• U.S. Patent No. 3,968,307 to Matsui et al discloses a multi-component mixed filament in which at least two spinning materials having poor affinity are mixed in a unitary filament in a nebular configuration.
• the patent teaches that, by using fibers composed of polyester and polyamide, the filament itself is opaque since polyamide and polyester have different refractive indexes. Accordingly, light is reflected irregularly due to the nebular configuration and the filament is delustered.
• U.S. Patent No. 4,216,264 to Naruse et al discloses a similar arrangement of using carbon black and TiO2, for use with core and sheath components. Accordingly, the denier is again rather large, for example, 20 denier/3 filaments.
• U.S. Patent No. 3,531,368 to Okamoto et al discloses, in Example IV thereof, the use of two polyethylene terephthalates having an intrinsic viscosity of 0.68 and 0.50, respectively, which are used as the polymers to make up a very fine filament part, in which the first polyethylene terephthalate contains 0.05% of TiO2 and 0.55 of carbon black, and the second polyethylene terephthalate has a high brilliancy.
• the drawn yarn consists of 16 filaments, each of which is 3.0 denier.
• the polyethylene terephthalate containing carbon black is uniformly dispersed in the polyethylene terephthalate having a brilliancy when the filament is viewed in cross-­section. However, the filament is deep black in color and has a brilliancy, which is undesirable for producing a white blackout fabric.
• a white blackout fabric consists essentially of fibers formed from a plurality of core components having a light blocking substance therein that substantially prevents the transmission of light therethrough; and a plurality of sheath components having a whitening agent therein; the sheath components and the core components being combined to form the fibers.
• a white blackout yarn includes a plurality of fibers with core components having a light blocking substance therein that substantially prevents the transmission of light therethrough, the light blocking substance being present in an amount equal to approximately .001-.002 weight % of the core components; and a plurality of sheath components having a whitening agent therein, the whitening agent being present in an amount equal to approximately 1.0-2.0 weight % of the sheath components.
• a white blackout fabric that is totally opaque to light is constructed from a fiber made from core and sheath components.
• the present invention uses the basic technology of using core components that contain carbon black and/or other suitable light blocking substances, and sheath components that contain TiO2 and/or other suitable whitening agents, with the components preferably having an approximately 3 denier weight with appropriate staple lengths so as to provide bi-component yarns of the desired size.
• an F.R. polyester component is used, although this is not essential to the present invention.
• other components such as standard polyesters, polyamids or chemical substances suitable for spinning into core and sheath components can be used.
• a white yarn that is totally opaque can be produced according to the present invention.
• approximately .001-.002 weight % of carbon black is used, based on the weight of the polyester in the core, and approximately 1.0 - 2.0 weight % of TiO2 is used, based on the weight of the polyester in the sheath.
• Such yarns can be achieved in any number of suitable ways.
• such totally opaque, white yarns can be made by altering the percentage compositions of the core and sheath components.
• such yarns can be made by altering the amount of carbon black in the core components and/or altering the amount of TiO2 in the sheath components.
• such yarns can be made by maximizing the crimp in the components and/or altering the geometry of the core components to maximize light reflectance and/or light diffusion.
• the crimp and the finish on the components should be satisfactory for carding the same into webs that can be cross lapped and/or carding the components into sliver so that the sliver can be spun on any conventional yarn making system.
• the core components could have a lighter gray or brown color, rather than a black color, making the opaqueness of the sheath less critical.
• the yarn itself could contain 200 individual filaments of 3 denier component, assuming the manufacture of a 9s cotton count or 600 denier equivalent component.
• the present invention differs from known fabrics that use carbon black primarily to discharge static electricity and not primarily for blackout.
• a maximum amount of carbon black is used.
• a yarn that is dark gray in color would be produced from a 300 denier yarn incorporating 20 individual strands of uncrimped 50% core and 50% sheath components, fully using the maximum amount of carbon black therein.
• the present invention consists essentially of the core and sheath components, and accordingly, the fabric is produced substantially without blending.
• core and sheath components according to the present invention can be used to eliminate, or at least substantially diminish, cloudiness that is inherent in all carded webs by utilizing specific percentages of these core and sheath components with regular or standard components.
• a fabric can be made from 80 ends of 300 denier texturized polyester warp yarn and 50 picks of 20s cotton count yarn made from core and sheath opaque components woven in a warp sateen configuration and then finished by at least one of the following methods: pre-shrinking, calendering and hydraulically entangling.
• a fabric can be made from 60 ends of 20s cotton count yarn and 50 picks of 20s cotton count yarn, both made from core and sheath opaque components woven in a warp sateen configuration and then finished by at least one of the following methods: pre-shrinking, calendering and hydraulically entangling.
• a fabric can be made from 24 ends of 4s cotton count yarn and 22 picks of 4s cotton count yarn, both made from core and sheath opaque components woven in a warp sateen configuration and then finished by at least one of the following methods: pre-shrinking, calendering and hydraulically entangling.
• a fabric can be made from a five ounce per square yard carded web which is hydraulically entangled and calendered.
• titanium dioxide is placed in both the sheath and the core. It is known that the addition of titanium dioxide to a fiber, although dulling the fiber, causes the same to be abrasive on spinning equipment and, above a certain amount, can be so undesirable as to make the fiber unusable in a practical sense.
• titanium dioxide is used in both the sheath and the core, with the amount used in the sheath being approximately 0-4% of the weight of the polyester in the sheath.
• the weight of the carbon black in the core is approximately .005-.01% and the weight of the TiO2 in the core is approximately 5-10%. This provides for dulling the fiber and affords maximum efficiency for yarn spinning and drapability.
• the total ratio of titanium dioxide to carbon black in both the sheath and the core determining the whiteness of the fiber. It has been found that approximately 1,000 parts titanium dioxide in both the sheath and core to one part carbon black in the core results in fibers that are commercially acceptable while providing appropriate whiteness.
• the weight of such a fiber should preferably be in the range of 1.5-8 denier.
• a textile structure that lends itself to full coverage can be made opaque by using the aforementioned opaque core and sheath components. This is true, regardless of the manner in which the fabric is formed.
• the present invention can be used with fabrics that are woven, knit, stitch bonded, needled, wet laid, dry laid, spun bonded and spun laced.
• the present invention provides a white blackout fabric from core and sheath components, and which is totally opaque to light, while being aesthetically pleasing.
• the core components are sufficiently dark to prevent the transmission of light therethrough and the sheath components are sufficiently opaque to prevent viewing of the darker core components.
• the present invention thereby has particular utility with drapery linings, printed and solid color hotel and motel draperies, theatre curtains, and woven and non-woven vertical blinds.
• the blackout fabric is soft, can be easily draped, and can be dyed and printed on.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Textile Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Multicomponent Fibers (AREA)
• Woven Fabrics (AREA)
• Treatment Of Fiber Materials (AREA)

Applications Claiming Priority (4)

Publications (2)

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ID=26926551

Family Applications (1)

Country Status (3)

Cited By (3)

Families Citing this family (1)

Citations (5)

Family Cites Families (3)

• 1989
  • 1989-08-09 CA CA 607865 patent/CA1331079C/fr not_active Expired - Fee Related
  • 1989-08-14 EP EP89308235A patent/EP0356100A3/fr not_active Withdrawn
  • 1989-08-16 JP JP1212014A patent/JPH0762286B2/ja not_active Expired - Lifetime

Patent Citations (5)

Non-Patent Citations (2)

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