US20110059288A1 - Flannel sheeting fabric for use in home textiles - Google Patents

Flannel sheeting fabric for use in home textiles Download PDF

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Publication number
US20110059288A1
US20110059288A1 US12/554,323 US55432309A US2011059288A1 US 20110059288 A1 US20110059288 A1 US 20110059288A1 US 55432309 A US55432309 A US 55432309A US 2011059288 A1 US2011059288 A1 US 2011059288A1
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Prior art keywords
fabric
yarn
textile according
flannel
base
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US12/554,323
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Jonathan G. Shavel
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
    • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/01—Surface features
    • D10B2403/012—Alike front and back faces
    • D10B2403/0121—Two hairy surfaces, e.g. napped or raised
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/2395—Nap type surface

Definitions

  • the present invention relates generally to development of an alternative to traditional cotton flannel used in home textiles; specifically to the development of a warp knit fabric of various polyester fiber deniers and the special unexpected and useful properties that this fabric demonstrates in comparison to cotton flannel used in the same home textiles products.
  • the standard and traditional cotton flannel is created by weaving a tightly spun cotton yarn in yarn sizes of NE 16-24 in the warp position with a soft twist cotton yarn in yarn sizes of NE 8-12 placed in the weft position. When woven, this allows soft twist yarns placed in the weft of the fabric to be held in place by tightly spun warp yarns. This is done to allow the softly twisted weft yarns to be napped or torn on the surface by a raising/brushing machine. The resultant napped, or brushed, surface is the ‘flannel’ effect.
  • This conventional flannel product has always suffered from the following cotton and manufacturing related issues: it shrinks, as the yarns are not stable; it wrinkles, as the yarns are delicate, and it pills, as the surface is composed of broken cotton fibers which are loosely held together in a traditional or slightly modified version of a 1 ⁇ 1 woven design of 1 warp yarn over 1 weft yarn.
  • Polyester yarns are knit on a warp knitting machine to make a base greige fabric. In a subsequent step, mechanical napping or brushing applied to both sides of the greige fabric.
  • the polyester greige cloth can be dyed and finished prior to being napped on two sides.
  • the fabric has the following useful advantages over cotton flannel: it does not appreciably shrink, it does not appreciably pill, and it does not appreciably wrinkle under standard industry testing conditions and in comparison to cotton flannel. Further, under these same testing conditions, the fabric demonstrates unexpected useful benefits of being stain resistant to acids and alkalis as well as fade resistant to light.
  • the fabric of the invention may be used as a bed sheet, a component of a comforter, a component of a mattress pad, a component of a decorative pillow, a component of a feather bed, a component of a window treatment, a component of a blanket or throw blanket, or one from the group consisting of a sheet set, a bed skirt, a sham, drapes, valances, tie backs, curtains, bed pillows, throw blankets, bed blankets, and window treatments, or as otherwise used in the manufacturing and offerings of the home textiles industry.
  • FIG. 1 is a top plan view of an embodiment of the invention.
  • the present invention relates to home textile products that are created from the unexpected benefit of the use of polyester yarns on a warp knitting machine to make a base greige fabric which is then processed, and coupled with the subsequent and novel step of mechanical napping or brushing applied to both sides of this processed fabric.
  • the processing can consist of scouring, bleaching, and/or dyeing and/or printing.
  • the finishing process can be the application of heat and/or mechanically applied tension for length and width stability.
  • An exemplary fabric 10 of the invention is shown in FIG. 1 .
  • Polyester has been used for decades in the manufacture of cloth and fill. Polyesters are polymers chemically composed of di-hydric alcohol and terephthalic acid. The resulting fiber is generally insoluble, shows resistance to weak concentrations of alkali (consequently, it is not affected by human sweat), and is durable. In the prior art, it is used primarily on conventional weaving and knitting machines for the manufacture of fabrics.
  • polyester yarns may be used with conventional warp knit machinery to manufacture a base fabric which may be subsequently processed to provide a new flannel sheeting fabric for use in home textiles, such as bed linens.
  • the warp knit machinery loops various yarns around each other to create a hybrid fabric which has both knit and weaving benefits.
  • the resultant hybrid fabric created is stable in its undyed, unprocessed, unfinished fabric form (which is commonly known in industry terms for all unfinished fabrics as ‘greige’, or ‘loom state’).
  • the warp knit machinery is conventional, such as a made by Karl Mayer of Germany.
  • the size of the yarn in the base of the fabric is 50 D ⁇ 48 F (denier/filament).
  • the face of the fabric is 75 D ⁇ 144 F.
  • the D (denier) refers to the size or thickness of the polyester yarns as measured by a constant of #1 D is 1 gram equals 9000 meters, #2 D equals 9000 meters in 2 grams, etc.
  • the ‘F’ refers to the number of filaments of this particular yarn which arises from both the number of spinnerets used in the manufacturing of this synthetic yarn and the rate of speed at which the solution is being pumped through the machine.
  • the filament is matched to the denier to create an end use yarn for specific properties of texture and drape.
  • the gauge or courses of the warp knit machinery is 7 ⁇ 570 threads per 280 cm. Dyeing and finishing is conventional (for cotton and synthetics).
  • the fabric is napped using planetary napping rollers, 4 times on the face and 2 times
  • the resultant fabric satisfies the need for a home textile flannel sheeting fabric material that does not appreciably shrink, pill, or wrinkle.

Abstract

Polyester yarns are knit on a warp knitting machine to make a base greige fabric. In a subsequent step, mechanical napping or brushing applied to both sides of the greige fabric.

Description

    FIELD OF THE INVENTION
  • The present invention relates generally to development of an alternative to traditional cotton flannel used in home textiles; specifically to the development of a warp knit fabric of various polyester fiber deniers and the special unexpected and useful properties that this fabric demonstrates in comparison to cotton flannel used in the same home textiles products.
    • BACKGROUND
  • The standard and traditional cotton flannel is created by weaving a tightly spun cotton yarn in yarn sizes of NE 16-24 in the warp position with a soft twist cotton yarn in yarn sizes of NE 8-12 placed in the weft position. When woven, this allows soft twist yarns placed in the weft of the fabric to be held in place by tightly spun warp yarns. This is done to allow the softly twisted weft yarns to be napped or torn on the surface by a raising/brushing machine. The resultant napped, or brushed, surface is the ‘flannel’ effect. This conventional flannel product has always suffered from the following cotton and manufacturing related issues: it shrinks, as the yarns are not stable; it wrinkles, as the yarns are delicate, and it pills, as the surface is composed of broken cotton fibers which are loosely held together in a traditional or slightly modified version of a 1×1 woven design of 1 warp yarn over 1 weft yarn.
  • Over the decades, much research and work has been done in the field of textile manufacturing to devise improved methods of producing a more stable flannel home textile fabric. These have included the use of better cotton, better spinning techniques, additions of ‘fixative’ chemicals, and mechanical processes to stabilize the end use cloth. However, these have all fallen short of the goal of creating a stable flannel product.
  • It is an object of the present invention to provide a stable flannel product that does not appreciably shrink, wrinkle, or pill.
    • SUMMARY OF THE INVENTION
  • Polyester yarns are knit on a warp knitting machine to make a base greige fabric. In a subsequent step, mechanical napping or brushing applied to both sides of the greige fabric.
  • The polyester greige cloth can be dyed and finished prior to being napped on two sides. The fabric has the following useful advantages over cotton flannel: it does not appreciably shrink, it does not appreciably pill, and it does not appreciably wrinkle under standard industry testing conditions and in comparison to cotton flannel. Further, under these same testing conditions, the fabric demonstrates unexpected useful benefits of being stain resistant to acids and alkalis as well as fade resistant to light.
  • In various forms, the fabric of the invention may be used as a bed sheet, a component of a comforter, a component of a mattress pad, a component of a decorative pillow, a component of a feather bed, a component of a window treatment, a component of a blanket or throw blanket, or one from the group consisting of a sheet set, a bed skirt, a sham, drapes, valances, tie backs, curtains, bed pillows, throw blankets, bed blankets, and window treatments, or as otherwise used in the manufacturing and offerings of the home textiles industry.
    • DESCRIPTION OF THE DRAWING
  • An embodiment of the invention is disclosed in the following detailed description and the accompanying drawings.
  • FIG. 1 is a top plan view of an embodiment of the invention.
    •  DETAILED DESCRIPTION OF THE INVENTION
  • The present invention relates to home textile products that are created from the unexpected benefit of the use of polyester yarns on a warp knitting machine to make a base greige fabric which is then processed, and coupled with the subsequent and novel step of mechanical napping or brushing applied to both sides of this processed fabric. The processing can consist of scouring, bleaching, and/or dyeing and/or printing. The finishing process can be the application of heat and/or mechanically applied tension for length and width stability. An exemplary fabric 10 of the invention is shown in FIG. 1.
  • Polyester has been used for decades in the manufacture of cloth and fill. Polyesters are polymers chemically composed of di-hydric alcohol and terephthalic acid. The resulting fiber is generally insoluble, shows resistance to weak concentrations of alkali (consequently, it is not affected by human sweat), and is durable. In the prior art, it is used primarily on conventional weaving and knitting machines for the manufacture of fabrics.
  • In accordance with the invention, polyester yarns may be used with conventional warp knit machinery to manufacture a base fabric which may be subsequently processed to provide a new flannel sheeting fabric for use in home textiles, such as bed linens. The warp knit machinery loops various yarns around each other to create a hybrid fabric which has both knit and weaving benefits. The resultant hybrid fabric created is stable in its undyed, unprocessed, unfinished fabric form (which is commonly known in industry terms for all unfinished fabrics as ‘greige’, or ‘loom state’).
  • Then, fabric dyeing and finishing processes (typically of the type used for cotton flannel) are performed on the fabric. Finally, the novel step of high speed mechanical napping or brushing is applied to both sides of the greige. This sequence of processes produces a two sided raised flannel effect on a wide width cloth that does not appreciably shrink, wrinkle, or pill.
  • In a preferred form, the warp knit machinery is conventional, such as a made by Karl Mayer of Germany. The size of the yarn in the base of the fabric is 50 D×48 F (denier/filament). The face of the fabric is 75 D×144 F. The D (denier) refers to the size or thickness of the polyester yarns as measured by a constant of #1 D is 1 gram equals 9000 meters, #2 D equals 9000 meters in 2 grams, etc. The ‘F’ refers to the number of filaments of this particular yarn which arises from both the number of spinnerets used in the manufacturing of this synthetic yarn and the rate of speed at which the solution is being pumped through the machine. The filament is matched to the denier to create an end use yarn for specific properties of texture and drape. The gauge or courses of the warp knit machinery is 7×570 threads per 280 cm. Dyeing and finishing is conventional (for cotton and synthetics). Finally, the fabric is napped using planetary napping rollers, 4 times on the face and 2 times on the back.
  • The resultant fabric satisfies the need for a home textile flannel sheeting fabric material that does not appreciably shrink, pill, or wrinkle.
  • Although the foregoing embodiments have been described in some detail for purposes of clarity of understanding, the invention is not limited to the details provided. There are many alternative ways of implementing the invention. The disclosed embodiments are illustrative, and not restrictive.

Claims (11)

1. A textile comprising:
warp knit fabric having a base and a face, wherein the face includes a polyester yarn and the base includes a polyester yarn, and wherein the face and the base are napped.
2. A textile according to claim 1 wherein the base yarn is 50 D×48 F.
3. A textile according to claim 1 wherein the face yarn is 75 D×144 F.
4. A textile according to claim 1 wherein the base yarn is 50 D×48 F and the face yarn is 75 D×144 F.
5. A textile according to claim 1 wherein the fabric is a polyester warp knit flannel
6. A textile according to claim 1 wherein the fabric is a sheet.
7. A textile according to claim 1 wherein the fabric is a component of a comforter.
8. A textile according to claim 1 wherein the fabric is a component of a mattress pad.
9. A textile according to claim 1 wherein the fabric is a component of a decorative pillow.
10. A textile according to claim 1 wherein the fabric is a component of a feather bed
11. A new home textile product comprised of one from the group consisting of a sheet set, a bed skirt, a sham, drapes, valances, tie-backs, curtains, bed pillows, throw blankets, bed blankets, and window treatments.
US12/554,323 2009-09-04 2009-09-04 Flannel sheeting fabric for use in home textiles Pending US20110059288A1 (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130118209A1 (en) * 2011-11-11 2013-05-16 Edmund Jin Fabric construction and method of manufacturing

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