SEMI-ABSORBENT, SEMI-RESISTANT, BREATHABLE FABRIC

• US 20140352073A1
• Filed: 11/07/2013
• Published: 12/04/2014
• Est. Priority Date: 06/04/2013
• Status: Abandoned Application

• Current Assignee: Welspun India Limited
• Original Assignee: Welspun India Limited
• Inventors: GOENKA, Dipali
• Application Number:
  US14/074,690
• Publication Number:
  US 20140352073A1
• Time in Patent Office: Days
• US Class Current: 5/691
• CPC Class Codes: A47C 27/006 breathable
• CPC Class Codes: B05D 3/007 After-treatment
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2307/728 Hydrophilic
• CPC Class Codes: B32B 2307/73 Hydrophobic
• CPC Class Codes: B32B 2479/00 Furniture
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/026 Knitted fabric
• CPC Class Codes: B32B 5/16 characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D03D 1/00 Woven fabrics designed to make specified articles
• CPC Class Codes: D03D 1/0017 Woven household fabrics
• CPC Class Codes: D03D 15/217 natural from plants, e.g. cotton
• CPC Class Codes: D03D 21/00 Lappet- or swivel-woven fabrics
• CPC Class Codes: D04B 1/22 specially adapted for knitting goods of particular configuration
• CPC Class Codes: D04B 1/26 : stockings
• CPC Class Codes: D06B 1/00 : Applying liquids, gases or vapours onto textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing or impregnating mercerising D06B7/00; solvent-treatment D06B9/00; treatment of selected parts of textile materials D06B11/00; with aid of vibration D06B13/00
• CPC Class Codes: D06M 15/227 : of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated
• CPC Class Codes: D06M 15/256 : containing fluorine
• CPC Class Codes: D06M 15/263 : of unsaturated carboxylic acids; Salts or esters thereof
• CPC Class Codes: D06M 15/6436 : containing amino groups
• CPC Class Codes: D06M 2101/06 : cellulosic
• CPC Class Codes: D06M 2200/12 : Hydrophobic properties
• CPC Class Codes: D06M 2200/50 : Modified hand or grip properties; Softening compositions
• CPC Class Codes: D06M 23/00 : Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
• CPC Class Codes: D06M 23/16 : Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment
• CPC Class Codes: D06N 3/047 : with fluoropolymers
• CPC Class Codes: D06N 3/08 : with a finishing layer consisting of polyacrylates, polyamides or polyurethanes or polyester
• CPC Class Codes: D06N 3/128 : with silicon polymers
• CPC Class Codes: D06N 3/186 : one of the layers is on one surface of the fibrous web and the other layer is on the other surface of the fibrous web
• CPC Class Codes: D10B 2401/021 : hydrophobic
• CPC Class Codes: D10B 2401/022 : hydrophylic
• CPC Class Codes: D10B 2403/0114 : with one or more yarns appearing predominantly on one face, e.g. plated or paralleled yarns for pile fabrics D03D27/00, D04B1/02, D04B21/02; for intarsia fabrics D04B1/126
• CPC Class Codes: D10B 2501/021 : Hosiery; Panti-hose
• CPC Class Codes: D10B 2503/06 : Bed linen
• CPC Class Codes: Y10T 442/3976 : Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]

Abstract

A semi-absorbent, semi-resistant, breathable fabric includes a single-layer having a first, hydrophilic side that absorbs water, and a second, hydrophobic side; wherein the first, hydrophilic side of the single-layer fabric quickly spreads out a liquid that is absorbed laterally to a wider area such that the absorbed liquid does not seep or pass through to the second, hydrophobic side of the single-layer fabric under gravitational force. A method of making a semi-absorbent, semi-resistant, breathable fabric includes: subjecting a first side of a single-layer fabric to a hydrophilic amino functional polysiloxane softener; treating a second opposite side of the fabric with a fluorocarbon compound under low pressure such that the fluorocarbon compound penetrates no more than half of the fabric thickness; and drying and curing the fabric, preferably at a temperature of about 145° C. to 155° C. for about three minutes to about five minutes.

Claims

1. A semi-absorbent, semi-resistant, breathable fabric comprising:

a single layer of fabric having a first, hydrophilic side that absorbs water, and a second, hydrophobic side relative to the first side such that a liquid that is absorbed on the hydrophilic side spreads out laterally to a wider area and does not seep through to the second, hydrophobic side of the single-layer fabric.

2. The semi-absorbent, semi-resistant, breathable fabric according to claim 1, wherein the fabric comprises natural fibers, synthetic fibers, regenerated fibers, and combination thereof.

3. The semi-absorbent, semi-resistant, breathable fabric according to claim 1, wherein the fabric is woven or knitted.

4. The semi-absorbent, semi-resistant, breathable fabric according to claim 1, wherein the thread count of the single layer of fabric is in the range of 120 TC to 1200 TC.

5. The semi-absorbent, semi-resistant, breathable fabric according to claim 1, wherein the yarn count of the single layer of fabric is in the range of 30 s count to 120 s count.

6. The semi-absorbent, semi-resistant, breathable fabric according to claim 3, wherein the single layer of fabric comprises weft yarns and warp yarns, and wherein each of the weft yarns and the warp yarns extends on both sides of the single layer of fabric and is hydrophilic on the first side and hydrophobic on the second side.

7. The semi-absorbent, semi-resistant, breathable fabric according to claim 3, wherein the single layer of fabric comprises weft yarns and warp yarns, and wherein each of the weft yarns and the warp yarns includes at least a first extent that is hydrophilic and at least a second extent that is hydrophobic relative to the first extent.

8. The semi-absorbent, semi-resistant, breathable fabric according to claim 3, wherein the single layer of fabric is woven from weft yarns and warp yarns, each of which has a uniform absorbency along its length, the hydrophilic and hydrophobic properties being imparted to the single layer of fabric after the fabric has been woven.

20. A mattress pad comprising the semi-absorbent, semi-resistant, breathable fabric according to claim 1.

9. A method of fabricating a semi-absorbent, semi-resistant, breathable single layer of fabric, comprising the steps of:

(a) subjecting a first side of a single layer of fabric to hydrophilic amino functional polysiloxane softener to impart hydrophilicity to the first side;

(b) treating a second, opposite side of the fabric with a fluorocarbon compound to impart hydrophobicity to the second side, the treatment being performed under low pressure such that the fluorocarbon compound does not penetrate more than 50% of the thickness of the single layer of fabric; and

(c) drying and curing the fabric to obtain the semi-absorbent, semi-resistant, breathable fabric.

10. The method of fabricating a semi-absorbent, semi-resistant, breathable fabric according to claim 9, wherein the method further includes preliminary steps for preparation of the single layer of fabric, comprising the steps of singeing de-sizing, washing and processing through a conventional bleaching route, and mercerizing.

11. The method of fabricating a semi-absorbent, semi-resistant, breathable fabric according to claim 9, wherein the single layer of fabric is woven from weft yarns and warp yarns, each of which has a uniform absorbency along its length, the hydrophilic and hydrophobic properties being imparted to the single layer of fabric after the fabric has been woven.

12. The method of fabricating a semi-absorbent, semi-resistant, breathable fabric according to claim 9, wherein said step (c) comprises drying and curing the fabric at a temperature of between 145°

C. and 155°

C. for a duration of about three minutes to five minutes.

13. The method of fabricating a semi-absorbent, semi-resistant, breathable fabric according to claim 9, wherein the fluorocarbon compound comprises;

(i) a fluorocarbon emulsion, and (ii) a paste consisting of an acrylic cross linking polymer;

urea;

a handle modifier and softener;

a synthetic thickening agent;

a fixing agent;

an antifoaming agent;

a liquor ammonia; and

water.

14. The method of fabricating a semi-absorbent, semi-resistant, breathable fabric according to claim 9, wherein the fluorocarbon compound comprises;

(i) a fluorocarbon emulsion, and (ii) a paste comprising 10% by weight of an acrylic cross linking polymer;

3% by weight of urea;

2% by weight of a handle modifier and softener;

1.8% by weight of a synthetic thickening agent;

0.5% by weight of a fixing agent;

0.5% by weight of an antifoaming agent;

1% by weight of a liquor ammonia; and

81.2% by weight of water.

15. The method of fabricating a semi-absorbent, semi-resistant, breathable fabric according to claim 9, wherein the ratio of fluorocarbon emulsion to the paste is 25:

75 by weight.

29. The method of fabricating a semi-absorbent, semi-resistant, breathable fabric according to claim 10, wherein the single layer of fabric is woven from weft yarns and warp yarns, each of which has a uniform absorbency along its length, the hydrophilic and hydrophobic properties being imparted to the single layer of fabric after the fabric has been woven.

16. A mattress pad, comprising:

(a) a single layer of woven fabric;

(b) a layer of wadding;

(c) a nonwoven fabric defining an enclosure in which the wadding is contained;

(d) wherein the single layer of fabric comprises a hydrophilic side and an oppositely facing hydrophobic side, with the single layer of fabric being stitched to the enclosure in covering relation to a top side of the enclosure, and with the hydrophilic side of the single layer of fabric facing away from the enclosure and the hydrophobic side facing the enclosure, whereby liquid that is absorbed by the hydrophilic side of the single layer of fabric on the top side of the mattress pad spreads across the hydrophilic top side of the mattress pad and does not seep through to the hydrophobic area of the single layer of fabric or to the wadding layer.

17. The mattress pad of claim 16, further comprising a skirt fabric or edge fabric stitched to the enclosure.

18. The mattress pad of claim 16, wherein the single layer of fabric comprises a breathable, woven fabric comprising warp and weft yarns, each of the yarns including at least a first extent that is hydrophilic and at least a second extent that is hydrophobic relative to the first extent.

19. (canceled)

21-28. -28. (canceled)