FAST DRYING CELLULOSIC FABRIC AND PROCESS TO PRODUCE SAME
Cellulosic fabrics and articles are disclosed that include a treatment to provide the fabric that has a balance of comfort, absorbency, wicking, and fast drying. Methods to produce the fabrics and articles are also disclosed.
1 . An article of manufacture, comprising:
a fabric, comprising at least about 45%, by weight, based on the total weight of the fabric, of at least one cellulosic material;
a treatment to form a treated fabric, wherein said treatment comprises:
a hydrophobic particle treatment portion; and
a chemically bonded treatment portion;
wherein said treated fabric is hydrophilic and fast drying.
2 . The article of claim 1 ,
wherein said fabric is constructed of a single compositional yarn.
3 . The article of claim 1 ,
wherein said fabric further comprises at least one functional yarn.
4 . The article of claim 3 ,
wherein said functional yarn is a yarn selected from the group consisting of an elastomeric yarn, an antistatic yarn, an anti-abrasion yarn, an antimicrobial yarn, a structural reinforcement yarn, and a combination thereof.
5 . The article of claim 1 , further comprising:
at least one functional additive, wherein said functional additive is selected from the group consisting of an antimicrobial agent, an odor control agent, an odor absorbing agent, an antistatic agent, a ultraviolent finish, a wrinkle resistance agent, an insect repellent, fabric sun protection, and a combination thereof.
6 . The article of claim 1 ,
wherein said treatment is uniformly distributed on or in said fabric.
7 . The article of claim 1 ,
wherein said treatment is distributed as a gradient in said fabric.
8 . The article of claim 1 ,
wherein said treatment is present at a level less than sufficient to form a coating on said fabric.
9 . The article of claim 1 ,
wherein said treatment is present at a level of less than about 5% by dry weight, based on the total weight of the fabric.
10 . The article of claim 1 ,
wherein said fabric consists essentially of cellulosic material.
11 . The article of claim 1 ,
wherein said fabric consists essentially of cotton.
12 . The article of claim 1 ,
wherein said fabric further comprises at least one synthetic fiber.
13 . The article of claim 1 ,
wherein said hydrophobic particle treatment portion comprises at least one material selected from the group consisting of polymer particles, metal particles, silica, and combinations thereof.
14 . The article of claim 1 ,
wherein said hydrophobic particle treatment portion comprises a plurality of polymer particles, wherein said polymer particles comprise at least one polymer selected from the group consisting of fluoro-containing homopolymer, fluoro-containing copolymer, polyvinyl acetate, polyvinyl acetate/acrylic copolymer, and combinations thereof.
15 . The article of claim 1 ,
wherein said hydrophobic particle treatment is formed from polytetrafluoroethylene.
16 . The article of claim 1 ,
wherein said hydrophobic particle treatment is formed from one or more of polyvinyl acetate and a polyvinyl acetate/acrylic copolymer.
17 . The article of claim 1 ,
wherein said hydrophobic particle treatment is formed from a combination of at least two of polytetrafluoroethylene, polyvinyl acetate, and a polyvinyl acetate/acrylic copolymer.
18 . The article of claim 1 ,
wherein said hydrophobic particles have a diameter less than about 1 μm in diameter.
19 . The article of claim 1 ,
wherein said hydrophobic particles have a diameter less than about 500 nm in diameter.
20 . The article of claim 1 ,
wherein said chemically bonded treatment portion is formed from a mixture comprising:
at least one hydrophilic monomer or polymer having a moiety reactive with a hydroxyl group on said cellulosic material; and
at least one hydrophobic fluoropolymer or fluoromonomer.
21 . The article of claim 20 ,
wherein said hydrophilic monomer or polymer having a moiety reactive with a hydroxyl group on said cellulosic material is present at a level of about 10% by weight to about 90% by weight, based on the total weight of said mixture.
22 . The article of claim 20 ,
wherein said hydrophilic monomer or polymer having a moiety reactive with a hydroxyl group on said cellulosic material is present at a level of about 40% by weight to about 70% by weight, based on the total weight of said mixture.
23 . The article of claim 20 ,
wherein said hydrophilic monomer or polymer having a moiety reactive with a hydroxyl group on said cellulosic material is present at a level of about 70% by weight to about 90% by weight, based on the total weight of said mixture.
24 . The article of claim 20 ,
wherein said hydrophobic fluoropolymer or fluoromonomer is present at a level of about 10% by weight to about 90% by weight, based on the total weight of said mixture.
25 . The article of claim 20 ,
wherein said hydrophobic fluoropolymer or fluoromonomer is present at a level of about 10% by weight to about 40% by weight, based on the total weight of said mixture.
26 . The article of claim 20 ,
wherein said hydrophobic fluoropolymer or fluoromonomer is present at a level of about 10% by weight to about 30% by weight, based on the total weight of said mixture.
27 . The article of claim 20 ,
wherein said chemically bonded treatment portion has a fluorine content of about 0.01% by weight to about 1% by weight, based on the total weight of said chemically bonded treatment portion.
28 . The article of claim 20 ,
wherein said hydrophilic polymer or monomer is formed from at least one monomer selected from the group consisting of vinyl acetate, substituted vinyl acetate, C 1 -C 6 alkyl(meth)acrylate, substituted C 1 -C 6 alkyl(meth)acrylate, and combinations thereof.
29 . The article of claim 20 ,
wherein said hydrophilic polymer is ethylene-vinyl acetate.
30 . The article of claim 20 ,
wherein said hydrophobic fluoropolymer comprises residues of at least one C 6 -C 16 fluorine-containing monomer, or a linear or branched congener thereof.
31 . The article of claim 20 ,
wherein said hydrophobic fluoropolymer comprises residues of at least one C 6 -C 16 perfluoroalkyl-containing monomer, or a linear or branched congener thereof.
32 . The article of claim 31 ,
wherein said hydrophobic fluoropolymer further comprises residues selected from the group consisting of C 6 -C 16 perfluoroalkyl-containing vinyl alcohol, C 6 -C 16 perfluoroalkyl-containing (meth)acrylate, and combinations thereof.
33 . The article of claim 1 ,
wherein said chemically bonded treatment portion comprises at least one compound:
having a moiety reactive with a hydroxyl group on said cellulosic material and;
having a hydrophobic organofluorine moiety.
34 . The article of claim 33 ,
wherein said moiety reactive with a hydroxyl group comprises a residue of at least one monomeric unit selected from the group consisting of vinyl acetate, substituted vinyl acetate, C 1 -C 6 alkyl(meth)acrylate, substituted C 1 -C 6 alkyl(meth)acrylate, and combinations thereof.
35 . The article of claim 34 ,
wherein said hydrophobic organofluorine moiety comprises a residue of at least one monomeric unit selected from the group consisting of C 6 -C 16 perfluoroalkyl-containing monomer, and combinations thereof.
36 . The article of claim 1 ,
wherein the chemically bonded treatment portion comprises a bonded end and an extended end, wherein said extended end comprises at least one fluorine atom.
37 . The article of claim 1 ,
wherein the weight ratio of said hydrophobic particle treatment portion to said chemically bonded treatment portion is about 1:1 to about 1:50.
38 . The article of claim 1 ,
wherein said article has a water weight gain of at least 40%.
39 . The article of claim 1 ,
wherein the article has a horizontal wicking time of no more than about 8 seconds.
40 . The article of claim 1 ,
wherein the article has an improvement of at least about 20% in comfort zone, in total WRR, and dry time compared to an untreated article.
41 . The article of claim 1 ,
wherein said fabric is a woven fabric, a knit fabric, a non-woven fabric, or a combination thereof.
42 . The article of claim 1 ,
wherein the article is a garment.
43 . The article of claim 44 ,
wherein the garment is a shirt, an undergarment, or a sock.
44 . The article of claim 1 ,
wherein the article is a linen.
45 . The article of claim 1 ,
wherein the article is a drying article.
46 . The article of claim 45 ,
wherein the drying article is a towel.
47 . A process for producing an article, comprising:
providing a fabric;
wherein said fabric comprises at least about 45%, by weight, based on the total weight of the fabric, of at least one cellulosic material;
providing a hydrophobic particle treatment;
providing a chemical treatment;
wherein said chemical treatment comprises:
at least one hydrophilic polymer having a moiety reactive with a hydroxyl group on said cellulosic material;
at least one hydrophobic fluoropolymer; and
at least one optional catalyst;
treating said fabric with said hydrophobic particle treatment at a level of about 0.05% by weight of dried solids to about 2% by weight of dried solids, based on the total weight of the fabric, and said chemical treatment at a level of about 3% by weight to about 10% by weight, based on the total weight of the fabric, to form a treated fabric;
optionally, padding said treated fabric; and
optionally, curing said treated fabric.
48 . The process of claim 47 ,
wherein said hydrophobic particle treatment and said chemical treatment are uniformly distributed on or in said fabric.
49 . The process of claim 47 ,
wherein said hydrophobic particle treatment and said chemical treatment are distributed over a gradient in said fabric.
50 . The process of claim 47 ,
wherein said hydrophobic particle treatment and said chemical treatment are conducted simultaneously.
51 . A process of claim 47 ,
wherein said hydrophobic particle treatment and said chemical treatment are conducted sequentially.
52 . A process of claim 47 ,
wherein said fabric is treated by said hydrophobic particle treatment and then by said chemical treatment.
53 . A process of claim 47 ,
wherein said fabric is treated by said hydrophobic particle treatment after said chemical treatment.
54 . The product produced by the process of claim 47 .
55 . The product produced by the process of claim 47 ;
wherein said product is hydrophilic and fast-drying.
56 . A composition, comprising:
a. a plurality of hydrophobic particles;
b. at least one hydrophilic monomer or polymer having a moiety reactive with a hydroxyl group; and
c. at least one hydrophobic fluoropolymer or fluoromonomer.
57 . The composition of claim 56 , further comprising:
d. at least one catalyst.
58 . The composition of claim 57 ,
wherein said catalyst is magnesium chloride, potassium chloride, antimony salt, or a mixture thereof.
59 . The composition of claim 57 ,
wherein said plurality of hydrophobic particles comprises at least one material selected from the group consisting of polymer particles, metal particles, silica, and combinations thereof.
60 . The composition of claim 57 ,
wherein said plurality of hydrophobic particles comprise at least one polymer selected from the group consisting of fluoro-containing homopolymer, fluoro-containing copolymer, polyvinyl acetate, polyvinyl acetate/acrylic copolymer, and combinations thereof.
61 . The composition of claim 57 ,
wherein said plurality of hydrophobic particles are formed from polytetrafluoroethylene.
62 . The composition of claim 57 ,
wherein said plurality of hydrophobic particles are formed from one or more of polyvinyl acetate and a polyvinyl acetate/acrylic copolymer.
63 . The composition of claim 57 ,
wherein said plurality of hydrophobic particles are formed from a combination of at least two of polytetrafluoroethylene, polyvinyl acetate, and a polyvinyl acetate/acrylic copolymer.
64 . The composition of claim 57 ,
wherein said plurality of hydrophobic particles have an average diameter less than about 1 μm.
65 . The composition of claim 57 ,
wherein said plurality of hydrophobic particles have an average diameter less than about 500 nm.
66 . The composition of claim 57 ,
wherein said hydrophilic polymer or monomer having a moiety reactive with a hydroxyl group is present at a level of about 10% by weight to about 90% by weight, based on the total weight of said components b and c.
67 . The composition of claim 57 ,
wherein said hydrophilic polymer or monomer having a moiety reactive with a hydroxyl group is present at a level of about 40% by weight to about 70% by weight, based on the total weight of said components b and c.
68 . The composition of claim 57 ,
wherein said hydrophilic polymer or monomer having a moiety reactive with a hydroxyl group is present at a level of about 70% by weight to about 90% by weight, based on the total weight of said components b and c.
69 . The composition of claim 57 ,
wherein said hydrophobic fluoropolymer or fluoromonomer is present at a level of about 10% by weight to about 90% by weight, based on the total weight of said components b and c.
70 . The composition of claim 57 ,
wherein said hydrophobic fluoropolymer or fluoromonomer is present at a level of about 10% by weight to about 40% by weight, based on the total weight of said components b and c.
71 . The composition of claim 57 ,
wherein said hydrophobic fluoropolymer or fluoromonomer is present at a level of about 10% by weight to about 30% by weight, based on the total weight of said components b and c.
72 . The composition of claim 57 ,
wherein said hydrophilic polymer or monomer having a moiety reactive with a hydroxyl group is formed from monomers selected from the group consisting of vinyl acetate, substituted vinyl acetate, C 1 -C 6 alkyl(meth)acrylate, substituted C 1 -C 6 alkyl(meth)acrylate, and combinations thereof.
73 . The composition of claim 57 ,
wherein said hydrophobic fluoropolymer or fluoromonomer comprises residues of at least one C 6 -C 16 fluorine-containing monomer, or a linear or branched congener thereof.
74 . The composition of claim 57 ,
wherein said hydrophobic fluoropolymer or fluoromonomer comprises residues of at least one C 6 -C 16 perfluoroalkyl-containing monomer, or a linear or branched congener thereof.
75 . The composition of claim 74 ,
wherein said hydrophobic fluoropolymer or fluoromonomer further comprises residues selected from the group consisting of C 6 -C 16 perfluoroalkyl-containing vinyl alcohol, C 6 -C 16 perfluoroalkyl-containing (meth)acrylate, and combinations thereof.