Abstract: The present invention provides systems and methods for the incorporation of glitter particulates in flocked pile fabrics, as well as fabrics manufactured using the same. The fabrics produced according to the invention comprise flocking and glitter particulates at the exposed surface of the adhesive used to attach the flocking and glitter particulates to the fabric. By adhering the glitter particulates to the exposed surface of the adhesive layer—rather than admixing the glitter particulates with the adhesive—the decorative effect is maintained while reducing the amount of glitter particulates used in the manufacturing process. In addition, the process does not require the passage of glitter particulates through an adhesive deposition tool, thereby eliminating shape and size restrictions imposed by the use of such tools.

Abstract: Air embossing systems, air lances, and methods of air embossing fabrics produce an unprecedented level of fine detail, crisp transition between unembossed and embossed regions, and a high degree of uniformity across the width of an embossed fabric. The air embossing systems can utilize air lances for directing a stream of air onto the embossable surface of a fabric that have at least one nozzle having a characteristic orifice dimension substantially less than that of conventional air lance nozzles, and also substantially less than a characteristic length of the nozzle. Air lances can also include one or more nozzles in the shape of an elongated slit oriented so as to be positioned across essentially the entire width of a fabric being embossed.

Abstract: The present invention is directed to unique flocked pile fabrics and methods for producing such fabrics. The fabrics provided according to one embodiment of the invention include an embossed pattern, characterized by a plurality of elongated depressions in the surface of the pile fabric, and a superimposed printed pattern, characterized by a scene or illustration including a plurality of visual features having elongated shapes. The inventive embossed, printed pile fabrics, having a superimposed embossed and printed pattern, advantageously superimpose the embossed pattern and the printed pattern upon the pile fabric so that the embossed pattern imparts a three-dimensional texture to the scene or illustration or pattern comprising the printed pattern. The texture provided by the embossed pattern can impart a visual effect to the scene or illustration which can render it more realistic than a similar scene or illustration printed upon a conventional unembossed pile fabric.

Abstract: Improved air embossing systems, improved air lances, and improved methods of air embossing fabrics, which are able to produce an unprecedented level of fine detail, crisp transition between unembossed and embossed regions, lack of undesired embossing artifacts, and a high degree of uniformity across the width of an embossed fabric, when compared to the performance of typical, conventional air embossing systems are disclosed. The disclosed air embossing systems utilize generally cylindrical, rotating stencils with air lances positioned therein for directing a stream of air through apertures in the stencil and onto the embossable surface of a fabric.

Abstract: The present invention discloses improved air embossing systems, improved air lances, and improved methods of air embossing fabrics, which are able to produce an unprecedented level of fine detail, crisp transition between unembossed and embossed regions, and a high degree of uniformity across the width of an embossed fabric, when compared to the performance of typical, conventional air embossing systems. The air embossing systems provided by the invention can utilize air lances for directing a stream of air onto the embossable surface of a fabric that have at least one nozzle having a characteristic orifice dimension substantially less than that of conventional air lance nozzles. The disclosed air embossing systems can also include air lances having nozzles positioned in close proximity to the embossable surface of a fabric being embossed, substantially closer than is typical for air lances employed in conventional air embossing systems.

Abstract: Air embossing systems, air lances and methods of air embossing fabrics produce fine detail, crisp transition between unembossed and embossed regions, and a high degree of uniformity across the width of an embossed fabric. The air embossing systems utilize air lances (210) for directing a stream of air onto the embossable surface (113) of a fabric (111) that have at least one nozzle (216) having an orifice dimension substantially less than that of conventional nozzles.

Abstract: An embossed pile fabric having a foreground and background with the foreground having a depth in the order of 1.5/2.0 to 100 times that of the background. The foreground can be formed by an engraving roll having portions that are either mill engraved or acid etched, and the background is formed by the engraving roll having portions formed with a router engraved technique.

Abstract: A printed multicolor synthetic pile fabric having a substrate and pile formed of fibers of substantially uniform length and diameter with the fibers arranged in random groups extending uniformly across the entire width and along the entire length of the fabric. Each group comprises a random number of fibers extending at an angle and in a direction that randomly varies from the angles and directions of the fibers in adjacent groups. The fibers within each group are preferably set in the greige goods.

Abstract: Methods of forming a printed multicolor synthetic pile fabric having a substrate and pile formed of fibers arranged in random groups extending essentially unifomn-y across the entire width and along the entire length of the fabric are disclosed. The methods can be utilized to form fabrics wherein each of the above-mentioned groups comprises a random number of fibers extending at angles and in directions that randomly vary from the angles and directions of the fibers in adjacent groups. The methods can involve washing griege goods for selected times and at selected temperatures so as to randomly re-orient the fibers forming the flocked surface of the fabric. In preferred embodiments, the fabrics are printed after fiber re-orientation.

Abstract: A transfer printed, flocked fabric includes a textile substrate, raised nylon fibers on the substrate, a black-pigmented adhesive adhering the nylon fibers to the substrate and disperse dye distributed in a pattern in upper portions of the nylon fibers and the upper portions of the nylon fibers being colored only by disperse dye, thereby forming a deep, dark, crock-fast, colored print.

Abstract: An embossing roll for embossing pile fabric having foreground portions that are either mill engraved or acid etched, and background portions formed with a router engraved technique. The foreground portions of the embossing roll have a depth in the order of 1.5/2.0 to 100 times that of the background portions.

Abstract: A simulated Jacquard fabric and method of fabrication. A flocked fabric is screen printed with specially engraved screens for each color of the design. Thereafter a blotch screen is used to overprint with dyes at a certain pressure that causes the formation of simulated binding or fine lines to simulate a Jacquard fabric.

Abstract: A pattern is impressed on flocked fabric by applying a patterned cylinder to the flocked surface before the adhesive that retains the flocking has cured. The projections on the cylinder surface tilt the flock fibers contacted by them to a new orientation, thereby forming the pattern in the flocked surface. Subsequent curing of the adhesive preserves the pattern.

Abstract: An AC electrostatic flocking method having a variable frequency alternating electrostatic field that optimizes flocked product characteristics and/or processing efficiency. The optimized frequency can be determined on-line or from a chart or computerized database containing pre-determined optimized frequencies. The optimized frequency varies depending upon the precursors used and the processing conditions and parameters. Multiple in-line flocking modules having alternating variable frequency electrostatic fields operating at different frequencies may be utilized.

Abstract: The present invention relates to a method for producing a mixed flock fabric of different filaments in which highly curled filaments are straightened, sized, cut into a length of 0.1 to 0.4 inch and electrostatically flocked with non-sized fibres onto a substrate, so that when the size is removed, there is formed a mixed flock fabric having mixed, stiffened and individual fibres.

Abstract: Method and apparatus for making a splinter-flocked fabric from a multifilament tow. The tow is formed into a wide, flat ribbon, the tow is impregnated with a size liquid in order to adhere the filaments to each other, and the tow is cut into flock fibre lengths while in the form of a wide, flat ribbon, thus producing flock fibre bands. The bands are broken up into a multiplicity of splinters of controlled denier, the splinters are electrostatically flocked on a substrate, and the size is then removed as by washing with warm water, to produce a splinter-flocked fabric.

Abstract: A pattern is printed with adhesive as a design on certain selected areas of a shrinkable substrate and the adhesive is dried. Flock is preferably applied to the selected design prior to drying. Supplemental adhesive is then applied to other areas ("background" areas) of the substrate, and is dried. Preferably such supplemental adhesive is applied over the surface of the entire substrate and over the adhering flock that has already been applied, and the entire substrate plus existing flock is covered with additional flock, followed by drying of the adhesive.The entire substrate thus prepared is then subjected to shrinkage, causing differential shrinkage of the design areas and the background areas, and producing a fabric having a novel three-dimensional pattern or design.The fabric product preferably has a plurality of upstanding flock fibres and the substrate is shrunken more tightly in some areas than in others.

Abstract: A continuous in-line flock cutting process is disclosed, for making flock from tow which contains a lubricant which is detrimental to the flock and must be removed.The tow is continuously fed, heat treated and immersed in an aqueous scouring liquid, and is continuously wet-processed. The excess scouring liquid is squeezed out, the tow is rinsed with water, rinse water is squeezed out, and a finish is applied to the tow and partially squeezed out in an in-line continuous process to remove a portion of the applied finish. Thus processed, the still-wet tow is continuously cut into wet flock, the wet flock is then dried and beaten to open up and separate the individual flock particles, and screened.

Abstract: A synthetic suede is disclosed comprising a flexible backing having a multiplicity of upstanding flock fibers adhered to the base, and a fatty acid radical cationic softener substantially uniformly distributed over at least portions of the fibers at or near their ends. Typical cationic softeners include the fatty acid quaternary ammonium softeners.