The present invention relates to a flocked fabric that retains characteristics typically attributed to fabrics used in upholstery and yet is suitable for outdoor use as a worn garment or as a luggable such as a knapsack or pouch.

The present invention relates to a flocked fabric having a substrate, adhesive and flock adhered to the substrate with the adhesive. A waterproof film may be arranged so that the substrate is between the adhesive and the film, such as through direct application of the film to the substrate or to a lining adjacent the substrate.

The substrate is in a stabilized condition and the adhesive is in a dried and cured condition. As laid-down, the flock fibers have an embedding portion within the adhesive, a protruding portion protruding out of the adhesive, and a bent portion between the embedding and protruding portions. The protruding portion is in a flattened and laid down condition to provide a substantially flat surface and arranged to lie on at least one of the adhesive and neighboring ones of the flock fibers. The bent portion is located where the flock emerges from the adhesive and the angular change in direction of orientation of the flock fibers is greater at the bent portion than at either the embedding or protruding portions. The stabilized condition is such that the substrate is prevented during flexing from stretching by an extent that would cause the adhesive to break apart.

The fabric is suitable for the manufacture of garments worn outdoors, such as sportswear, rainwear and hunter's outerwear, as well as for the manufacture of knapsacks. The substrate, or a combination of the substrate and film, may be stabilized, which means it is sufficiently resistant to stretching that the adhesive will not break apart. Indeed, the film, if applied appropriately to the substrate such as through lamination, may provide the needed stabilization for the adhesive.

For a better understanding of the present invention, reference is made to the following description and accompanying drawings, while the scope of the invention is set forth in the appended claims.

FIGS. 1 and 2 are schematic cross-sections of the flocked fabric in accordance with the respective embodiments of the present invention.

FIG. 3 is an elevational schematic view of the flocked fabric being subjected to a dry ink transfer process in accordance with the present invention.

FIG. 4 is a schematic view of laid down flock being brushed to stand upright.

FIG. 5 is a schematic cross-section of the flocked fabric as in FIG. 2, except showing a lining between the substrate and the film.

FIG. 6 is a schematic cross-section of the flocked fabric of Fig. 1, but showing additional layers.

FIG. 1 shows the fabric in accordance with the invention being in the form of a woven substrate 2 to which is adhered flock 5 by an acrylic, polyurethane, latex or other type of adhesive 4. The flattened flock 5 is thermally set into a laid down and substantially flattened and, if the fiber length is long enough, entangled state. The transfer printing process leaves a layer of colored dry ink print 6 on the flattened flock 5. The substrate 2 is preferably made of a polycotton blend, woven polyester, woven polypropylene material or nylon. A pre-coat adhesive 21 may be applied and dried to fill interstices of the substrate. Thereafter, the adhesive 4 is applied and then flock is adhered to the substrate with the adhesive 4. Otherwise, the pre-coat adhesive may be dispensed with by applying just the adhesive 4 in a one pass application.

The woven polyester and woven polypropylene are examples of suitable materials for the substrate 2 because they are hydrophobic, i.e., they do not appreciably absorb moisture and are well suited for lamination with waterproof breathable films, such as those manufactured by Gortex™ or Dry-Plus™ or Vapex™. With such materials forming the fabric, moisture will not be retained on the inside of the fabric. Fig 2 schematically illustrates a waterproof film 8 applied to the substrate 2. The film 8 may be breathable or non-breathable.

FIG. 3 illustrates a dry ink transfer process used to flatten the flock fibers and transfer dry ink onto the flock. A pattern or solid color 10 is printed onto special print paper 11. The print paper 11 and flocked fabric 12 are fed together between rollers 13, 14 in a conventional screen transfer printing machine, such as that of Stork under model numbers TC 101 and TC 131 or of Kannegieser of Germany. At least one of the rollers is heated at a temperature of approximately 400 degrees Fahrenheit and elevated pressure is applied by the rollers against the fabric and sheet for approximately 30 seconds to enable the transference of the dry ink of a multicolored print pattern or solid color 10 onto the flock. As a result, the memory of the flock fibers changes so that they no longer have a tendency to return to the erect condition but instead return to a flattened and laid down condition. Instead of rollers, any type of pressure elements, such as pressure plates, could be used or even a vacuum.

While substantially flat, the flock fibers may not be perfectly flat but inclined because their free ends rest on neighboring flock or adhesive. The flock, which has an end fixed in the adhesive, may bend to reach its laid down condition. This may involve causing the flock to lie on adjacent flock or adhesive to provide the flat surface.

The preferred embodiment of the invention employs fiber (preferably 0.08 to 3 denier nylon or rayon or polyester fiber or polypropylene), which is adhered to a substrate that is a polycotton blend or a hydrophobic such as 100 percent polyester with an acrylic based and/or polyurethane adhesive (two coats) and/or blends of such adhesives.

Fine flock (1 to 2 denier) with short fiber length (0.025 to 0.05 inches) provide a flatter surface when flattened than coarser flock (3 denier and up) with longer fiber lengths so that a transferred print looks more distortion-free on the flattened surface.

The greater the density and meshing of the flock fibers flattened into a laid down condition, the more water resistant the fabric may be expected to be, because the laid down fibers act as a barrier against water penetration. For this reason, the preferred fiber denier is 0.08 to 3 to provide the desired density.

As shown in Fig. 4, after the flocked woven fabric has been transfer printed, the flock may be brushed in a conventional manner with a brush 20 so that the flock stands up 5A rather than remains in a laid down or flattened state 5B. Brushing will change the feel and the look of the fabric to some extent, but it will still have the benefit of having been transfer printed upon so that vivid colors in the print will still be apparent.

As shown in Fig. 5, the coating or film 8 of Fig. 2 need not be applied directly to the substrate 2 where the substrate itself is sufficiently stabilized for the adhesive 4. If desired, the film 8 may be applied instead to a conventional lining 7, which in turn is arranged next to the substrate or perhaps separated from the substrate by an air space 9. Where the film 8 is applied to the lining 7, it need not be applied on the substrate 2. The film 8 may be breathable or non-breathable and may be applied by spraying or using other conventional applying techniques to secure the film to the substrate 2 or lining 7 as desired. Some examples of films that may be laminated onto the back of the substrate or lining include vinyl, polyurethane, rubber and a space fabric.

Fig. 6 shows a Teflon™ coating 20 added as a water repellent finish to provide enhanced water resistance, preferably by immersing the fabric into the Teflon™ coating. Such a coating may be applied to any of the other embodiments in the same manner. For purposes of this application, films, coatings and laminations are used interchangeably and construed as being the same or equivalents and may be referred collectively as a waterproof layer where their purpose is to block the penetration of water.

The present invention envisions the use of woven fabrics and stabilized knitted fabrics, both of which may hereafter be referred to as stabilized fabrics. As such, they avoid stretching the adhesive by such an extent that would cause the adhesive to break apart or fall apart which could lead to flock fall out.

To the extent that adhesives are commercially available that retain their integrity and do not fall apart when the underlying substrate is flexed, i.e., the adhesive may have some level of inherent give and take to allow it to flex with the substrate, such a substrate is to be treated as a stabilized substrate within the meaning of the invention although the adhesive is primarily responsible for the stabilization of the fabric.

The invention also encompasses a knitted circular knit or fleece on one side and flock on the other side with a film in the middle. The film provides sufficient stability to permit flocking into the film itself.

In accordance with an embodiment of the invention, the fabric has a stabilized substrate; a cured adhesive on the substrate; and a plurality of flock fibers protruding from said adhesive, each having an embedded portion within the adhesive; characterised in that the plurality of flock fibers have a protruding portion in a laid down condition on at least one of said adhesive and neighboring flock fibers, and a bent portion between said embedded and protruding portions, the fabric further characterised by: (a) a level of abrasion resistance sufficient to resist abrading into pieces from commercially acceptable machine washing that softens the fabric; (b) a level of water penetration resistance sufficient to block water from penetrating through to the substrate to saturate the same; (c) a level of water penetration resistance sufficient to withstand water penetration by a column of water that is over twice a height of that to which the fabric may withstand penetration of water with the flock fibers in a erect condition prior to being put into the laid down condition; and (d) a level of drape that is higher with the flock fibers being laid down than with the flock fibers standing in an erect condition prior to being laid down. The flocked fabric in accordance with the invention may then be cut in accordance with a fabric pattern and then folded and stitched into a luggable. A luggable is a knapsack, fanny sack, pouch, back pack or the like that is carried by the wearer and accommodates storage of consumer goods.

While the foregoing description and drawings represent the preferred embodiments of the present invention, it will be understood that various changes and modifications may be made without departing from the spirit and scope of the present invention.