Mechanisms of pilling formation and reduction by attrition methods

Abstract

In this study, the mechanisms of the fuzz and pilling formation were studied in order to develop an effective anti-pilling treatment. With the appreciation that the root of the pilling problem is the existence of a limited amount of pillable fuzz in the fabrics, physical treatments that include acceleration of fuzz generation and fuzz removal were proposed. Acceleration methods for fuzz generation, including tumbling, flat abrasion and brushing, have been investigated. Attrition methods, including the use of laser and lint shaver, have been also explored. The effects of the treatments were assessed by Random Tumble Pilling Tester and ICI Pilling Box. Based on these assessments, promising anti-pilling treatments were identified. The experimental results of knitted fabrics made from both conventional and Nu-Torque™ ring yarn indicate that the identified treatments could effectively increase the pilling resistance of worsted knitted fabrics by accelerating the fuzz generation and reducing the amount of potential pillable fuzz on the surface of the fabric. A wear trial on treated commercial sweaters also indicates that the treatment is also effective on finished garment. Assessment results show that the treatment does not affect colour, bursting strength and thermal insulation property of the fabric or garments. Based on the findings achieved, a prototype device was built to implement an efficient fuzz generation of fabrics. The working principle, operation parameters and evaluation of the treated sample are presented. It is a systematic study on the mechanisms and feasibility of effective anti-pilling treatments towards the commercial application.