Ecsaine

In 1970, after years of experimentation, a Toray Industries scientist succeeded in creating the world's first ultra-microfiber. A few months later, his colleague perfected a new process capable of transforming this invention into an amazing new fabric.

This fabric, which was later trademarked as Ecsaine®, winning a number of prestigious awards for technological excellence, combines the rich aesthetics of a suede surface with benefits no animal product could ever offer. Ecsaine is soft, supple and sensuous to the touch. Yet it's also resistant to stains and discoloration. It's even machine-washable or dry-cleanable.

How Is All This Possible?

The magic of Ecsaine begins with ultra-microfibers so fine they cannot be seen by the human eye, ultra-microfibers so microscopically minute a single pound of them could be stretched from the earth to the moon and back.

Transforming ultra-microfibers this fine into a practical fabric demands a complex, multiply patented process, part of which is summarized in the illustrations and chart shown here.


Ecsaine begins with polymer ultra-microfibers spun so light and fine, a strand measuring more than 50 miles long would weigh less than a gram.

These ultra-microfibers are extruded through protective spinnerets, creating what we call the "Islands in the Sea" configuration, with ultra-microfiber filaments "afloat" in each strand.

These strands are then transformed via a complex process that includes ironing, curling, cutting and needle-punching into a soft felt-like material which is then impregnated with a special adhesive binder.

Once the material is formed, the protective polymer coating is dissolved with a solvent and the material is further processed to create a fabric that is, almost paradoxically, as soft and supple as it is strong and durable. Magnified thousands of times, this cross-section reveals the densely complex yet mono-layer structure of Ecsaine.

The end result: Ecsaine, a richly complex non-woven fabric offering an unparalleled combination of luxury, appeal, performance and ease of care for an extraordinary array of applications.

Ecsaine: Science