Fabric with Moisture Management Function

Abstract

It is described a knitted/woven fabric with moisture management function comprising a first fabric layer having a first yarn and a second yarn knitted together to form a first layer being semi-hydrophilic or hydrophobic (comprising of lower moisture regain fibers), a second fabric layer comprising a third yarn and a fourth yarn knitted together to form the second fabric layer, the second fabric layer being fully hydrophilic (comprising of higher moisture regain fibers), wherein the first fabric layer has a moisture regain lower than the moisture regain of the second fabric layer providing a hydrophilic gradient between the first fabric layer and the second fabric layer of the knitted fabric pushing moisture through the first fabric layer in contact with the wearer's skin and out through the second fabric layer.

Claims

1. A fabric with moisture management function comprising: a first fabric layer comprising a first yarn forming the first layer being semi-hydrophilic with a first moisture regain; and a second fabric layer comprising a second yarn forming the second fabric layer, the second fabric layer being hydrophilic with a second moisture regain, wherein the first moisture regain is lower than the second moisture regain providing a moisture regain gradient between the first fabric layer and the second fabric layer of the fabric pulling moisture through the first fabric layer and pushing it out through the second fabric layer.

2. The fabric of claim 1, wherein the fabric is a weft or warp knitted fabric or a woven fabric.

3. The fabric of claim 1, wherein the first moisture regain of the first fabric layer is in the range of 0.2%-6%, the second moisture regain of the second fabric layer is in the range of 4%-16% and the moisture regain gradient is greater than 3%.

4. The fabric of claim 3, wherein the moisture regain gradient is between 3% to 15%.

5. The fabric of claim 1, wherein at least one of the first yarn and the second yarn is a synthetic polymer.

6. The fabric of claim 1, wherein the first yarn is selected from a group of a nylon, a polyester, a polypropylene, an acrylic, cotton, wool, silk, regenerated cellulosic fibers or any blend combination thereof.

7. The fabric of claim 1, wherein the first fabric layer further comprises a third yarn joined together with the first yarn and the second fabric layer further comprises a fourth yarn joined together with the second yarn.

8. The fabric of claim 7, wherein the third yarn is an elastane.

9. The fabric of claim 7, wherein the first fabric layer is a composite blend of a synthetic polymer plaited with an elastane.

10. The fabric of claim 1, wherein the second yarn comprises a natural fiber, a regenerated cellulosic fiber or a blend of natural or regenerated cellulosic fibers with synthetic fibers.

11. The fabric of claim 10, wherein the synthetic fibers are nylon, a polyester, a polypropylene, an acrylic, or a combination thereof.

12. The fabric of claim 10, wherein the second yarn is selected from the group consisting of a cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose, cupro, artificial silk, nylon, a polyester, a polypropylene, an acrylic and any combination thereof.

13. The fabric of claim 7, wherein the fourth yarn is a synthetic polymer.

14. The fabric of claim 13, wherein the fourth yarn is an elastane.

15. The fabric of claim 7, wherein the second fabric layer is a composite blend of a natural fiber plaited with an elastane or a blend of natural fiber and synthetic fiber.

16. The fabric of claim 15, wherein the synthetic fiber is nylon, a polyester, a polypropylene, an acrylic, or a combination thereof.

17. The fabric of claim 1, wherein the second yarn is a synthetic polymer.

18. The fabric of claim 17, wherein the second yarn is selected from a group consisting of a nylon, a polyester, a polypropylene, an acrylic, a blend with cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose, cupro, and artificial silk, and a combination thereof.

19. The fabric of claim 1, wherein the second fabric layer is pitched to increase its surface area.

20. A fabric with moisture management function comprising: a first fabric layer comprising a first yarn forming the first layer being semi-hydrophilic with a first moisture regain; and a second fabric layer comprising a second yarn forming the second fabric layer, the second fabric layer being hydrophilic with a second moisture regain, wherein the first moisture regain is lower than the second moisture regain providing a moisture regain gradient between the first fabric layer and the second fabric layer of the fabric pulling moisture through the first fabric layer and pushing it out through the second fabric layer, wherein the fabric is knitted and further comprises a connecting yarn binding together the first fabric layer and the second fabric layer.

21. The fabric of claim 20, wherein the connecting yarn is at least a single strand.

22. The fabric of claim 20, wherein the connecting yarn is a synthetic polymer.

23. The fabric of claim 20, wherein the connecting yarn is an elastane.

24. The fabric of claim 20, wherein the connecting yarn is a natural fiber.

25. The fabric of claim 20, wherein the connecting yarn is a zig-zag structure between the first fabric layer and the second fabric layer.

26. The fabric of claim 1, wherein the fabric is knitted from a single jersey plaited construction, a double jersey plaited construction, a tricot or warp knit construction.

27. The fabric of claim 7, wherein at least one of the first yarn, the second yarn, the third yarn and the fourth yarn is produced by compact spinning.

28. The fabric of claim 1, wherein the first fabric layer and the second fabric layer are woven with a number of yarn cross overs desired.

29. The fabric of claim 28, wherein the yarn cross over is of 3 up and 3 down, 3 up and one down, 3 up and 2 down, or 4 up and 1 down.

30. An article of apparel comprising a fabric with moisture management function, the fabric comprising: a first fabric layer comprising a first yarn forming the first layer being semi-hydrophilic with a first moisture regain; and a second fabric layer comprising a second yarn forming the second fabric layer, the second fabric layer being hydrophilic with a second moisture regain, wherein the first moisture regain is lower than the second moisture regain providing a moisture regain gradient between the first fabric layer and the second fabric layer of the fabric pulling moisture through the first fabric layer and pushing it out through the second fabric layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Reference will now be made to the accompanying drawings.

[0036] FIG. 1 illustrates a schematic representation of a double jersey plaited construction fabric as encompassed herein in accordance to an embodiment.

[0037] FIG. 2 illustrates a schematic representation of a single jersey plaited construction fabric in accordance to another embodiment.

[0038] FIG. 3 illustrates a compact spinning technique used for the fabrication of the yarns as encompassed herein.

[0039] FIG. 4A illustrates the outer layer a fabric in accordance to an embodiment.

[0040] FIG. 4B illustrates the inner layer of the fabric shown in FIG. 4A in accordance to an embodiment.

[0041] FIG. 5 illustrates a schematic representation of a double woven construction fabric as encompassed herein in accordance to an embodiment.

[0042] FIG. 6 illustrates a schematic representation of a plaited tricot (warp) knitted construction fabric as encompassed herein in accordance to an embodiment.

DETAILED DESCRIPTION

[0043] In accordance with the present disclosure, it is provided a knitted or woven fabric with moisture management function comprising a first fabric layer comprising a first yarn and forming a next to skin back fabric layer, the first fabric layer having a first moisture regain and being a semi-hydrophilic or hydrophobic layer and a second fabric layer comprising a second yarn forming a face fabric layer facing towards outside, the second fabric layer having a second moisture regain and being a hydrophilic layer. In case of a knitted fabric, it can further comprise a connecting yarn binding together the first fabric layer and the second fabric layer.

[0044] As described herein, the moisture from a wearer's skin is pushed through the first fabric layer and pulled out through the second fabric layer due to the presence of a moisture regain gradient between the first fabric layer and the second fabric layer of the knitted fabric.

[0045] In an embodiment, the moisture regain of the first fabric layer is in the range of 0.2%-6% while the moisture regain of the second fabric layer is in a range of 4%-16% and the moisture regain gradient between the two fabric layers is greater than 3%. For example, the moisture regain gradient between the two fabric layers is greater than 3%, such as e.g. between 3%-15%.

[0046] As seen in FIG. 1, the fabric 10 comprises a first layer 12 which is the layer next to the skin A (inner layer) and a second layer 14 which correspond to the layer of the fabric 10 facing the exterior B (outer layer) and away from the skin A. As illustrated in FIG. 1, in an embodiment, a connecting yarn 16 binds together the first fabric layer 12 and the second fabric layer 14 tightening the fabric 10 together. The moisture from a wearer's skin is pushed through the first fabric layer 12 towards the second fabric layer 14. The presence of a hydrophilic (moisture regain) gradient between the first fabric layer 12, being a semi-hydrophilic layer, and the second fabric layer 14, representing a hydrophilic layer, of the fabric 10 allows the moisture to be pushed as indicated from the direction of the arrow between region A of the skin towards exterior region B.

[0047] The first fabric layer 12 in an embodiment comprises a first yarn 18 and the second fabric layer 14 comprises a second yarn 23. In the illustrated embodiment of FIG. 1, the first fabric layer 12 further comprises a third yarn 20 knitted or woven together to form the next to skin A inner fabric layer 12, the first fabric layer 12 being a semi-hydrophilic or hydrophobic layer as mentioned. It is encompassed that the first yarn 18 and the third yarn 20 are a synthetic polymer, such as for example but not limited to, a polyester, a polypropylene, an acrylic, a polyacrylic or any combination thereof. As illustrated herein, the third yarn 20 is an elastane, resulting in a first fabric layer 12 being a composite blend of a synthetic polymer plaited with an elastane. In one embodiment, the first yarn 18 can be a composite of synthetic polymer and natural fiber such as for example, cotton, wool, silk or regenerated cellulosic fibers and can be configured as semi-hydrophilic with a first moisture regain. For example the first yarn 18 can be a blend of 70-95% synthetic polymer (e.g., polyester) and 5-30% natural fibers (e.g., cotton).

[0048] The second fabric layer 14 further comprises a fourth yarn 24 knitted or woven together to form a face (outer) fabric layer 14 facing towards outside B, the second fabric layer 14 being a hydrophilic layer. As encompassed, the second yarn 23 comprises a natural fiber, such as for example and not limited to, a cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose or a combination thereof. The second yarn 23 can alternatively be a composite blend of a modal and a cotton. Alternatively, the second yarn can also be a synthetic polymer such as for example a nylon, a polyester, a polypropylene, an acrylic, a polyacrylic or a combination thereof. The fourth yarn 24 can be a synthetic polymer, such as elastane. As a further embodiment, it is encompassed a second fabric layer 14 comprising a composite blend of a natural fiber plaited with an elastane. In one embodiment, the second yarn 23 is a composite blend of natural or regenerated cellulosic fiber and synthetic fiber such as nylon, a polyester, a polypropylene, an acrylic. One means to increase the hydrophilic nature of the second layer 14 is to increase its surface area. Accordingly, it is encompassed that the second fabric layer 14 can be pitched to increase its surface area.

[0049] The connecting yarn 16 binding together the first fabric layer 12 and the second fabric layer 14 is at least a single strand. As encompassed herein, the connecting yarn 16 is an elastane. It is also encompassed that the connecting yarn 16 is a synthetic polymer such as for example a nylon, a polyester, a polypropylene, an acrylic, a polyacrylic or a combination thereof. Alternatively, the connecting yarn 16 as described herein can comprise preferably a natural fiber such as for example a cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose or a combination thereof. The connecting yarn is preferably a zig-zag structure (an overlap) between the first fabric layer 12 and the second fabric layer 14. It is encompassed that the zig-zag structure consist of a lapping back and forth between first and second layer fabrics in order to connect them (FIG. 6). The connecting yarn 16 can be single strand or multiple strands. Each strand of the plurality of strands of the connecting yarn 16 can have independent zig-zag (underlap and overlap) structure.

[0050] It is thus described a fabric construction comprising an hydrophilic side and a semi hydrophilic or hydrophobic side allowing maximum moisture control. The fabric describe herein has the characteristic to push the moisture by a hydrophilic gradient using semi-hydrophilic and fully-hydrophilic layers next to each other. The combination of potentially 4 different types of fibers and the semi-hydrophilic or hydrophobic and fully-hydrophilic surfaces next to each other allows for efficient moisture management and quick drying.

[0051] As described herein, in some embodiments, the described fabric is made with a knitting construction which can be a weft knitted or wrap knitted structure. For example, the fabric can be a single jersey plaited construction (see FIG. 2) or a double jersey plaited construction for example (see FIG. 1) or Tricot warp knit plaited structure. As illustrated in FIG. 2, the fabric 100 has a single jersey plaited construction with a first layer 112 that comprises a first yarn 118 having the first moisture regain and a second layer 114 that comprises a second yarn 123 with the second moisture regain. The first moisture regain is lower than the second moisture regain providing a hydrophilic gradient between the first fabric layer 112 and the second fabric layer 114 of the fabric 100 thus pushing the moisture through the first fabric layer 112 and out through the second fabric layer 114. The fabric 100 further comprising a plaited yarn 125. The plaited yarn 125 can be elastane to increase the elasticity of the fabric 100.

[0052] In an embodiment, the moisture regain of the first fabric layer is in the range of 0.2%-6% and the moisture regain of the second fabric layer is in the range of 4%-16% and the moisture regain gradient between the two fabric layers is greater than 3%.

[0053] In an embodiment, at least one of the first, second, third or fourth yarn are fabricated using a compact spinning technique to spin the cotton/micromodal yarn for example that helps reducing pilling and better handfeel.

[0054] As seen in FIG. 3, in traditional spinning machines, such as ring spinner 31, the fiber stream is twisted without first being brought close together by compressing it (compacting) and the resulting yarn may pill or feel rough due to the broad twisting triangle 32 formed before the fibers are twisted. Compact spinning 30 involves narrowing and decreasing the width of the band of fibers (b.sub.comp) so that it is much narrower than the width of the fibers band (b.sub.ring) in the ring spinning 31 (see FIG. 3). Such compacted fibers band is then twisted into a yarn, and the x twisting triangle is eliminated. Compacting the fiber stream first causes the fiber stream in the form of the flat band of fibers to be condensed into a compact fiber stream with increased frictional contact points between the fibers. Compact spinning allows to produce compact yarns. Thus, compact spinning is a process where fiber strand drawn by drafting system is condensed before twisting it.

[0055] In some embodiment, at least one of the first, second, third or fourth yarn are fabricated using a ring spinning technique, such as Sirospun™, core spun, compact spun where one yarn can be a natural fiber and the other yarn can be a synthetic fiber. Any other spinning technique (e.g. air jet spinning, ring spinning, mule spinning) can be used without departing from the scope of the invention.

[0056] FIG. 4 provides a picture of a fabric comprising 26% cotton and 26% modal forming the outer layer with higher moisture regain fibers in A), and 25% elastane and 23% nylon forming an inner layer with lower moisture regain allowing and moisture management as described herein.

[0057] FIG. 5 illustrates an example of fabric construction that is double weave 150. The first 152 and the second layers 154 are woven in order to keep one fabric to one side in a way that the number of yarn cross overs is reduced. For example, in the illustrated example of fabric construction in FIG. 5, the cross over is 3 up C and 3 down D but it can be a sequence of 3 up and one down, 3 up and 2 down, or 4 up and 1 down etc.

[0058] As encompassed herein, the knitted fabric described herein with moisture management can be any type of articles of apparel including shirts, headwear, coats, jackets, pants, underwear, gloves, socks, and footwear.

[0059] While the disclosure has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations including such departures from the present disclosure as come within known or customary practice within the art and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims.