PROTECTIVE WOVEN FABRIC

Abstract

A woven fabric having warp yarns and weft yarns, wherein said warp yarns and said weft yarns comprise a core and a sheath, said core comprising a first core component and a second core component, wherein the first core component has a breaking tenacity, measured with DIN EN ISO 2062, of at least 6 g/den, more preferably of at least 10 g/den, more preferably of at least 14 g/den, even more preferably of at least 20 g/den, wherein the second core component comprises elastomeric elements, and wherein elasticity of the fabric in warp direction is at least 20% (measured according to ASTM D3107) and elasticity of the fabric in weft direction is at least 20% (measured according to ASTM D3107).

Claims

1. A woven fabric having warp yarns and weft yarns, wherein said warp yarns and said weft yarns comprise a core and a sheath, said core comprising a first core component and a second core component, wherein the first core component has a breaking tenacity, measured with DIN EN ISO 2062, of at least 6 g/den, wherein the second core component comprises elastomeric elements, and wherein elasticity of the fabric in warp direction is at least 20% (measured according to ASTM D3107) and elasticity of the fabric in weft direction is at least 20% (measured according to ASTM D3107).

2. A woven fabric according to claim 1, wherein the material of the first core component is selected from UMWPE, aramid, liquid crystal polymers, polyamide, polyester, preferably UHMWPE.

3. A woven fabric according to claim 1, wherein said first core component and said second core component are connected together by intermingling, twisting or co-feeding, preferably co-feeding.

4. A woven fabric according to claim 1, wherein said sheath comprises staple fibers.

5. A woven fabric having according to claim 1, wherein the weave of the fabric is a single layer weave.

6. A woven fabric according to claim 1, wherein elasticity of the fabric in weft direction is at least 30%.

7. A woven fabric according to claim 1, wherein the elasticity in warp direction is comprised between 25% and 40%.

8. A woven fabric according to claim 1 wherein the warp yarns and/or the weft yarns have the following composition in weight: first core component is between 10% and 60% of the weight of the warp/weft yarn, the second core component is between 1.5% and 40% of the weight of the warp/weft yarn, the sheath between is between 40% and 88.5% of the weight of the warp/weft yarn.

9. A woven fabric according to claim 1, wherein count of the warp yarns and the weft yarns is comprised between NE 4 and NE 80.

10. A woven fabric according to claim 1, wherein count of the first core component is comprised between 30 den and 500 den.

11. A woven fabric according to claim 1, wherein count of the second core component is comprised between 20 and 500 den.

12. A woven fabric according to claim 1, wherein the warp density is between 15 and 70 warps/cm, and the weft density is between 15 and 50 wefts/cm.

13. A woven fabric according to claim 1, wherein warp tensile strength and weft tensile strength, measured with ASTM D5034, are greater than 50 Kg.

14. A woven fabric according to claim 1, wherein warp tear strength and weft tear strength, measured with ASTM D1424 are greater than 10000 g.

15. A garment, wherein at least a portion of the garment is made from the woven fabric according to claim 1.

16. A yarn comprising a core and a sheath, said core comprising a first core component and a second core component, wherein the first core component has a breaking tenacity of at least 6g/den, and wherein the second core component comprises elastomeric elements.

17. A yarn according to claim 16, having the following composition in weight: the first core component is between 10% and 60% of the weight of the yarn, the second core component is between 1.5% and 40% of the weight of the yarn, the sheath is between is between 40% and 88.5% of the weight of the yarn.

18. A yarn according to claim 16, having a count comprised between NE 4 and NE 80, wherein count of the first core component is comprised between 30 den and 500 den, wherein count of the second core component is comprised between 20 and 500 den.

19. A yarn according to any claims 16, wherein the elongation at break of the first core component is less than 10%.

20. A yarn according claim 16, wherein, wherein said first core component and said second core component are connected together by intermingling, twisting or co-feeding, preferably co-feeding.

21. A woven fabric having according to claim 5, wherein the weave of the fabric is selected from sateen, twill and canvas.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] FIG. 1 is a preferred weaving report for the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0044] The present invention relates to a woven fabric having warp yarns and weft yarns.

[0045] The warp and weft yarns have the same structure, i.e. a core comprising a first core component and a second core component, the core being covered by a sheath.

[0046] Typically the core does not comprise other components. Preferably, the core comprises a single first core component and a single second core component.

[0047] It is not however excluded that the core comprises more than one first and/or more than one second yarn.

[0048] The first core component provides high resistance to abrasion and is typically a low elastic component.

[0049] In more detail, the fist core component, when tested with ISO 2062 has a breaking tenacity equal to or greater than 6 g/den, more preferably equal to or greater than 10 g/den, even more preferably greater than or equal to 14 g/den. Most preferred embodiments have breaking tenacity greater than or equal to 20 g/den, e.g. between 20 g/den and 50 g/den.

[0050] Preferably, the first core component has low elasticity, and thus low stretchability. In particular, according to a preferred solution, when, tested with DIN EN ISO 2062, elongation at break of the first core component is less than 10%, more preferably less than 8%.

[0051] The first core component may be a single filament yarn, or a yarn comprising a plurality of filaments and/fibers. The first core component is typically a UHMWPE yarn.

[0052] As previously discussed, the count of the first core component is comprised between 30 den and 500 den, more preferably between 60 and 200 den, even more preferably between 75 and 150 den.

[0053] The second core component is preferably a single filament yarn, or a yarn comprising a plurality of filaments. Preferred elastomeric yarns are elastane yarns. Count of the second core component is comprised between 20 and 500 den, more preferably between 40 and 200 den, even more preferably between 70 and 105 den.

[0054] As known, e.g. from ASTM D4849, an elastomeric yarn is a non-textured yarn which can be stretched repeatedly at room temperature to at least twice its original length and which after removal of the tensile force will immediately and forcibly return to approximately its original length.

[0055] The two core components are combined via twisting, intermingling or co-feeding. The co-feeding technique, better discussed below, is the preferred solution.

[0056] Twisting is a known technique. Twisting is usually performed so that the two core components (i.e. the first core component and the second core component) so as to obtain 20-2500 twists/meter, preferably 100-1000, twists/meter, and most preferably 300-600 twist per meter.

[0057] Intermingling can be carried out according to the known techniques of the art, such as open or closed intermingling jets. The system is arranged to provide a number of connecting points that is within the range of 20 to 200 points per meter, preferably 50 to 120 points per meter and most preferably 95 to 105. The method of measuring the number of intermingling point is by direct count of the combined fibers; in the latter method, the elastic core “yarn” is put on a black or dark surface and is inspected by eye, possibly with a magnifying glass, and the connecting points in a meter of yarn are manually counted.

[0058] Another possible connecting technique is co-feeding, also known as co-extrusion. With co-feeding, the two core components are forced through a restriction where the two yarns are compressed together to such a degree that they remain attached also after exiting the restriction. A suitable restriction is e.g. a “V”-shaped roll; in a preferred embodiment, the two core components are fed to a roll having a V-shape, in particular, they are fed together and forced into the bottom of the “V” where they are compressed together and remain bound. The co-fed yarns are preferably spun with the fibers of the sheath immediately after the co-feeding step.

[0059] The core is covered with a sheath, typically a sheath of staple fibers, typically cotton fibers.

[0060] The final warp and weft yarns have thus a count that is preferably comprised between NE 4 and NE 80, more preferably between NE 8 and NE 60, even more preferably between NE 10 and NE 20.

[0061] The warp and weft are woven via a single layer weave, preferably chosen between a canvas weave, a sateen weave and a twill weave.

[0062] Warp density of the final fabric is preferably comprised between 15 and 70 warps/cm, more preferably 20 and 50 warps/cm, even more preferably between 25 and 35 warps/cm.

[0063] Weft density of the final fabric is preferably comprised between 15 and 50 wefts/cm, more preferably between 20 and 30 wefts/cm.

[0064] Elasticity of the fabric in warp direction and in weft direction is at least 20%, measured according to ASTM D3107.

[0065] Please note that, in ASTM D3107, a sample may be stretched by means of a weight of 3.0 lb or 4.0 lb. It has been proven that there are no significant differences in the test results if either a 3.0 lb or 4.0 lb weight is used. In the present disclosure, stretch according to ASTM D3107 was measured by means of a 3.0 lb weight.

[0066] As a standard procedure for ASTM D3107, load is applied for 30 minutes.

[0067] The woven fabric of the present invention is thus characterized in that it has an elasticity, i.e. it can be stretched, in warp direction of at least 20%, preferably between 30% and 40%, and in that elasticity in the weft direction is at least 20%, more preferably at least 30%, even more preferably, at least 35%.

[0068] According to a preferred embodiment, the fabric of the present invention is a woven stretch fabric, both in warp and weft direction, as e.g. discussed in ASTM D4850, according to which a stretch woven fabric is a woven fabric which is capable of at least 20% stretch in either warp or filling direction, or both, under forces and conditions encountered in use, and almost complete recovery after removal of the force.

[0069] Preferably, elasticity of the fabric in weft direction is higher than the elasticity of the fabric in warp direction. It is however possible that the two values are substantially identical, or that elasticity of the fabric in warp direction is higher than the elasticity of the fabric in weft direction

[0070] In view of the fact that the woven fabric of the present invention has high elasticity in both warp and weft direction, it can be defined as a “bi-stretch” woven fabric.

[0071] As used herein, “elasticity” values refer to the percentage of stretch in weft and in warp, measured according to ASTM D3107.

[0072] Another advantage of the bi-stretch fabric of the present invention is that, providing high elasticity in both warp and weft direction, an improvement of recovery, and a reduction of the growth, is obtained.

[0073] Test method EN 17092 provides five different classes of protective garments, according to their performance (from best to worst): AAA, AA, A, B and C. A protective fabric according to the present invention is at least an “A” fabric.

[0074] The invention will now be disclosed with reference to the following non-limiting examples.

EXAMPLES

[0075]

TABLE-US-00001 TABLE 1 warp warp weft weft 1.sup.st 2.sup.nd 1.sup.st 2.sup.nd warp core core weft core core warp weft count count count count count count density density (Ne) (den) (den) Ne (den) (den) (wrps/cm) (wfts/cm) Ex. 1 16/1 75 70 20/1 75 105 35.8 22 Ex. 2 10/1 150 70 10/1 150 70 25 18 Ex. 3 10/1 150 70 10/1 150 70 25 18

TABLE-US-00002 TABLE 2 warp weft warp weft tensile tensile warp tear weft tear elasticity elasticity strength strength strength strength % % (Kg) (Kg) (g) (g) Ex. 1 30 61.6 131 82 >13900 >13900 Ex. 2 29.6 42.4 152 147 >13900 >13900 Ex. 3 26.4 24 138 100 >13900 >13900

Example 1

[0076] In example 1, the fabric has the features as per table 1. The warp yarns are different from the weft yarns. The warp yarns are a NE 16/1 yarn, having a 75 den UHMWPE yarn as a first core components coupled via co-feeding process to a 70 den elastane yarn as the second core component. Before coupling with the first core component, the elastane has a 3.7 draft. Composition of the warp yarn, by weight, is thus 71.5% cotton, 22.5% UHMWPE, 6% elastane. Twist multiple of the final warp yarn is 3.40, while the number of twists per meter of the final yarn is 535.

[0077] In the weft yarns, the elastane yarn is coarser (105 den), but the sheath is finer, so that the final yarn is finer (count of 20 NE).

[0078] Composition of the weft yarn, by weight, is thus 60.5% cotton, 28.2% UHMWPE, 11.3% elastane

[0079] Twist multiple of the final weft yarn is 4.20, while the number of twists per meter of the final yarn is 828.

[0080] As known, Twist level (measured in twist per inch) =Twist Multiple*α√yarn count (measured in English Cotton Number), i.e. Twist=α√NE, wherein a is the twist multiple value.

[0081] The fabric has a twill 3/1 weave and, on the reed, has 20 warps/cm an 18.2 wefts/cm, while in the final fabric there are 35.8 warps /cm and 22 wefts/cm. Weight of the fabric is 12.2 oz.

[0082] The fabric was black overdyed, with black warp yarns and weft black yarns.

[0083] The fabric was tested with ASTM D3107 for elasticity, with ASTM D5034 for tensile strength, and with ASTM D1424 for tear strength. Results of the tests are as per table 2. Please note that testing machine for tear strength had a maximum weight applicable of 13900 grams (g). When tested at this maximum level, the fabric did not break, so tear strength is recited as greater than 13900 g.

Example 2

[0084] In example 2, the fabric has the features as per table 1. The warp yarns are identical to the weft yarns. The warp and weft yarns are NE 10/1 yarns, having a 150 den UHMWPE yarn as a first core components coupled via co-feeding process to a 70 den elastane yarn as the second core component. Before coupling with the first core component, the elastane has a 3.7 draft. Composition of the warp and weft yarns, by weight, is thus 68% cotton, 28.2% UHMWPE, 3.8% elastane.

[0085] Twist multiple of the final warp and weft yarns is 4.20, while the number of twists per meter of the final yarns is 523.

[0086] The fabric has a twill 3/1 weave and, on the reed, has 18 warps/cm an 14.2 wefts/cm, while in the final fabric there are 25 warps /cm and 18 wefts/cm. Weight of the fabric is 14.5 oz.

[0087] The warp yarns of the fabric were indigo dyed.

[0088] The fabric was tested with ASTM D3107 for elasticity, with ASTM D5034 for tensile strength, and with ASTM D1424 for tear strength. Results of the tests are as per table 2. Please note that testing machine for tear strength had a maximum weight applicable of 13900 grams (g). When tested at this maximum level, the fabric did not break, so tear strength is recited as greater than 13900 g.

[0089] When tested with EN 17092, this fabric was classified as an AAA fabric.

Example 3

[0090] Fabric of example 3 uses the same yarns and the same weave of example 2. The dying technique is however different. In particular the fabric was black overdyed, with black warp yarns and black weft yarns. Due to the different dyeing technique, values of elasticity, strength and fabric weight are different with respect to example 2, (weight being 13.3 oz).

[0091] A fabric according to the present invention tailored into a garment, in particular a protective fabric for motorcycle, as a protective pair of pants or a protective jacket.

[0092] At least a portion of the garment consist in the present fabric. In other words, for at least part of the fabric, the inner surface of the fabric coincides with the inner surface of the garment, as well as the outer surface of the fabric coincides with the outer surface of the fabric, such that no other layers of fabrics are superimposed to the fabric of the present invention for at least part of the garment. In other words, at least a portion of the garment is made of a single layer fabric according to the present invention.

[0093] When tested with EN 17092, this fabric was classified as an AAA fabric.