Multi-component combination yarn system for moisture management in textiles and system for producing same

Abstract

The invention provides a thermal control combination yarn system including a first plurality of the yarns within the system including microdenier or almost microdenier hydrophobic yarns, such as, for example, polypropylene (PP) and a second plurality of the yarns including less hydrophobic ultra microfibers (UMF), wherein the first plurality of yarns is in direct contact with the second plurality of yarns. The yarn system can include from 97% yarns made of a microdenier or almost microdenier hydrophobic material and 3% yarns made of a less hydrophobic ultra microfibers (UMF) material to 97% yarns made of the less hydrophobic ultra microfibers material and 3% yarns made of a microdenier or almost microdenier hydrophobic material.

Claims

1. A garment comprising a knit fabric comprising a thermal control combination yarn system comprising: a first plurality of microdenier hydrophobic yarns consisting of polypropylene (PP) and having approximately 1 filament per denier, wherein a first surface of the garment consists essentially of the first plurality of yarns, which are configured to wick moisture, comprising liquid water, from the first surface; and a second plurality of yarns comprising hydrophobic ultra microfibers (UMF), which are relatively less hydrophobic than the microdenier yarns, wherein the UMF are made of sub filaments which are formed from split co-extruded filament fibers consisting of a combination of nylon and polyester and having approximately 1 filament per denier, wherein upon splitting, there are between 10 and 50 sub filaments per co-extruded filament fiber and micro-cracks have been created, wherein a second surface of the garment consists essentially of the second plurality of yarns, which are configured to disperse moisture wicked by the first plurality of yarns, wherein the first plurality of yarns is in direct contact with the second plurality of yarns, and wherein the first plurality of yarns and the second plurality of yarns are present in the system in a proportion of from 70 to 90% of the first plurality of yarns to from 10 to 30% of the second plurality of yarns, based on total yarns in the system.

2. The garment according to claim 1 for active sportswear use having enhanced cooling and thermal transition properties wherein the first surface of the garment is configured to come in contact with the skin of the wearer thereof and to wick moisture from the surface of the skin thereof, and the second surface of the garment is configured to disperse moisture wicked by the first plurality of yarns and facilitate the evaporation thereof.

3. The garment according to claim 1 having enhanced insulating and thermal transition properties wherein the second surface of the garment is configured to come in contact with the skin of the wearer thereof to spread body moisture near the skin and help create an insulating layer, and the first surface of the garment is configured to trap the insulating moisture along a surface of the second plurality of yarns.

4. The garment of claim 1, wherein the UMF of the second plurality of yarns have about 10 filaments per denier.

5. The garment of claim 1, wherein the first plurality of yarns and the second plurality of yarns have the same denier, and wherein the denier of the first plurality of yarns and the second plurality of yarns is between 15 and 400.

6. The garment of claim 1, wherein the first plurality of yarns and the second plurality of yarns are present in the system in a proportion of about 76% of the first plurality of yarns and about 24% of the second plurality of yarns, based on total yarns in the system.

7. The garment of claim 1, wherein the knit fabric is knit in a jersey configuration.

8. A garment comprising a knit fabric comprising a thermal control combination yarn system comprising: a first plurality of microdenier hydrophobic yarns consisting of polypropylene (PP) and having approximately 1 filament per denier, wherein a first surface of the garment consists essentially of the first plurality of yarns, which are configured to wick moisture, comprising liquid water, from the first surface; and a second plurality of yarns comprising hydrophobic ultra microfibers (UMF), which are relatively less hydrophobic than the microdenier yarns, wherein the UMF are made of sub filaments which are formed from split co-extruded filament fibers consisting of a combination of nylon and polyester and having approximately 1 filament per denier, wherein upon splitting, there are between 10 and 50 sub filaments per co-extruded filament fiber and micro-cracks have been created, wherein a second surface of the garment consists essentially of the second plurality of yarns, which are configured to disperse moisture wicked by the first plurality of yarns, wherein the first plurality of yarns is in direct contact with the second plurality of yarns, and wherein the first plurality of yarns and the second plurality of yarns are present in the system in a proportion of from 70 to 90% of the first plurality of yarns to from 10 to 30% of the second plurality of yarns, based on total yarns in the system, and wherein the knit fabric is knit in a jersey configuration.

9. The garment according to claim 8 for active sportswear use having enhanced cooling and thermal transition properties wherein, the first surface of the garment is configured to come in contact with the skin of the wearer thereof and to wick moisture from the surface of the skin thereof, and the second surface of the garment is configured to disperse moisture wicked by the first plurality of yarns and facilitate the evaporation thereof.

10. The garment according to claim 8 having enhanced insulating and thermal transition properties, wherein the second surface of the garment is configured to come in contact with the skin of the wearer thereof to spread body moisture near the skin and help create an insulating layer, and the first surface of the garment is configured to trap the insulating moisture along a surface of the second plurality of yarns.

11. The garment of claim 8, wherein the UMF of the second plurality of yarns have about 10 filaments per denier.

12. The garment of claim 8, wherein the first plurality of yarns and the second plurality of yarns have the same denier, and wherein the denier of the first plurality of yarns and the second plurality of yarns is between 15 and 400.

13. The garment of claim 8, wherein the first plurality of yarns and the second plurality of yarns are present in the system in a proportion of about 76% of the first plurality of yarns and about 24% of the second plurality of yarns, based on total yarns in the system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a photograph of 100% cotton fabric at 0 time. Absorption of dye is about 1 cm. The absorption was immediate and there was no treatment or surfactant on the fabric

(2) FIG. 2 is a photograph of 100% polyester fabric at 0 time. Absorption of dye is about 1 cm. The absorption was immediate since the fabric is treated with a surfactant that neutralizes the hydrophobic quality of the polyester yarns.

(3) FIG. 3 is a photograph of the PP/UMF combination fabric with a drop of dye placed on the fabric surface at 0 time. In this case the drop is placed on the side of the fabric which is PP. There is no absorption of dye since no surfactant is being used which keeps the fabric highly hydrophobic. The drop will be absorbed into the fibers when the pressure or heat on the drop is greater than the adhesive pressure of the drop surface.

(4) FIG. 4 is a photograph of the PP/UMF combination fabric with a drop of dye placed on the side of the UMF at 0 time. There is immediate initiation of absorption of the dye. Absorption of dye is about 2 cm at 0 time.

(5) FIG. 5 is a photograph of the PP/UMF combination fabric with a drop of dye placed on the side of the UMF at 30 seconds. The absorption of the dye is at approximately 4 cm in 30 seconds.

(6) FIG. 6 is a photograph of a 100% cotton after 1 minute. The absorption of the dye is approximately 2 cm.

(7) FIG. 7 is a photograph of 100% polyester fabric. The size of the stain is approximately 1.75 cm after 1 minute. It should be noted that the stain on the reverse side is exactly the same as the size of the stain on the face of the fabric.

(8) FIG. 8 is a photograph of a PP/UMF fabric with the dye on the UMF side. The spread of the dye is 5 cm after 1 minute.

(9) FIG. 9 is a photograph of a 100% cotton fabric after 2 minutes demonstrating a dye spread of approximately 2.5 to 3 cm.

(10) FIG. 10 is a photograph of a 100% polyester fabric after 2 minutes demonstrating a dye spread of approximately 2.5 cm.

(11) FIG. 11 is a photograph of a PP/UMF fabric with the dye on the UMF side. The spread of the dye is approximately 6.5 cm after 2 minutes. (What is seen is a low power view of a knit underside of a blended fabric wherein Black is PP and White is UMF).

(12) FIG. 12 is a photograph of 100% cotton fabric after 3 minutes demonstrating a dye spread of approximately 3.5 to 4 cm.-100% cotton

(13) FIG. 13 is a photograph of 100% polyester fabric after 3 minutes demonstrating a dye spread of approximately 4 cm.

(14) FIG. 14 is a photograph of a PP/UMF fabric with the dye on the UMF side. The spread of the dye is approximately 7.5 cm in 3 minutes.

(15) FIG. 15 is a photograph of 100% cotton fabric after 5 minutes demonstrating a dye spread of approximately 4.5 to 5 cm. The stain on the opposite side of the fabric is exactly the same as the face.

(16) FIG. 16 is a photograph of 100% polyester fabric after 5 minutes demonstrating a dye spread of approximately 4 cm. The stain on the opposite side of the fabric is exactly the same as the face.

(17) FIG. 17 is a photograph of a PP/UMF fabric with the dye on the UMF side. The spread of the dye is approximately 8.5 cm after 5 minutes. There is no dye on the opposite side of the fabric.

(18) FIG. 18 is a photograph of 100% cotton fabric after 10 minutes demonstrating a dye spread of approximately 4.5 to 5 cm. The size of the stain on either face of the fabric was exactly the same.

(19) FIG. 19 is a photograph of 100% polyester fabric after 10 minutes demonstrating a dye spread of approximately 4 cm. The size of the stain on either face of the fabric was exactly the same.

(20) FIG. 20 is a photograph of a PP/UMF fabric with the dye on the UMF side. The spread of the dye is approximately 9.5 to 10 cm. It should be noted that there is no surfactant on the PP/UMF fabric and no appearance of the dye stuff on the opposite side of the fabric.

(21) FIG. 21 is a photograph of 100% cotton fabric after 20 minutes demonstrating a dye spread of approximately 4.5 to 5 cm. The size of the stain on either face of the fabric was exactly the same.

(22) FIG. 22 is a photograph of 100% polyester fabric after 20 minutes demonstrating a dye spread of approximately 4 cm. The size of the stain on either face of the fabric was exactly the same.

(23) FIG. 23 is a photograph of a PP/UMF fabric with the dye apparent on the UMF side alone. The spread of the dye is approximately 11 cm.

(24) FIG. 24 is a photograph of a PP/UMF fabric being photographed from the PP side. There is no dye on the PP side but what can be seen is the reflection of the dye coming through the fabric from the UMF side. The absorption of dye was approximately of 11 cm. in 20 minutes.

(25) FIG. 25 is a photograph of a PP/UMF fabric being photographed at an angle from the PP side. There is no dye on the PP side which is easier to see when looked at from an angle. The reflection demonstrates a dye spread of approximately 11 cm in 20 minutes. No surfactant is on the fabric.

(26) FIG. 26 is an SEM photograph of a UMF single filament demonstrating the ultra micro fiber configuration.

(27) FIG. 27 is a high powered view of a plyed yarn. The black is a PP filament. The white is a UMF fiber.

(28) FIG. 28 is a high powered view of a blended fabric. The black is a PP yarn. The white is a UMF yarn.

(29) FIG. 29 is a low powered view of the top surface of a knit blended fabric. The black is a PP yarn. The white is a UMF yarn.

(30) FIG. 30 is a low powered view of the underside of a knit blended fabric. The black is a PP yarn. The white is a UMF yarn.

(31) FIG. 31 is a graph demonstrating average results of 8 bicyclists wearing a 100% cotton test and then a PP/UMF shirt demonstrating the physiological differences occurring to the subjects in the experiment.

(32) FIG. 32 is an SEM image of an Island in the Sea Ultra Microfiber.

(33) FIG. 33 is an SEM image of a Split Pie Ultra Microfiber, showing an “Island in the Sea” configuration of the UltraMicro Fiber.

(34) FIG. 34 is Side View of a Knit Fabric Demonstrating a Top and Bottom to the Textile. Depending on the tightness of the knit the loops will be the dominant yarns on the outside of the fabric. Depending on whether one seeks a warming or cooling fabric this yarn can be changed from a PP to a UMF or the opposite.

(35) FIG. 35 is Side View of a Knit Fabric Demonstrating a Top and Bottom View of a Knit Fabric. This type of knit will appear almost the same on top and bottom but normally in this type of knit the darker color yarns would be on top which would demonstrate a wale or stripe along the length of the fabric.

(36) FIG. 36 is a Typical 2×1 Woven Twill. The top side of the fabric is the side shown in the Figure. The white yarns show up as the dominant yarn in the Figure and are polypropylene. The black yarn is the UMF which is the background yarn.

(37) FIG. 37 is a Typical 4×1 Woven Twill. The top side of the fabric is the side shown in the Figure. The white yarns show up as the dominant yarn in the Figure and are polypropylene. The black yarn is the UMF which is the background yarn.

(38) FIG. 38 is Side View of Knits Demonstrating Two Levels.

DETAILED DESCRIPTION OF THE INVENTION AND EXAMPLES

(39) The primary positive physical characteristics of PP fibers for apparel applications are: Good bulk and cover, very lightweight (olefin fibers have the lowest specific gravity of all fibers) High strength (wet or dry) Resistant to deterioration from chemicals, mildew, insects, perspiration, rot and weather Abrasion resistant Low moisture absorption Stain and soil resistant Lowest static component of any man-made fiber Sunlight resistant Good washability, quick drying, unique wicking (moisture transport) Resilient, moldable, very comfortable Thermally bondable. Characteristics viewed as a drawback to the use of PP fibers for apparel applications are: Low melting temperature which prevents it from being ironed like cotton, wool, nylon etc., Hard to be dyed after manufacturing, except after substantial treatment and modification, High crystallinity and poor thermal conductivity which leads to limited texturizability, i.e.; drawn polypropylene requires a contact time of 2 seconds in the heater compared to PET (POY) which requires only 0.4 seconds. Poor UV and thermal stability which requires addition of expensive UV stabilizers and antioxidants to overcome this problem, Poor resilience compared to PET and Nylon, Creeping due to its low Tg(−15 to −20° C.), Poor adhesion to glues and latex, and Flammability characterized in that PP melts and burns like wax.

(40) Probably the single characteristic that limits the use of PP fibers in the textile industry is the dry stiff nature of the fibers drawn from this polymer which is why its primary use in textiles is for cord, carpets, upholstery, and mattress tickings.

(41) Many UMF are made from a combination of polyester (PET) and nylon (PA) fiber which is extruded in an ultra micro-fiber (UMF) configuration which can be seen in the SEM photos attached hereto as seen in FIG. 3. However, any polymer which can be extruded to yield a very high surface area can be used.

(42) The key to the uniqueness of UMF is the very high level surface area.

(43) Fiber Characteristics of polyester (PET) from which UMF can be made are as follows: a. Strong b. Resistant to stretching and shrinking c. Resistant to most chemicals d. Quick drying e. Crisp and resilient when wet or dry f Wrinkle resistant g. Mildew resistant h. Abrasion resistant i. Retains heat-set pleats and creases j. Easily washed

(44) The basic nylon (PA) fiber properties from which UMF can be made are described below: 1. Length: Length of a nylon (PA) filament is unlimited and staple fiber lengths are controllable. 2. Fineness: Nylon (PA) fiber fineness is also controllable. 3. X-sectional shape: Normally round shape but the cross sectional shape could be changed. 4. Strength of nylon (PA) fiber is very high. Its tenacity varies from 4.6 to 5.8 g/den. 5. Extensibility: Nylon (PA) is characterized by highly extensible fibers. Extension at break is 30% but the problem is poor recovery from extension. For that reason it is not used as a sewing thread for garments. 6. Resiliency: It has good resiliency properties. Nylon (PA) fibers, yarn or fabric do not crease easily. For that reason it is widely used for the pile fabric production. For instance velvet, carpet etc. 7. Frictional Resistance: Nylon (PA) fiber shows good frictional resistance. Due to high strength and its good frictional resistance property it is widely used for rope. 8. Moisture regain: moisture regain of nylon (PA) fiber varies from 4.2 to 5%. Nylon (PA) fiber does not absorb water easily. Water molecules can not enter into the inside of the fiber easily. For this reason nylon (PA) fabric can be dried easily. So it can be used as a raincoat.
Ultra Micro Fibers (UMF)

(45) Very common in the textile industry are the use of microfibers (MF) but far less so the use of ultra microfibers (UMF) especially in apparel. They can take many forms such as a very fine filament made from one polymer, side by side configurations of one or more polymers, or concentric configurations of one or more polymers. In addition, they can be made a wide variety of polymers.

(46) The polymers given below can be used as any part of UMF in a yarn either alone or together in a variety of configurations: PET (polyester); PEN polyester; Nylon 6,6; PCT polyester; Polypropylene (PP); PBT polyester; Nylon 6; co-polyamides; Polylactic acid (PLA); polystyrene; Acetal; polyurethane (PU); Soluble co polyester; HDPE, LLDPE.

(47) The UMF in accordance with this invention are characterized in that they are comprised of hydrophobic materials which can have a lower hydrophobic reading than polypropylene. Such reference, therefore, includes classically, materials that would ordinarily be classified as hydrophobic, however, they are less hydrophobic than the hydrophobic polymers from which they are made due to the high surface area they obtain in the co-extrusion process.

(48) As stated above, preferred for use in the UMF of the present invention is a combination of polyester (PET) and nylon (PA) fiber.

(49) The term microdenier as it relates to synthetic fibers refers to synthetic fibers with denier per filament (dpf) of less than one. An example would be a 150 denier polyester fiber that was made from 150 individual filaments. This is commonly used today in almost all nylon and polyester garments to enhance garment performance. The scope of this invention includes the use of yarns comprising microfibers in conjunction with yarn comprising PP fibers which will produce a garment that is effective but less effective than when PP yarns are used in conjunction with yarns comprising ultra microfibers (UMF).

(50) Thus the present invention is directed in another aspect to a combination yarn system having enhanced thermal control properties wherein a plurality of the yarns within said system comprise polypropylene (PP) and a plurality of the yarns comprise microfibers (MF) and wherein the ratio of said yarns to each other within said system range from between 97% PP and 3% MF to 97% MF and 3% PP.

(51) Since it is also possible, based on the teachings of the present specification, to substitute PP with micro-denier yarns made from PET or polyaramide (PA) and to produce a garment that is effective, although it is possible that the same is less effective than those produced with PP yarns, the present invention also includes within its scope a combination yarn system having enhanced thermal regulating properties wherein a plurality of the yarns within said system comprise yarns made from fibers selected from PET and PA and a plurality of the yarns comprise ultra microfibers (UMF) and wherein the ratio of said yarns to each other within said system range from between 97% PET or PA and 3% UMF to 97% UMF and 3% PET or PA. In some embodiments, the thermal control combination yarn system comprises micro-denier yarns made form polyester or polyaramide, having a preponderance of such micro-denier yarns being surface-exposed on a first surface of said system and a second plurality of yarns within said system comprising ultra microfibers (UMF) comprised of a relatively low hydrophobic material as compared to the micro-denier yarns, and the ratio of the micro-denier yarns to the UMF are from between 97% PET or PA and 3% UMF to 97% UMF and 3% PET or PA.

(52) The combination yarn systems of the present invention are also contemplated to include a 1 denier per filament, or other denier per filament values of polyester (PET) or nylon (PA) yarn UMF of polypropylene (PP) yarn. Such arrangement, however, will yield in some embodiments, a garment that is less effective than those produced whereby the polypropylene yarns are most proximal to a site away from which the mobilization of water is desired, and the UMF are located distal to the polypropylene yarn.

(53) The term Ultra microfibers (UMF) as used herein, relates to fibers having no less than 10 filaments per denier and usually refers to fibers composed of filaments which have been chemically split to a further reduction in size or extruded in such a way that the filaments are smaller in thickness than 1 denier per filament. A commonly used fiber would be a 160 denier fiber which is made up of 72 filaments which have each been divided into 16 sub-filaments. FIG. 1 shows a cross section of an ultra micro-fiber (UMF). The exemplified material is comprised of 100% cotton and at time 1, there is an absorption of dye of approximately 1 cm, which is essentially immediate. FIG. 2 demonstrates a UMF fiber comprised of 100% polyester at time 0, showing absorption of the dye of approximately 1 cm, with essentially immediate absorption, where the fabric further comprises a surfactant to neutralize hydrophobic quality of the polyester. FIG. 3 shows a side view of a chemically split fiber comprised of polypropylene (PP)/UMF showing the stain present on the PP side indicating no absorption of dye on the UMF side. No surfactant was present on this sample and the fabric was highly hydrophobic. FIG. 4 shows a cross section of an orderly fiber in the UMF configuration comprised of PP/UMF. The stain is indicative of absorption on UMF side, showing an essentially immediate absorption of dye of approximately 2 cm. No surfactant was present and the fabric is still hydrophobic yet nonetheless absorbs the stain due to the high surface area of the UMF in the fabric.

(54) There is more than one method for the production of these ultra microfibers which is known to people familiar in the art. In addition, a variety of almost any combination of extruded polymers can be used to obtain the effect. Common names to describe the UMF production are “Islands-In-The-Sea” or “Splittable Pie” systems which ultimately produces the desired effect in the fibers.

(55) A typical cross-section of an Island-In-The-Sea fiber is seen in FIG. 5. This particular fiber contains 64 individual small fibers of one polymer spun inside of a matrix, or sea, of another fiber. The fiber shown has a denier of approximately three but is divided into 64 sub-filaments. The fabric is comprised of PP/UMF and the stain pattern on the UMF side of the fabric is shown. Absorption of the dye of a front of approximately 4 cm. in 30 seconds was found. The fabric contained no surfactant.

(56) The islands compose approximately 80% of the fiber and the sea is approximately 20% of the fiber. These microdenier filaments are developed when the sea polymer is dissolved after the yarn or fabric has been woven or knit. A chemically split single filament demonstrating ultra microfiber (UMF) configuration is shown in FIG. 6. The material shown is comprised of 100% cotton having an absorption of dye of approximately 2 cm in 1 minute, with the stain size being essentially identical on either face of the fabric.

(57) Splittable Pies is another name for a way to produce ultra microdenier (UMF). Using this concept, a 2 to 4 dpf bicomponent pie yarn is again spun and processed with standard techniques. Once in fabric form, a mild caustic solution is applied to the fabric causing the individual fibers to split apart from the main fiber. If a 32 segment pie of nylon/polyester as shown in FIG. 7 is used, the final dpf of the fibers are in the range of 0.1. In this aspect, a 100% polyester material is shown, having a dye absorption of approximately 1.75 cm. in 1 minute. The size of the stain on either fabric face was essentially the same.

(58) Brushing and other type of finishing techniques can be used to enhance the effects.

(59) The polyester/polypropylene fiber pies shown stay together during spinning but come apart with various types of down-stream processing. The yarn shown in the photomicrographs in FIG. 7 consists of 198 three-denier filaments before drawing.

(60) With the use of modern bicomponent technology, microdenier fibers with a dpf of less than 0.2 can now be produced and processed economically and in large quantities. The industry is no longer limited in fiber dpf to the lowest homopolymer denier that can be spun or processed into fabric with reasonable yields.

(61) According to the present invention polypropylene (PP) contributes to the yarn of the present invention and to the textiles and garments made therefrom, the following properties: Low moisture absorption—due to the high amount of crystallization of PP the polymer imparts a very high hydrophobic quality to the fiber i.e. more than polyester and nylon which are considered hydrophobic themselves. This extreme hydrophobic quality forces the movement of water along its surface (wick action). This movement is necessary to force the movement of water in adjacent UMF which will ultimately thin out the layer of absorbed water as much as possible and as quickly as possible to facilitate its evaporation and thus reduce the surface temperature of the substrate. Lowest static component of any man-made fiber—due to this quality there is almost uninhibited movement of the absorbed water. This quality is necessary to assist in the movement of the water in the adjacent UMF. Good washability, quick drying, unique wicking (moisture transport)—due to this quality the fabric will dry much more quickly than a UMF fabric alone

(62) According to the present invention UMF contribute to the yarn of the present invention and to the textiles and garments made therefrom, the following properties:

(63) High moisture gathering—due to the high surface area, these fibers will gather water through a capillary action. This water will ultimately settle within the micro-cracks created by the splitting of the UMF.

(64) Softness—this quality will mask the stiffness of the PP fibers.

(65) Elongation—this quality is necessary to make a normal textile fabric which is not a quality of PP.

(66) According to the present invention it has now been discovered that the unique combination of the present invention creates a synergistic interaction of adhesion, cohesion, and capillary action as described hereinafter.

(67) Capillary action is the tendency of a liquid to rise in narrow tubes or to be drawn into small openings such as those between grains of a rock. Capillary action, also known as capillarity, is a result of the intermolecular attraction within the liquid and solid materials. A familiar example of capillary action is the tendency of a dry paper towel to absorb a liquid by drawing it into the narrow openings between the fibers.

(68) The mutual attractive force that exists between like molecules of a particular liquid is called cohesion. This force is responsible for holding a raindrop together as a single unit. Cohesion produces the phenomenon known as surface tension, which may allow objects that are more dense than the liquid to be supported on the surface of the liquid without sinking. When an attractive force exists between two unlike materials, such as a liquid and a solid container, the attractive force is known as adhesion. Adhesion is the force that causes water to stick to the inside of a glass. If the adhesive force between the liquid and solid is greater than the cohesive force within the liquid, the liquid is said to wet the surface and the surface of the liquid near the edge of the container will curve upward. In cases where the cohesive force is greater than adhesion, the liquid is said to be non-wetting and the liquid surface will curve downward near the edge of the container.

(69) The combination of the adhesive forces and the surface tension that arises from cohesion produces the characteristic upward curve in a wetting fluid. Capillarity is the result of cohesion of water molecules and adhesion of those molecules to the solid material forming the void. As the edges of the container are brought closer together, such as in a very narrow tube, the interaction of these phenomena causes the liquid to be drawn upward in the tube. The more narrow the tube, the greater the rise of the liquid. Greater surface tension and increased ratio of adhesion to cohesion also result in greater rise. However, increased density of the liquid will cause it to rise to a lesser degree.

(70) The force with which water is held by capillary action varies with the quantity of water being held. Water entering a natural void, such as a pore within the soil, forms a film on the surface of the material surrounding the pore. The adhesion of the water molecules nearest the solid material is greatest. As water is added to the pore, the thickness of the film increases, the capillary force is reduced in magnitude, and water molecules on the outer portion of the film may begin to flow under the influence of gravity. As more water enters the pore the capillary force is reduced to zero when the pore is saturated. The movement of groundwater through the soil zone is controlled, in part, by capillary action. The transport of fluids within plants is also an example of capillary action. As the plant releases water from its leaves, water is drawn upward from the roots to replace it.

(71) The surface tension of water provides the necessary wall tension for the formation of bubbles with water. The tendency to minimize that wall tension pulls the bubbles into spherical shapes (LaPlace's law).

(72) The pressure difference between the inside and outside of a bubble depends upon the surface tension and the radius of the bubble. The relationship can be obtained by visualizing the bubble as two hemispheres and noting that the internal pressure which tends to push the hemispheres apart is counteracted by the surface tension acting around the circumference of the circle.

(73) Surface tension is responsible for the shape of liquid droplets. Although easily deformed, droplets of water tend to be pulled into a spherical shape by the cohesive forces of the surface layer. The spherical shape minimizes the necessary “wall tension” of the surface layer according to LaPlace's law.

(74) Thus for example surface tension and adhesion determine the shape of a raindrop on a leaf. Falling drops take a variety of shapes due to oscillation and the effects of air friction. A water droplet can act as a lens and form an image as a simple magnifier.

(75) The relatively high surface tension of water accounts for the ease with which it can be nebulized, or placed into aerosol form. Low surface tension liquids tend to evaporate quickly and are difficult to keep in an aerosol form. All liquids display surface tension to some degree. The surface tension of liquid lead is utilized to advantage in the manufacture of various sizes of lead shot. Molten lead is poured through a screen of the desired mesh size at the top of a tower. The surface tension pulls the lead into spherical balls, and it solidifies in that form before it reaches the bottom of the tower.

(76) A key to the ability of the fabric produced according to the present invention to function in a surprising manner is the control of the flow of water throughout the fibers of the fabric. The effect that has been obtained is a mechanical control of the water transport along the surface and inside the micro-cracks of the two yarns which give a synergistic quality to each other when UMF yarn and PP yarn are physically in close proximity to one another (FIGS. 9 and 10). A lesser effect of water evaporation can also be obtained if the PP is blended with a micro denier yarn such as a 1 filament per denier yarn but the effect will not be as marked.

(77) Each type of yarn fiber contributes a needed attribute to the fabric. The PP contributes the wicking and restricts the gathering of the liquid into the fabric. The UMF contributes the transport vehicle for the water as well as the ability to remove the water from the body quickly. The UMF will also increase the surface area and move the water. The water moves quicker when next to a highly hydrophobic surface which pushes the water through the fabric on the surface and in the fibers.

(78) Thus as stated, in especially preferred embodiments of the present invention there are provide textiles, fabrics and garments incorporating a combination yarn system as defined comprising a plurality of yarns made from polypropylene (PP) and a plurality of UMF yarns, wherein a majority of said UMF containing yarns are each adjacent to at least three polypropylene containing yarns

(79) While the invention will now be further described in connection with certain particular embodiments in the following examples so that aspects thereof may be more fully understood and appreciated, it is not intended to limit the invention to these particular embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the scope of the invention as defined by the appended claims. Thus, the following examples will serve to illustrate the practice of this invention, it being understood that the particulars shown are by way of example and for purposes of illustrative discussion of particular embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of formulation procedures as well as of the principles and conceptual aspects of the invention.

UMF Example 1

(80) Application in Knit Fabrics

(81) Knit fabrics are “composed of intermeshing loops of yarn.” There are two types of knits: weft knits and warp knits. While the technology described can be adapted to either type of knit, the garment used in the experiment described below was made as a weft knit.

(82) Weft knits are characterized by the fact that each weft yarn lies more or less at right angles to the direction in which the fabric is produced. The intermeshing yarn traverses the fabric cross-wise yarns.

(83) While the manufacturing processes are clear to those familiar with the art, the following is a brief description describing the structure and technology of knit fabrics in general.

(84) “The width and length of knit fabrics are referred to as crosswise and lengthwise, respectively. A course is a “row of loops across the width of a fabric.” A wale is a ‘column of loops along the length of the fabric.” Courses, therefore, lie in the crosswise direction and wales in the lengthwise direction. Unlike woven fabrics, courses and wales are not composed of different sets of yarn. Rather, courses and wales are formed by a single yarn.

(85) In some knit fabrics—for example, the 1×1 rib fabric . . . and the double weft knits . . . —both the face and back show columns of wales. Other knit fabrics—for example, the jersey knit . . . and the tricot knit . . . —show vertical columns of loops on one side and horizontal rows of loops on the other side. The first group of fabrics may be described as having wales on both sides and the second group as having wales on one side and courses on the other. Yet other knit fabrics, such as purl fabric . . . show horizontal rows of loops on both sides. Such fabrics may be described as having courses on both side.

(86) All knit fabrics have both wales and courses, In some knits, however, the vertical appearance of wales predominates on one or both side; in other knits the horizontal feature of courses predominates.

(87) The basic unit of knit fabric is the loop. In weft knits, loops are called needle loops. A needle loop has a head and two legs. It also has a foot that meshes with the head of the needle loop in the course below it. The feet are usually open in weft knits the yarn does not cross over itself. The section of yarn connecting two adjacent needle loops is called the sinker.

(88) In warp knits, the needle loop is referred to as an overlap due to the type of motion taking place to form it. The length of yarn between overlaps, the connection between stitches in consecutive courses, is called an underlap. The length and direction of the underlaps are quite important in the design of warp knits. The feet of the overlaps may be open or closed, depending on whether the yarn forming the underlaps continues in the same or opposite direction from that followed during formation of the overlap.

(89) Each loop in a knit fabric is a stitch. A loop is always drawn through a previously formed loop . . . each stitch meshes through the previously formed loop toward the viewer, in what is called a knit stitch.”

(90) The openness or closeness of the knit as well as the stitch density can vary depending on the weight, stretch, or permeability of the fabric desired for which there is an almost infinite number of combinations.

(91) In the case of the following, the fabrics were knit on a circular machine having 21 needles per inch in a jersey knit configuration. The weight of the fabric in the garment was 120 grams to the square meter. The garment made from the fabric was a basic t-shirt style with short sleeves. The fit of the garment was snug but not tight. 1. The subjects were all males between the ages of 27 and 31. 2. Each subject followed the same regimen of exercise. 3. Each subject used a stationary bicycle “Excite Selection from Technogym” which had a heart monitor built into the handlebar. 4. Each subject did the test a total of 6 times. 3 with a cotton shirt and 3 with a shirt made from 76% PP/24% UMF. 5. All tests were conducted in a room that was 18 C with a relative humidity of approximately 50% and were indoors. 6. No subject was on medication or had an known maladies. 7. Each session was 24 hours apart for each subject. 8. The exercise duration was 60 minutes and wattage can be seen on the chart which was the same for all subjects.

(92) To test the efficacy of the invention an experiment was conducted. The parameters of the experiment were as follows:

(93) In each session 6 tests were performed at least 24 hours apart, 3 while wearing a shirt made from PP/UMF and 3 while wearing a shirt made from 100% cotton. In all cases a standardized exercise was performed on the bike. The exercises of duration of 45 minutes each were divided in 8 successive periods with each having a specific output measured in Watts:

(94) TABLE-US-00001 0 to 5 minutes 100 watts 5 to 10 minutes 110 watts 10 to 15 minutes 120 watts 15 to 20 minutes 130 watts 20 to 25 minutes 140 watts 25 to 30 minutes 160 watts 30 to 35 minutes 180 watts 35 to 37 minutes 200 watts 37 to 40 minutes 180 watts 40 to 45 minutes 160 watts 45 to 50 minutes 120 watts 50 to 55 minutes 110 watts 55 to 60 minutes 100 watts

(95) Heartbeat levels were recorded at the end of each period so that they were measured at 5, 10, 15, 20, 25, 30, 35, 37, 40, 45, 50, 55, and 60 minutes.

(96) All data is represented as an average of the group. As shown by the data there is a surprisingly observable difference in the heart beats per minute between the subjects when they wore a cotton shirt and when they wore a PP/UMF shirt. All people who did the test wearing a PP/UMF shirt, wherein the ratio of the yarns to each other within said garment are 25% UMF and 75% PP and wherein the inner surface of said garment was characterized by a preponderance of surface exposure of the PP yarns, and UMF the outer surface of the garment was characterized by a preponderance of surface exposure of the UMF yarns which in this case were made from a polyester and a nylon in an Island in the Sea configuration as per FIG. 32, reported that subjectively they came off the exercise bicycle feeling as if the regimen of exercise was lighter than with the cotton shirt. Also, the shirts were visibly less wet with the PP/UMF than with the cotton which was soaked in perspiration.

Example 2

(97) Application in Woven Fabrics

(98) While many configurations of fabrics with moisture movement can be formulated in a preferred embodiment woven twill fabrics are most appropriate. Woven fabrics, unlike knit fabrics, are basically comprised of yarns running the length of the fabric (warp yarns) and the width of the fabric (weft yarns). Changes in the weave configuration can change the appearance and physical qualities of the fabric. In the case of moisture movement the twill weave is chosen because it allows for a mass producible configuration that allows each yarn to perform its specified task. A twill fabric is one in which the weave repeats on a three or more warp and filling yarns and diagonal lines are produced on the face of the fabric. Therefore, the interlacing pattern is over more than one yarn and under one or more yarns. The progression of interlacing is by one, thereby producing the diagonal line.

(99) All twill fabrics have a series of diagonal lines, or twill lines, on at least one side of the fabric due to the interlacing of the yarns. When the twill lines appear more prominently on one side, that side is the face. When the lines are equally prominent, a convention related to direction of twill line is used to establish the face side. The diagonal lines on the face of the will fabrics may run from lower left corner of the fabrics to the upper right corner, creating a right handed twill, or from the lower rig corner to the upper left corner creating a left handed twill.

(100) In our case, the UMF can be placed so that they are either a majority of the face or a majority of the back depending on the desired effect.

(101) In a further embodiment, two yarns of 75 denier each are twisted together. In this case, the yarns are both 75 denier. The one yarn is a 75 denier yarn with 68 filaments made from polypropylene. The second yarn in the twist is a 75 denier 36 filaments ultra micro yarn which is split 16 times yielding an effect filament count of 576. In this case, the ultra-microfiber yarn is made from a nylon core which has 16 cogs around its diameter and a polyester fiber which fits into each one of the cogs. The method for plying these yarns are those commonly used in the polymer fiber industry with a twist and an attachment to assure that the individual yarns act as a single unit yarn (FIG. 8). In this figure, a fabric comprised of 100% PP/UMF was evaluated for dye absorption, showing absorption on the UMF side of approximately 5 cm. in 1 minute.

(102) For comparison it is to be noted that, a polyester yarn often used in many apparel applications is a 2/150/144. This means there are 2 yarns twisted together, each 150 denier in thickness and each made up of 144 filaments.

(103) The yarns produced in example 1 can be used to produce a woven or a knit fabric by methods known per se in the art since in most cases the same denier yarns can be used in both weaving and knitting with only a slight adjustment in the twist of the finished yarn. Thus, the process of forming a fabric on a loom by interlacing the warp (lengthwise yarns) and the filling (crosswise yarns) with each other is well known. Filling is fed into the goods from cones, filling bobbins or quills which carry the filling picks through the shed of the loom. Filling may also be in shuttles loom. The three basic wears are plain, twill, and satin. All other weaves, no matter how intricate, employ one or more of these basic weaves in their composition. There are many variations to the basic principles which make different types of fabric surfaces and fabric strengths. Examples of common weaves that will be known to anyone familiar with the art are: plain, tabby, taffeta, twill, satin, basket, rib, pique, pile, jacquard, leno, etc. In this example, different yarns can be inserted in the warp or weft or the yarns can be plied together and inserted in the warp, weft, or both warp and weft. For comparison it is noted that almost any denier yarns can be used in either the warp or the weft or both. The fabric can be made with yarns that are twisted together and placed in either the warp or the weft or both however; it is also possible to obtain the effect by weaving a fabric that has either UMF in one direction of the weave and PP in the other direction. Any combination or configuration can be used to obtain the same affect.

(104) It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative examples and attached figures and that the present invention may be embodied in other specific forms without departing from the essential attributes thereof, and it is therefore desired that the present embodiments and figures be considered in all respects as illustrative and not restrictive, reference being made to the appended claims, rather than to the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.