Fabric system

Abstract

A composite yarn comprising one or more ultra-high molecular weight polyethylene fibers wrapped around one or more polyurethane-polyurea copolymer fibers.

Claims

1. A composite yarn comprising: one or more polyurethane-polyurea copolymer fibres; and one or more ultra-high molecular weight polyethylene fibres, wherein the one or more ultra-high molecular weight polyethylene fibres are wrapped around the one or more polyurethane-polyurea copolymer fibres, and wherein the one or more polyurethane-polyurea copolymer fibres are between 20 and 40 denier.

2. The composite yarn according to claim 1 wherein the one or more ultra-high molecular weight polyethylene fibre is between 10 and 250 denier.

3. A fabric system comprising: ultra-high molecular weight polyethylene yarn, polyurethane-polyurea copolymer yarn, and a further natural or synthetic yarn, wherein the polyurethane-polyurea copolymer yarn is between 20 and 40 denier.

4. The fabric system according to claim 3 wherein the ultra-high molecular weight polyethylene fibre is between 10 and 250 denier.

5. The fabric system according to claim 3 wherein the further natural or synthetic yarn is a polyamide chosen from the group nylon 6, nylon 6:6, nylon 5:10 or nylon 6:12.

6. The fabric system according to claim 3 wherein the further natural or synthetic yarn is between 10 and 150 denier.

7. The fabric system according to claim 3 comprising a composite yarn comprising: one or more polyurethane-polyurea copolymer fibres; and one or more ultra-high molecular weight polyethylene fibres, wherein the one or more ultra-high molecular weight polyethylene fibres are wrapped around the one or more polyurethane-polyurea copolymer fibres, and wherein the one or more polyurethane-polyurea copolymer fibres are between 20 and 40 denier.

8. A method of manufacturing the composite yarn of claim 1 comprising the step of wrapping an ultra-high molecular weight polyethylene yarn around a polyurethane-polyurea copolymer yarn.

9. The method of manufacturing the composite yarn according to claim 8 wherein the ultra-high molecular weight polyethylene yarns are wrapped around the polyurethane-polyurea copolymer yarn at a rate of between 200 and 800 turns per meter.

10. The method of manufacturing the composite yarn according to claim 8 wherein the ultra-high molecular weight polyethylene yarns are S twisted yarns.

11. The method of manufacturing the composite yarn according to claim 8 wherein the ultra-high molecular weight polyethylene yarns are Z twisted yarns.

12. The method of manufacturing the composite yarn according to claim 8 wherein at least some of the ultra-high molecular weight polyethylene yarns are S twisted yarns and at least some of the some of the ultra-high molecular weight polyethylene yarns are Z twisted.

13. The method of manufacturing the composite yarn according to claim 8 wherein the wrapping is by air intermingling, single covering, double covering or combinations thereof.

14. A method of manufacturing fabric system having a first yarn of nylon and a second yarn comprising a composite of ultra-high molecular weight polyethylene and polyurethane-polyurea copolymer, the method comprising the step of knitting the first yarn with the second yarn to create a structure chosen from the group comprising single jersey plain knit, weft-locknit, cross-miss and birds-eye knit.

15. A garment comprising the composite yarn of claim 1.

16. A garment comprising a fabric system including ultra-high molecular weight polyethylene yarn between 20 and 40 denier, polyurethane-polyurea copolymer yarn and a further natural or synthetic yarn.

17. A garment having at least two panels wherein at least one of the panels comprises a fabric system including ultra-high molecular weight polyethylene yarn, polyurethane-polyurea copolymer yarn between 20 and 40 denier and a further natural or synthetic yarn.

18. The composite yarn according to claim 1 wherein the one or more ultra-high molecular weight polyethylene fibre is between 75 and 125 denier.

19. The fabric system according to claim 3 wherein the ultra-high molecular weight polyethylene fibre is between 75 and 125 denier.

20. The fabric system according to claim 3 wherein the further yarn is between 20 and 75 denier.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawings will be provided by the Office upon request and payment of the necessary fee.

(2) Further disclosure, objects, advantages and aspects of preferred and other embodiments of the present application may be better understood by those skilled in the relevant art by reference to the following description of embodiments taken in conjunction with the accompanying drawings, which are given by way of illustration only, and thus are not limitative of the disclosure herein, and in which:

(3) FIG. 1 is a schematic diagram illustrating the operation of a knitting machine when fed two yarns simultaneously for plating and indicating the technical back (1) and technical face (3);

(4) FIGS. 2(a), 2(b), 2(c) and 2(d) illustrate fabric structures in detail as structural notations for 2(a) plain, 2(b) weft locknit, 2(c) cross miss and 2(d) birds eye;

(5) FIGS. 3(a), 3(b), 3(c) and 3(d) illustrate the technical back of polyester/nylon fabric having 3(a) plain, 3(b) weft locknit, 3(c) cross miss and 3(d) birds eye fabric structures;

(6) FIGS. 4(a), 4(b), 4(c) and 4(d) illustrate the technical back of UHMWPE/nylon fabrics having 4(a) plain, 4(b) weft locknit, 4(c) cross miss and 4(d) birds eye fabric structures;

(7) FIGS. 5(a), 5(b), 5(c) and 5(d) illustrate a number of plots depicting the results of mean stretch and residual extension tests for polyester/nylon (dark shading) and UHMWPE/nylon (light shading) where the y-axis refers to percentage; 5(a) stretch in warp direction, 5(b) stretch in weft direction, 5(c) residual extension in warp direction, and 5(d) residual extension in the weft direction; and

(8) FIGS. 6(a) and 6(b) include, respectively, graphical representations illustrating the mean value of coefficient of friction (MIU) and mean deviation of surface roughness (SMD) in warp (5) and weft (7) directions for the plain single jersey fabric made of UHMWPE/nylon plated fabric.

(9) FIG. 7 is a diagram illustrating the method of manufacture of the composite yarn according to the present invention using a double covering method.

(10) FIGS. 8(a), 8(b) and 8(c) illustrate test results comparing the fabric system of the present invention against three prior art fabric systems including plots of survival weft (crossways) indicating deterioration time (FIG. 8(a)), survival warp (length) and deterioration time (FIG. 8(b)) and fabric weight (FIG. 8(c)).

(11) FIGS. 9(a), 9(b), 9(c), 9(d), 9(e) and 9(f) illustrate six different knitting structures, FIGS. 9(a) to 9(f) corresponding to structures T1 to T6, respectively.

DETAILED DESCRIPTION

Yarns & Fabric

(12) The yarns and fabric system of the present invention is suitable for use in producing fabric, or garments comprising the fabric, or panels for insertion into garments.

(13) A fabric according to the present invention has been made from composite yarn and an air textured continuous filament nylon yarn of 75 denier linear density. This particular yarn is selected for three main reasons: 1. when the fabrics relaxing after knitting the textured yarn has the ability to add bulkiness to the fabric and for this reason, when it is dyed it provides better colour coverage; 2. a higher level of cover can be achieved with lower fabric weight using textured yarns compared to non-textured yarns; and 3. a lower GSM fabric can be achieved. As part of the finishing process the fabric can under go several treatments such as stretch and set that have the effect of reducing the fabric weight per GSM.

(14) The composite yarn preferably comprises one or more different combinations of 10 to 100 denier UHMWPE flat continuous filament yarn wrapped around an elongated 20 to 40 denier Spandex low or high power filament yarn. The 40 denier Spandex yarn tends to provide a higher level of stretch to the fabric system than is usually required for sporting garments, and typically 20 denier Spandex will be more appropriate. The Spandex yarn tends to improve fabric recovery properties, countering the comparatively poor recovery property of fabric made of UHMWPE (which is due to its low surface friction). The yarn twist rate for the covered yarn will vary depending on the desired resultant characteristic and whether it is SC, DC or TC (which is the combination referred to above). The covering process it typically either S, Z, intermingling or combination.

(15) In order to achieve different level of finished fabric weights to suit different requirements, the composite yarn may be varied in weight from 10 Denier up to 100 Denier or more. The level of Spandex and the TPM may also vary. A lower denier UHWMPE can be used with a high tension or low tension Spandex. As a function of fabric weight, a low tension Spandex will produce a lower GSM fabric with a low TPM. Hence if a very thin fabric, with high abrasion resistance qualities was required, typically one would pick a low denier UHWMPE and a low tension spandex, low TPM, with either single covering or double covering. If hand feel was very important, then a DC option together with the finishing process of stretch and setting would be required. The UHWMPE is low level may require intermingling then double covering which may be termed triple covering.

(16) The requirement for hand feel is at least partly dependent on the weight of the garment. The heavier the garment, the harder the hand feel. The softer the garment the better the hand feel but the worse lower the abrasion resistance.

(17) Samples of the fabric system were made using a Santoni SM8-EVO4 circular knitting machine, which is a 26 gauge single jersey machine with 16 inch diameter cylinder and 8 feeders. During fabric manufacture the step motor position was kept constant to ensure constant stitch height at production for all fabrics. Yarn input tension and take down air pressure were also kept constant. Four fabric structures were selectedplain single jersey, weft-licknit, cross-miss and birds-eye.

(18) The fabrics were double faced, with the nylon yarn becoming the technical face while the composite yarn was the technical back. The knitting machine was a single jersey weft knitting machine, hence a plating technique was used for fabric development. Plating is a knit construction, in which two or more yarns are fed simultaneously. The second yarn is generally of a different colour or type. During the knitting process the second yarn is placed under the first yarn, so that each yarn can be rolled to a specific side of the fabric. In many cases, one yarn/colour appears on the face of the fabric, and the other yarn/contrast colour appears on the back. (It is also possible to obtain double faced fabrics using double jersey weft knitting, warp knitting, and weaving methods.)

(19) There are several advantages associated with having double faced fabrics, including: Nylon in technical face can be dyed in various colours and is not limited to a narrow range of solution dyed colours. However, it is highly recommended to control the temperature of the long wet processes such as scouring and dyeing at 60 C. Alternatively, it is possible to replace nylon with any other natural and/or manmade fibre which can be dyed at temperatures at or below at 60 C.; the use of DC allows UHWMPE to be covered with nylon (super micro fibre) and hidden with the covering yarn taking the dye in addition to improving hand feel. Hand feel can be further improved by other commercial means such as stretching and setting; the finishing process (heat setting) can take place at 140 C. for no more than two minutes; UHMWPE is comparatively inert to chemicals, and has comparatively low moisture absorption; a fabric comprising UHMWPE yarn as an inner layer adjacent a wearer's skin and a yarn having better moisture absorption fibre as the outer layer will provide better moisture management properties than a fabric made of UHMWPE yarn alone.
Fabric Knitting

(20) Fabrics according to the present invention may be manufactured using any suitable knitting machine known in the art, including production weft, warp or seamless knitting machines such as the machine mentioned abovecharacterised as a Santoni SM8-EVO4 circular 26 gauge single jersey machine with 8 feeders and a cylinder of 16 inch diameter. This knitting machine is particularly preferred for development because it allows the user to select needle-to-needle operations electronically, has a reduced number of feeders and it provides electronically-controlled stitch regulation by means of an independent step motor on each feeder and it facilitates multiple-yarn feeding up to eight yarns with variations in the colour and patterning.

(21) Preferably, during operation the stepping-motor position is set constant ensuring the constant stitch height is maintained during production for all samples. Yarn-input tensions and the take-down air pressure are also kept constant. Two yarns may be fed simultaneously in the manner illustrated in FIG. 1. This method of feeding two or more yarns simultaneously is called plating. The basic rule of plating is that the yarn fed nearest to the needle head shows on the reverse side of the needle loop and therefore shows on the surface of the technical back. The second yarn is in a lower position and tends to show on the technical face (Spencer, D. J., Knitting Technology: A comprehensive handbook and practical guide. 3rd ed. 2001, Cambridge, England: Woodhead Publishing Limited.)

(22) Fabric according to the present invention and knitted as described above has been investigated and the physical properties have been investigated (including physical properties such as weight, stretch and recovery, optical porosity, comfort, cooling, surface roughness and surface friction in the wet relaxed state).

(23) Several combinations of fabrics were manufactured in two groups. In one example a 140 denier air-textured filament Nylon 6.6 yarn was used as the ground yarn for both groups. For the plate yarn, a 100 denier air-textured filament polyester yarn was used in the first group of fabrics and a 100 denier flat-filament UHMWPE yarn was used for the second group of fabrics. Four fabric structures were selected, namely (i) single jersey plain, (ii) weft-locknit, (iii) cross-miss and (iv) birds-eye.

(24) Fabric weight, courses and wales per centimeter, thickness and optical porosity values for both yarn combinations are presented in Table 1. Even though the fabrics were manufactured under constant knitting conditions, fabric weight results show that there is a difference with regards to the knit structure as well as the yarn combination. As illustrated in the theoretical structures of FIGS. 2(a), 2(b), 2(c) and 2(d), structures that comprise miss stitches should have much longer V shapes on the technical face and consequently, higher porosity than the plain structure. In fact in practice it does not happen that way. In order to carry the held loop over miss stitches and wait until the next knit stitch comes up, stitches should rob yarns from consecutive stitches. After the wet process, the fabrics which have reached their wet relaxed status exhibited different properties between each structure.

(25) There is not much difference between a polyester/nylon fabric (fabrics used in garments today) and its structurally equivalent UHMWPE/nylon fabric.

(26) TABLE-US-00001 TABLE 1 Physical properties of finished fabrics Optical Yarn Knit Weight Courses Wales Thickness porosity combination Structure (g/m.sup.2) (per cm) (per cm) (mm) (%) Polyester/ PNPlain 220 18.8 12.6 0.85 7.4 Nylon WNWeft-locknit 242 24.2 13.1 1.02 5.2 CMCross-miss 262 30.9 13.5 1.06 4.0 BEBirds-eye 263 31.3 13.5 1.06 3.7 UHMWPE/ PNPlain 210 16.8 12.9 0.85 7.7 Nylon WNWeft-locknit 230 23.8 12.9 0.89 5.0 CMCross-miss 246 28.4 12.9 0.92 3.6 BEBirds-eye 268 31.9 12.8 0.93 2.6
Fabric Stretch and Residual Extension

(27) UHMWPE/nylon fabrics of the present invention appear to have lower extensibility than polyester/nylon fabrics in the warp direction. This was true of all four fabrics, (i.e. 25%, 16%, 9% and 29%) in plain, weft-locknit, cross-miss and birds-eye fabrics respectively. In the weft direction, stretchability of the UHMWPE/nylon combination is slightly higher for plain and weft-locknit fabrics (6% and 4%) but 5% and 14% lower for cross-miss and birds-eye fabrics relative to the polyester/nylon combination. Different loop and float structures in the fabrics greatly affected the stretchability in the weft direction. The higher the successive numbers of miss stitches, the lower the stretch of the fabric. Though the weft-locknit and cross-miss have similar numbers of consecutive misses, cross-miss exhibited lower stretch than weft-locknit due to high and even distribution of miss stitches in the cross-miss fabrics. This same stitch pattern also imparts high stretch characteristics to the cross-miss fabric as compared to the other three fabrics in the warp direction.

(28) Residual extension for the UHMWPE/nylon yarn combination is always higher than the polyester/nylon yarn combination in both directions within every knit structure. In the warp direction, the residual extensions range between 26% and 54% and in the weft direction they lie between 23% and 61% for the UHMWPE/nylon combination. For the polyester/nylon combination, the residual extensions range between 9% and 27% and between 8% and 12% in the warp and weft directions respectively. Higher residual extension values of fabrics made of UHMWPE/nylon make them unfit for apparel fabrics.

(29) Surface Friction and Roughness

(30) TABLE-US-00002 TABLE 2 Surface Roughness and Friction Test Results of Finished Fabrics Test Fabric Std Std Std Yarn direction code MIU deviation MMD deviation SMD deviation Polyester/ Warp PN 0.412 0.009 0.014 0.001 5.963 0.557 Nylon WN 0.351 0.016 0.031 0.003 17.380 0.356 CM 0.358 0.001 0.012 0.001 9.752 0.348 BE 0.369 0.004 0.014 0.001 11.192 0.630 Weft PN 0.239 0.006 0.005 0.003 2.837 0.367 WN 0.233 0.004 0.006 0.001 2.898 0.063 CM 0.216 0.004 0.005 0.001 3.688 0.069 BE 0.237 0.006 0.005 0.001 4.113 0.138 UHMWPE/ Warp PN 0.252 0.009 0.020 0.001 12.020 0.851 Nylon WN 0.259 0.008 0.022 0.002 14.468 0.869 CM 0.218 0.018 0.014 0.002 7.152 0.353 BE 0.254 0.006 0.021 0.003 11.353 0.348 Weft PN 0.140 0.002 0.008 0.001 7.600 0.610 WN 0.117 0.066 0.007 0.001 3.258 0.237 CM 0.113 0.003 0.009 0.002 3.197 0.301 BE 0.185 0.006 0.008 0.001 3.065 0.345

(31) Surface roughness and friction were measured on the technical back of the fabrics, the side which contacts the skin during wear. Columns of interlocking semi-circles formed by the heads of the needle loops and the bases of the sinker loops determine the surface properties of the fabric. In this case, the UHMWPE yarns are preferentially in contact with the measuring probes of the test equipment. FIGS. 6(a) and 6(b) illustrate the MIU and SMD graphs obtained for UHMWPE/nylon plain fabric in the warp and weft directions. It can be seen that both surface friction and roughness values are always higher in the warp direction than the weft direction, not only in plain fabric but also in every other fabric structure (Table 2).

(32) It is an advantage of the fabric system of the present invention is that when compared to fabric systems of the prior art, it has lower friction and roughness on the wearer's skin, and can thus be used to form more comfortable garments.

(33) FIGS. 3(a), 3(b), 3(c), 3(d), 4(a), 4(b), 4(c) and 4(d) show the technical back of the fabrics. FIGS. 2(a), 2(b), 2(c) and 2(d) clearly illustrate the difference in the appearance of textured polyester yarns and flat filament UHMWPE yarns after wet relaxation of the fabrics. Both Plain fabrics do not differ much in appearance compared with the other knitted fabrics. The mean coefficient of friction in the warp direction in polyester/nylon fabrics is always higher when compared to the equivalent UHMWPE/nylon structure. This observation is replicated in the weft direction as well. This is attributed to the inherently low coefficient of friction of UHMWPE fibres as compared with polyester fibres. The shape and length of heads and bases, as well as the texture of the yarns have definitely affected the SMD values of the fabrics. As an example, the SMD of plain polyester/nylon fabric in the warp direction is 5.94 but for the plain UHMWPE/nylon fabric the SMD in the same direction is 12.02. It seems the textured yarns are smoothed out more easily than flat filament yarns under the static load of the probe although their appearance is similar.

(34) Colouring and DyingFabric Finishing

(35) The fabric system of the present invention can be dyed and coloured in the same manner as fabrics of the prior art and the appearance is comparable. Hence fabrics of the present invention can be combined or integrated with fabrics of the prior art to give a consistent colour, look and feel.

(36) The colouring methods described herein are applied to Nylon. This dying process can add weight to the finished fabric, typically by approximately 6%. Any weight gain through knitting and colourisation is commonly offset by stretch and heat setting. The weight gain (gsm increase) is normally caused by two factors, (i) the proportion of Spandex in the fabric (strength of Spandex, that is, whether high or low tension), and (ii) the amount of dye added during the colourisation process.

(37) Scouring and dyeing processes were carried out in the same bath. UHMWPE has a low heat resistance and its melting temperature is around 150 C. The critical temperature for safe use of fibre is at or below 70 C. and the fibre tends to lose tensile strength at higher temperatures. The entire finishing process can be carried out at maximum of 60 C.

(38) At the start of the dying process, a dye bath was filled with water at a material to liquor ratio of 1:20 and the temperature was raised to 40 C. A solution of 1% Albegal SET and 2 g/l Triton X100 was added with thorough stirring. Fabric manufactured according to the present invention was added to the solution and scoured for 15 minutes at a temperature at 40 C. with occasional stirring. The dye mixture was prepared by mixing 0.5% derma fur red RN 150%, 0.5% derma fur yellow RT and 0.5% derma fur blue BT 200% which are low molecular weight acid dyes supplied by Chemcolour Industries Australia Pty. Limited. The dye mixture was then added to the scouring bath left for 15 minutes. Subsequently, a 0.5% formic acid solution was added and the temperature was increased to 60 C. within 20 minutes. More 0.5% formic acid solution was added and left for another 25 minutes at 60 C. Then the dyed fabrics were rinsed in cold water and hydro-extracted. Fabrics were dried flat in the drying cabinet, and then conditioned for 24 hours under standard atmospheric conditions of 202 C. and 652% relative humidity

(39) When subjected to a series of tests, fabrics made of UHMWPE/nylon yarns performed equally as well as polyester/nylon fabrics in terms of surface roughness, friction and colour. In fact, the performance of cross-miss and birds-eye structures is better than the performance of the control fabrics in terms of surface roughness and friction.

(40) Test Methods

(41) The following standard test methods and modified test methods were used to evaluate the structural and physical properties and the performance of the fabrics: Australian Standard (AS) 2001.2.13-1987Determination of mass per unit area and mass per unit length of fabrics AS 2001.2.6-2001Determination of the number of wales and courses per unit length in knitted fabric AS 2001.2.15-1989Determination of thickness of textile fabrics British Standard (BS) 4952 1992Methods of test for elastic fabrics 2.1Determination of extension at a specified force 2.4Determination of residual extension Optical porosity

(42) Microscopic images were obtained with the light coming normally through the porous area of the fabric from below to calculate optical porosity. Motic trinocular zoom microscope together with the Motic image plus2.0 software was used. These images were processed using Imagetool software to calculate the percentages of black and white pixels of the images in which black pixels represented the area covered with yarns and white pixels represented the porous area.

(43) $\mathrm{Optical}\mathrm{porosity}=\frac{\mathrm{white}\mathrm{pixels}}{\mathrm{black}\mathrm{pixels}+\mathrm{white}\mathrm{pixels}}100\%$
Test for Impact Abrasion Resistance

(44) A test method was developed in order to assess the impact abrasion resistance of the fabrics. The European standard EN13595-2:2002 is a test method that has been developed to determine the impact abrasion resistance of protective clothing including jackets, trousers and one piece or divided suits for professional motorcycle riders. This test method was referred and modified as suitable to test light weight, thin (thickness is approximately 1 mm or less) knitted fabrics.

(45) This method was modified only slightly. The weight at impact we reduced to 2 kg as this enabled the current available industry garments to record a destruction time. To further help this a 60 grit belt was used.

(46) The speed of the test machine was 28 km/h+ as per the European standard.

(47) Test for Surface Friction and Roughness

(48) KES-FB4 AUTO A Kawabata friction and roughness evaluation method is used to objectively measure the feel of a fabric, when the fabric is picked and stroked between fingers. This test method was used to assess surface properties of the technical back of the fabrics.

(49) $\begin{array}{cc}\mathrm{MIU}=\frac{1}{X}.Math.x& \left(\mathrm{Equation}2.1\right)\\ \mathrm{MMD}=\frac{1}{X}.Math.-\stackrel{\_}{}.Math..Math.x& \left(\mathrm{Equation}2.2\right)\\ \mathrm{SMD}=\frac{1}{X}{}_o^x.Math.T-\stackrel{\_}{T}.Math..Math.x& \left(\mathrm{Equation}2.3\right)\end{array}$

(50) Three main parameters MIU, MMD, SMD can be obtained directly using the software that has been integrated with the test equipment. MIU represents the mean coefficient of friction measured over 20 mm length forward and backward and MMD represents the mean deviation of from the average. SMD represents the mean deviation of the thickness measured in micrometers. Equations 2.1, 2.2 and 2.3 are the three mathematical fundamentals for MIU, MMD and SMD. The speed of both the roughness and friction probes was 1 mm/sec. The static load for the friction probe was 50 g and for the roughness probe was 10 g. 400 g force was the initial tension used on all the samples.

(51) Test for Moisture Management Properties

(52) Liquid moisture transfer properties of fabrics can be evaluated using moisture management tester (MMT). There are two concentric moisture sensors i.e. upper and lower sensor in the instrument. The test fabric should be placed on the lower sensor and upper sensor should be lowered carefully as both sensors touch the fabric. A constant amount of synthetic sweat is introduced onto the upper side of the fabric, which is the skin side. The spread of the solution will be in three ways. 1. Spread outward on the upper surface of the fabric 2. Transfer through the fabric to the bottom surface 3. Spread outward on the lower surface of the fabric

(53) These movements of moisture will be sensed and measured by the upper and lower moisture sensors.

(54) Fabrics can be categorized in to seven different types based on the MMT results, in terms of liquid moisture transfer properties, and they are as follows: 1. Water proof fabric 2. Water repellent fabric 3. Slow absorbing and slow drying fabric 4. Fast absorbing and slow drying fabric 5. Fast absorbing and quick drying fabric 6. Water penetration fabric 7. Moisture management fabric [25]

(55) Moisture management properties are considered only as a secondary requirement for this project. The objective of this study is to place the developed fabrics in the strategic places of garments for improved protection. So these fabrics do not necessarily have to have better moisture management properties. The test results were used to compare the properties of the commercial fabrics and the developed fabrics.

(56) The fabric system of the present invention was equal to the currently available sporting garments available on the market today which is rating 5.

(57) Comparison with Prior Art Garments

(58) The fabric system of the present invention has been tested against the following three fabric systems of the prior art: 1. cycling knicks from Bio-Racer with Dyneema pad inserted; 2. the fabric disclosed in U.S. Pat. No. 5,210,877; and 3. the thermo-regulating, cut resistant yarn and fabric described in US patent application 2011/0300366 and the cut resistant composite yarn described in US patent application 2012/0060563 A1.
1. Comparison with BioRacer

(59) The fabric system of the present invention was tested in a like for like comparison with Bio-Racer cycling knicks including a Dyneema pad which was stitched into the corners of the shorts for extra protection.

(60) A comparison of the two fabric systems is provided in Table 3.

(61) TABLE-US-00003 TABLE 3 Like for like comparison with Bio-Racer knicks Fabric System - present Bio-Racer Fabric - Dyneema invention Knicks Layer configuration A single layer of fabric Double layers of fabric (insertion of a pad) Structure and yarn Weft knit - Single jersey Inner fabric - weft knit double combination birds eye structure jersey (Interlock structure) Technical face - nylon (75 d) Technical face - spandex covered Technical back - nylon spandex (40 d) covered Technical back - micro fibre UHMWPE (100 d) Dyneema (according to the advertisement) Outer fabric - warp Knitted 80/20 nylon/lycra Weight (g/m.sup.2) 365 Inner - 325 {close oversize brace} Total - 545 Outer - 220 Thickness (mm) 1.23 1.76 Stretch (%) Warp - 95 Warp - 58 Weft - 97 Weft - 107 Residual extension Warp - 22 Warp - 10 (%) Weft - 21 Weft - 29 Abrasion time (s) 3.36 (3.00 < 230-300 gsm)) 3.87

(62) In summary, the Bio-Racer fabric system is different to the fabric system of the present invention. The pad can not be dyed or coloured and also limits the movement/recovery and the wicking of the garment.

(63) The fabric system of the present invention has greater stretch and residual extension overall. The abrasion time for the Bio-Racer fabric is higher but the fabric is also thicker; the fabric of the present invention offering a higher protection rate per unit GSM.

(64) 2. Comparison with the Fabric of U.S. Pat. No. 5,210,877

(65) U.S. Pat. No. 5,210,877 describes outwear garments for cyclists comprising protective fabric panels comprising high performance yarn of ultra high molecular weight polyethylene fibre of approximately 215 denier, such as Spectra in combination with Lycra or other yarns such as those of wool, or acrylic, nylon, polyester, spandex or other natural or manmade fibre. The panels typically comprise separate, single layer, light weight, abrasion resistant, woven, knit or knit-woven protective fabric.

(66) The fabric system of the present invention provides the benefits set out in Table 4 when compared to the fabric system disclosed in U.S. Pat. No. 5,210,877:

(67) TABLE-US-00004 TABLE 4 Comparison with U.S. Pat. No. 5,210,877 Fabric System - present invention U.S. Pat. No. 5,210,877 UV Stability Does not include Spectra or Kevlar, Spectra break downs in the and remains stable in direct contact direct sunlight, with sunlight Weight 360 GSM (Max), and can be reduced Not disclosed. Estimated 500+ below 300 GSM GSM Friction Friction resistance (decay) time of 3.7 s Not disclosed. Estimated 1 to Resistance at 360 GSM, and 3 s at >300 GSM. 1.2 s Can be reduced to approx. 250-280 denier without affecting results. Structure Lower GSM in a complete structure The Spectra used is a minimum which allows integration with many of 215 gsm, hence depending other or similar UHWMPE fibres on knit structure will typically be at 400 GSM or greater. Too heavy for integration with most sports fabrics. Breathability Softer, cooler Following from comments above - will increase wearer's core temperature, but reduces wicking and natural cooling. Comfort & Less friction on the skin & Feel subsequently more comfortable Colour Able to be coloured and dyed, enabling Spectra is orange and cannot integration into all types of garments. be dyed hence cannot be readily colour integrated or printed with sponsor logos/ advertising. Any fashion colouring or styling will be limited. Elasticity Greater elasticity. Greater stretch and return; good resistance in both weft and warp directions Testing results for the U.S. Pat. No. 5,210,877 patent under the same conditions are around 1 sec. The GRT Fabric system, which is significantly thinner, is 300 to 400% better.
3. Comparison with the Fabric of US-2011/0300366 and US-2012/0060563

(68) US patent applications 2011/0300366 and 2012/0060563 Staple fibres of coolmax and UHMWPE have been spun into a yarn, using ring spinning method to develop a thermo-regulating, cut resistant yarn. Table 5 below shows different percentages of fibres used to develop experimental yarns and fabrics. These yarns may also contain an elastomeric filament. Fabrics can be woven, knitted, non-woven and combinations. These fabrics claimed to be used for clothing items such as gloves, aprons, chaps, pants, shirts, jackets, coats, socks, undergarments, vests and hats and have improved thermo-regulating properties and cut resistant.

(69) TABLE-US-00005 TABLE 5 Comparative testing Fabric types UHMWPE % Polyester (coolmax) % Comparative 1 100 0 Experiment 1 10 90 Experiment 2 25 75 Experiment 3 50 50 Experiment 4 75 25 Comparative 2 0 100
Further benefits of the fabric system of the present invention are set out in Table 6.

(70) TABLE-US-00006 TABLE 6 Fabric types Yarn 1 Yarn 2 Yarn 3 Machine type Comparative 440dtex 78dtex nylon 110dtex lycra 13 gauge Example 1 UHMWPE (solution dyed) (needles per inch) knitting machine Experiment 1 440dtex 78dtex nylon 110dtex lycra 13 gauge composite yarn (solution dyed) knitting machine 5% mineral fibre 95% UHMWPE Experiment 2 440dtex 156dtex nylon 110dtex lycra 13 gauge composite yarn (solution dyed) knitting machine 5% mineral fibre 95% UHMWPE Comparative 220dtex 65dtex nylon 36dtex lycra 18 gauge Example 2 UHMWPE (solution dyed) knitting machine Experiment 3 220dtex 65dtex nylon 36dtex lycra 18 gauge composite yarn (solution dyed) knitting machine 5% mineral fibre 95% UHMWPE

(71) The composite yarns described in US-2011/0300366 and US-2012/0060563 have been manufactured using a double covering method as depicted in FIG. 7. In this manufacturing process the nylon yarn (10) is been wrapped around the elongated Lycra yarn (12) in S direction, then dyed nylon yarn (14) is been wrapped around in Z direction to cover the un-dyeable yarn (10). Several knitted fabrics has been prepared and tested using these composite yarns.

(72) As per the test results set out in Table 7, cut resistance of fabrics that have been developed using 5% mineral fibres and 95% UHMWPE have strength increased by 3 to 3.5 times compared to fabric made with 100% UHMWPE.

(73) TABLE-US-00007 TABLE 7 Comparison with US patent applications 2011/0300366 and 2012/0060563 Fabric System - present US patent applications invention 2011/0300366 & 2012/0060563 Use Mainly friction resistant Mainly stab/cut resistant. Not typically used for sporting applications Weight Thinner, lighter weight, Bulkier, thicker, thus difficult to thus easier to integrate integrate with other materials. with other materials. Higher GSM. Lower GSM Breathability Thicker and heavier therefore wicking and cooling not as efficient. Colouring Can be extensively Can be coloured to some extent coloured

(74) Many fabrics of the prior art have been developed for specific purposes, such as protecting soldiers, fire fighters or police during the course of their work. These fabrics have been designed to provide protection against projectiles such as bullets, sharp weapons such as knives, or impact such as a blow from a baton. Fabrics developed for these types of purposes are typically very thick and heavy. For example, Kevlar or Dyneema fabric used as inserts in trousers for motorcyclists weighs more than 600 g/m.sup.2, and Kevlar bullet proof vests are very thick. Many of the fabrics of the prior art have a limited life span as they are sensitive to UV light and the colours of high performance fibre products are limited mostly to yellow, white and black, because they are unable to be dyed and cannot receive a printed a logo or other advertising indicia. Furthermore, the fabrics of the prior art have significant drawbacks in terms of moisture management, weight, wicking, heat transfer management, ability to be integrated into garments without detracting from the look and feel, and comfort for the everyday user.

(75) The aforementioned prior art fabrics have significant benefits when used for their intended purpose, but cannot successfully be adapted for use in general apparel or garments for high activity such as playing sport. They are not typically suitable for those playing sport, athletes, children or the elderly.

(76) The fabric system of the present invention was further tested and compared with the following commercially available fabrics used for sporting applications: Commercial Fabric 1fabric used in summer sports garments such as running shorts or pants, cycling shorts or pants; Commercial Fabric 2fabric used in a winter sports garment such as a long pair of running pants (thicker for warmth), or a longer pair of cycling pants or jersey; and Test Fabric 3 produced with regular knit and used for protection, similar to the fabric described in U.S. Pat. No. 5,210,877.

(77) The testing results comparing weight and time to deterioration of both the weft and warp are set out in Table 8 and FIGS. 8(a) to 8(c).

(78) TABLE-US-00008 TABLE 8 Comparisons Yarns Used Combination Details A Commercial Fabric 1 General Single Layer Fabric B Commercial Fabric 2 Winter Multiple Layer Fabric C Nylon/UHMWPE 140 denier Nylon & 100 denier UHMWPE D Nylon/UHMWPE/Spandex 75 denier Nylon, 100 denier UHMWPE & 40 denier Spandex Survival Weft (cross ways) Time to deteriorate: seconds A Commercial Fabric 1 0.1 B Commercial Fabric 2 0.1 C Test Fabric 3 0.28 D Fabric System - Present invention 1.375 Survival Warp (length) Time to deteriorate: seconds A Commercial Fabric 1 0.1 B Commercial Fabric 2 0.1 C Test Fabric 3 1.1 D Fabric System - Present invention 3.35 up to >6 (minimum) Weight GSM A Commercial Fabric 1 210 B Commercial Fabric 2 300 C Test Fabric 3 300 D Fabric System - Present invention 230 to 360

(79) As can be seen from Table 8, the fabric system of the present invention is significantly better by a factor of 3, when compared with the Test Fabric 3, and 30 to 40 times better than the two commercial fabrics tested.

(80) The tested weight of fabric system of the present invention was slightly higher than Commercial Fabric 1 to higher than Test Fabric 3. The tests have revealed that the fabric system of the present invention can lower the GSM to below 300, which is lower than Test Fabric 3, or the winter weight sports garment, but is similar to summer weight thin garments or garments such as running tights. This still provides results 3 to 4 times better then the Test Fabric 3 and 30 to 40 times better than the two Commercial Fabrics when comparing like to like.

(81) Additional Yarn Combinations

(82) In addition to the fibres and fabrics described above the following additional combinations were tested: A150 Denier UHWMPE with DC low power Spandex & Nylon 75 Denier A250 Denier UHWMPE with DC high power Spandex & Nylon 75 Denier A350 Denier UHWMPE with SC low power Spandex & Nylon 75 Denier A450 Dener UHWMPE with SC high power Spandex & Nylon 75 Denier A550 Denier UHWMPE with DC low power Spandex & Nylon Super Micro Fibre A650 Denier UHWMPE with DC high power Spandex & Nylon Super Micro Fibre A750 Denier UHWMPE with SC low power Spandex & Nylon Super Micro Fibre A850 Denier UHWMPE with SC high power Spandex & Nylon Super Micro Fibre A930 Denier UHWMPE with DC low power spandex & Nylon Super Micro Fibre A1030 Denier UHWMPE with DC high power Spandex & Nylon Super Micro Fibre A1130 Denier UHWMPE with TC low power Spandexx & Nylon Super Micro Fibre A1230 Denier UHWMPE with TC high power Spandex & Nylon Super Micro Fibre

(83) The abbreviation DC refers to UHWMPE and Nylon Super Micro Fibre, and TC refers to UHWMPE and 2 Nylon Super Micro Fibre

(84) All 12 new additional combinations provided results 30 greater than current commercially available yarns, subject to application. Table 9 sets out testing results for the fabrics, based on T5 structure:

(85) TABLE-US-00009 TABLE 9 Fabrics Weight GSM Structure Time to Deteroriate A1 to A4 269 GSM T5 6.0 + seconds A5 to A8 244 GSM T5 6.0 + seconds A9 to A12 220 GSM T5 3.5 + seconds

(86) Fabrics A1 to A4 were thicker and heavier than the other fabrics and provided the highest level of resistance independent of knitting structure. Fabrics A5 to A8 were not as thick, with the SC being slightly lighter weight, however better hand feel was achieved with the DC fabrics. Fabrics A9 to A12 were lighter than the other fabric, and exhibited lower resistance, but the resistance was still 30 times greater than commercially available equivalents and the hand feel was significantly better.

(87) Further testing was also conducted on the knitting structures, using structures T1 to T6 illustrated in FIGS. 9(a) to 9(f), which were all formed of eight feeds and correspond to the following unit cell sizes: T122 T224 T342 T444 T524 T6single jersey, 11

(88) The structures T5, T1, T3 and T2 produced the most optimal results across all the samples tested. Specifically, they exhibited the lightest weight, highest resistance, best hand feel, greatest utility and were the most wearable fabrics.

(89) While this invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modification(s). This application is intended to cover any variations uses or adaptations of the invention following in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth.

(90) As the present invention may be embodied in several forms without departing from the spirit of the essential characteristics of the invention, it should be understood that the above described embodiments are not to limit the present invention unless otherwise specified, but rather should be construed broadly within the spirit and scope of the invention as defined in the appended claims. The described embodiments are to be considered in all respects as illustrative only and not restrictive.

(91) Various modifications and equivalent arrangements are intended to be included within the spirit and scope of the invention and appended claims. Therefore, the specific embodiments are to be understood to be illustrative of the many ways in which the principles of the present invention may be practiced. In the following claims, means-plus-function clauses are intended to cover structures as performing the defined function and not only structural equivalents, but also equivalent structures. For example, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface to secure wooden parts together, in the environment of fastening wooden parts, a nail and a screw are equivalent structures.

(92) Comprises/comprising and includes/including when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. Thus, unless the context clearly requires otherwise, throughout the description and the claims, the words comprise, comprising, includes, including and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of including, but not limited to.