ELASTIC FABRIC AND PROCESS OF PREPARATION

Abstract

The disclosure provides a woven fabric, wherein all warp and weft yarns may be elastic. One or more of the weft and warp yarns may have a stretchable core comprising a first elastic fiber and a second fiber that may be less elastic than said first fiber. The elastic warp yarns may have a twist level with a twist multiplier in the range of 2.5 to 6. In embodiments, a woven fabric may include all warp and weft yarns being elastic, all weft and warp yarns having a stretchable core comprising a first elastic fiber and a second fiber that is less elastic than said first fiber, and the elasticity of the fabric in warp direction is at least 25% and elasticity of the fabric in weft direction (E.sub.weft) is at least 25%, preferably at least 30%, more preferably 40%. In embodiments, the elasticity of the fabric in the warp direction may be at least 25%.

Claims

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39. A woven fabric comprising; elastic warp yarns; elastic weft yarns, said elastic warp yarns and elastic weft yarns each having a stretchable core and an inelastic fibers sheath covering said core, said stretchable core including a first elastic fiber and a second fiber that is less elastic than said first elastic fiber; said woven fabric having an elasticity in warp direction of at least 25% (measured according to ASTM D3107 - Stretch); and said elastic warp yarns having a twist level with a twist multiplier in the range of 2.5 to 6.

40. The woven fabric according to claim 39, comprising: wherein the twist multiplier is in the range of 3.5 to 4.7.

41. The woven fabric according to claim 39, comprising: wherein said first elastic fiber and said second fiber are intermingled with a number of connecting points within the range of 20 to 1000 twists per meter; said elasticity in said weft direction is greater than said elasticity in said warp direction; said second fiber comprises a PBT elastomultiester, a bicomponent PTT/PET or PTT/PBT, or nylon; and said first elastic fiber comprises a polyolefin elastomer or a polyurethane elastomer.

42. The woven fabric according to claim 39, comprising: wherein said first elastic fiber is stretchable to at least 400% of an initial length of said first elastic fiber and said second fiber is stretchable to at least 20% of an initial length of said second fiber but is less stretchable than said first elastic fiber.

43. The woven fabric according to claim 39, comprising: wherein said woven fabric comprises denim.

44. A clothing article comprising: a woven fabric, said woven fabric comprising elastic warp yarns and elastic weft yarns; said elastic warp yarns and elastic weft yarns each having a stretchable core and an inelastic fibers sheath covering said core, said stretchable core including a first elastic fiber and a second fiber that is less elastic than said first elastic fiber, said woven fabric having an elasticity in warp direction of at least 25% (measured according to ASTM D3107 - Stretch), and said elastic warp yarns having a twist level with a twist multiplier in the range of 2.5 to 6.

45. The clothing article according to claim 44, comprising: wherein the twist multiplier lies in the range of 3.5 to 4.7 and said elasticity in weft direction is greater than said elasticity in warp direction.

46. The clothing article according to claim 44, comprising: wherein said first elastic fiber is stretchable to at least 400% of an initial length of said first elastic fiber and said second fiber is stretchable to at least 20% of an initial length of said second fiber, said second fiber being less stretchable than said first elastic fiber.

47. The clothing article according to claim 44, comprising: wherein said first elastic fiber and said second fiber are intermingled with a number of connecting points within the range of 20 to 1000 twists per meter; said elasticity in said weft direction is greater than said elasticity in said warp direction; said second fiber comprises a PBT elastomultiester, a bicomponent PTT/PET or PTT/PBT, or nylon; and said first elastic fiber comprises a polyolefin elastomer or a polyurethane elastomer.

48. The woven fabric according to claim 39, comprising: said woven fabric having elasticity in weft direction of at least 40% (measured according to ASTM D3107 - Stretch).

49. The clothing article according to claim 44, comprising: said woven fabric having elasticity in weft direction of at least 40% (measured according to ASTM D3107 - Stretch).

50. The woven fabric according to claim 39, further comprising: wherein elasticity of the fabric in weft direction (E.sub.weft) is higher than the elasticity in warp direction (E.sub.warp).

51. The woven fabric according to claim 39, further comprising: wherein elasticity of the fabric in warp direction (E.sub.warp) is higher than elasticity in the weft direction (E.sub.weft).

52. The clothing article according to claim 44, comprising: wherein elasticity of the fabric in weft direction (E.sub.weft) is higher than the elasticity in warp direction (E.sub.warp).

53. The clothing article according to claim 44, comprising: wherein elasticity of the fabric in warp direction (E.sub.warp) is higher than elasticity in the weft direction (E.sub.weft).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0072] The novel features believed characteristic of the disclosed subject matter will be set forth in any claims that are filed. The disclosed subj ect matter itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:

[0073] FIGS. 1A and 1B show how the minimum warp elasticity required can be determined.

[0074] FIG. 2 is a perspective schematic view of an exemplary embodiment of a fabric.

[0075] FIG. 3 displays a process for producing an elastic woven fabric in accordance with embodiments.

[0076] FIG. 4 displays a process for producing an elastic woven fabric in accordance with embodiments.

[0077] FIG. 5 displays a process for producing an elastic woven fabric in accordance with embodiments.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0078] Reference now should be made to the drawings, in which the same reference numbers are used throughout the different figures to designate the same components.

[0079] It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. Thus, a first element discussed below could be termed a second element without departing from the teachings of the present disclosure.

[0080] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

[0081] The disclosure relates to a woven fabric having elastic warp yarns and elastic weft yarns. The woven fabric may be characterized in that it may have an elasticity, i.e., it can be stretched, in the warp direction of at least 25%, preferably at least 30%, measured according to ASTM D3107 MOIDIFIED - Stretch after 3 home wash, and in that elasticity of the fabric in weft direction (E.sub.weft) may be equal to or higher than the elasticity of the fabric in warp direction (E.sub.warp).

[0082] In view of the fact that, in embodiments, the woven fabric of the disclosure may be elastic in both the warp and weft directions, it may be defined as a “bi-stretch” woven fabric.

[0083] As used herein, the term “elastic yarn” may refer to a yarn comprising an elastomeric fiber covered by a wrap, i.e., a core-spun yarn, and which may provide characteristics of elasticity to the woven fabric.

[0084] Suitable fibers for the elastic filament may include polyurethanic fibers such as, but not limited to elastane (e.g. Lycra®, Dorlastan (a registered trademark of Asahi Kasei Spandex Europe GMBH, LLC), spandex (Radicci Spandex Co.), and lastol (Dow Chemical XLA).

[0085] Suitable fibers for the less elastic, control, filament may include, but are not limited to: polyamides such as nylon (e.g., nylon 6, nylon 6,6, nylon 6,12, and the like), polyester, polyolefins (such as polypropylene and polyethylene), mixtures and copolymers of the same, and PBT and bicomponent filaments (namely elastomultiesters such as PBT/PET and PTT/PET filaments). In embodiments, suitable staple fibers for the sheath may include, but are not limited to: polyester fibers and natural fibers, preferably cotton fibers, that can be dyed.

[0086] In embodiments, elastic yarns which may be utilized in the disclosure may thus be disclosed in WO2012/06248. In embodiments of the elastic yarns, the two filaments of the core may be twisted at a twisting number of at least 200 twists per meter, preferably 300 to 600 twists/meter, which may result in the two filaments elongating and retracting as a single filament.

[0087] In embodiments, the comfort level of the bi-stretch fabric may be improved. This improvement may be obtained due to the E.sub.warp being lower than the E.sub.weft. In this bi-stretch fabric, the warp yarns may provide a better support against the gravity and the greater E.sub.weft than E.sub.warp may allow a better shaping of the body.

[0088] In embodiments, an elastic woven fabric may have an elasticity in the warp direction (E.sub.warp) in the range of at least 25%, according to ASTM D3107 MODIFIED - Stretch after 3 home washes and elasticity of the fabric in weft direction (E.sub.weft) may be equal to or higher than the elasticity in the warp direction (E.sub.warp).

[0089] In embodiments, an elastic woven fabric may have an elasticity in the warp direction (E.sub.warp) in the range of at least 30%,-and more preferably at least 40%, according to ASTM D3107 MODIFIED - Stretch after 3 home washes. In embodiments, wherein E.sub.weft may be higher than E.sub.warp, due to the fact that E.sub.weft is higher than E.sub.warp, the comfort level of the bi-stretch fabric of the invention may be improved. This improvement may be obtained because, when E.sub.warp is lower than E.sub.weft, the warp yarns of the bi-stretch fabric may provide a better support against gravity; at the same time, a higher E.sub.weft may allow a better shaping of the body.

[0090] In embodiments, an elastic woven fabric may have an elasticity in the warp direction (E.sub.warp) in the range of 25% to over 75%, preferably 25% to 90%, more preferably 30% to 90%, most preferably 30% to 60%, according to ASTM D3107 MODIFIED - Stretch after 3 home washes, and the elasticity in the weft direction (E.sub.weft) comprised in the range of 30% to over 150%, preferably 30% to 150%, more preferably 50% to 140%, measured according to ASTM D3107 MODIFIED - Stretch after 3 home washes.

[0091] In embodiments, the elastic woven fabric may have elasticity in the weft direction (E.sub.weft) that may be twice the elasticity in the warp direction (E.sub.warp), preferably two to three times E.sub.warp.

[0092] In embodiments, improved recovery and reduced growth may be obtained by the bi-stretch fabric due to the providing of high elasticity in both warp and weft direction.

[0093] In embodiments, improved performance may be obtained by the bi-stretch fabric due to the high elasticity that may be more than what people may need in their daily lives. In view of this, normal daily use may not require the use of all elastic and elongation capacity of the fabric. Therefore, in embodiments, the fabric of the disclosure may not be overstretched or stressed, thus avoiding damage and lack of performance such as lack of recovery, increased growth, and bagging.

[0094] As an example, in the so called “super-skinny” garments, the garment’s cut is usually smaller than the normal body size. Therefore, just wearing super skinny garments may cause the fabric to stretch, which the garments may be made of. In view of this fact, normal use may cause stretching of the fabric of which the super-skinny garment is made. In view of this fact, a normal use can cause overstretching of the fabric of the super-skinny garment and damage to the fabric, as well as bagging at knees and elbows. In embodiments, the bi-stretch fabric of the disclosure may avoid overstretching, damage, bagging, and other problems. In embodiments, these problems may be avoided due to the fact that the fabric of the disclosure may be able to move with human skin, i.e., may be able to move as human skin moves.

[0095] In embodiments, the elastic corespun yarn may have an English cotton count ranging from 8 Ne to 90 Ne, preferably from 10 Ne to 80 Ne, more preferably from 12 Ne to 60 Ne.

[0096] In embodiments, the elastic woven fabric may have a weight in the range of 3 oz/yard.sup.2 to 20 oz/yard.sup.2 after wash (according to ASTM D3776), preferably in the range of 4 oz/yard.sup.2 to 15 oz/yard.sup.2 after wash (according to ASTM D3776), more preferably from 7 oz/yard.sup.2 to 14 oz/yard.sup.2 after wash (according to ASTM D3776).

[0097] In embodiments, the bi-stretch fabric may be a denim fabric.

[0098] In embodiments, an elastic woven fabric may be produced by a process 300 (FIG. 3) including determining 305 the minimum warp elasticity (E.sub.warp) required and weaving 310 warp yarns and weft yarns, wherein said woven fabric may be elastic in both the warp and the weft direction and the fabric in the warp direction may be at least 25%, preferably at least 30% (ASTM D3107 MODIFIED - Stretch after 3 home wash), and elasticity of the fabric in weft direction (E.sub.weft) may be equal to or higher than the elasticity in warp direction (E.sub.warp), preferably two times the value of E.sub.warp, and most preferably two to three times the value of E.sub.warp.

[0099] In embodiments, the fabric may not be heat set, i.e., the fabric may not undergo a thermal treatment to set its elasticity to a pre-set value. It was surprisingly found that when the elastic yarns are used, in particular the elastic yarns above disclosed by reference to WO2012/062480, the resulting fabric may not have to be heat-set to avoid the occurrence of problems such as curling and torqueing. In embodiments, a fabric as mentioned above may undergo a thermal treatment.

[0100] In embodiments, possible combinations of stretch values (elasticity) measured by ASTM D3107 (stretch) after three home washings may include values in the ranges of: 30-75; 33-35; 53-75; 27-65; 28-50; 35-100; 40-100 40-120, wherein the elasticity is given for warp-weft.

[0101] Making reference to FIGS. 1A and 1B, the minimum warp elasticity required may be determined by measuring the variation in the distance between two benchmark points “A” 30 and “B” 40 taken at two opposite ends of a joint 20, such as an elbow or a knee, for example, along the axis of the limb 10 (e.g. an arm or a leg), on the skin of the future user.

[0102] In embodiments, the limb 10 may be an arm or a leg.

[0103] In embodiments, the joint 20 may be an elbow or a knee.

[0104] For example, in order to make trousers, the determination may be carried out, in embodiments, on a knee, namely above and below a knee. On the contrary, if the purpose is to obtain a fabric to make shirts, the minimum warp elasticity required may be determined on an elbow in embodiments.

[0105] In FIG. 1A, when the limb 10 is unbent, two benchmarks “A” 30 and “B” 40 may be taken at two opposite ends of a joint 20 along the axis of the limb 10.

[0106] In embodiments, the distance between benchmark “A” 30 and benchmark “B” 40 when the limb 10 is unbent may be the value X. In embodiments, when the limb 10 is bent, as shown in FIG. 1B, the distance measured along the skin of the limb 10 between benchmark “A” 30 and benchmark “B” 40, taken at two opposite ends of a joint 20, may increase to a value Y. The percentage of the variation of distance X to distance Y may be calculated with the formula (Y-X)/X. The result obtained may indicate the minimum warp elasticity required for a fabric.

[0107] In embodiments, the minimum warp elasticity required may be at least the value calculated using formula (Y-X)/X, wherein X may be the distance between the two benchmarks “A” 30 and “B” 40, taken at two opposite ends of the joint 20, along the axis of a limb 10, when the limb 10 is unbent, and Y may be the distance between the same two benchmarks when the limb 10 is bent.

[0108] In embodiments, the fabric may be woven in order to obtain an elastic woven fabric having an E.sub.warp that may be greater than the value of (Y-X)/X and preferably at least twice the value of (Y-X)/X.

[0109] In embodiments, the warp elasticity E.sub.warp of the fabric may be 20% higher than the value of (Y-X)/X, preferably 30% higher than the value of (Y-X)/X, and more preferably 40% higher than the value of (Y-X)/X.

[0110] In embodiments, the disclosure may further provide a process 400 for preparing an elastic woven fabric as disclosed above and shown in FIG. 4. In embodiments, the process may include determining 405 the minimum warp elasticity required for the fabric. In embodiments, the process may further include selecting 410 an elastic yarn and a rigid yarn to be used in at least the warp yarns. In embodiments, the process may further include weaving 415 warp yarns and weft yarns, wherein said woven fabric may be elastic in both the warp and the weft directions. In embodiments, the elasticity of the fabric in the warp direction (E.sub.warp) may be at least 30% and the elasticity of the fabric in the weft direction (E.sub.weft) may be higher than the elasticity in the warp direction (E.sub.warp) (ASTM D3107 MODIFIED - Stretch after 3 home washes). In embodiments, the elasticity of the fabric in the warp direction (E.sub.warp) may be at least 30% and the elasticity of the fabric in the warp direction (E.sub.warp) may be higher than the elasticity in the weft direction (E.sub.weft) (ASTM D3107 MODIFIED - Stretch after 3 home washes).

[0111] In embodiments, the minimum warp elasticity required for the fabric may be calculated using formula (Y-X)/X, wherein X may be the distance between two benchmarks “A” 30 and “B” 40 taken at two opposite sides of a joint 20 along the axis of a limb 10 when the limb 10 is unbent and Y may be the distance between the same two benchmarks when the limb 10 is bent.

[0112] In embodiments, the disclosure may further provide a process 500 for preparing an elastic woven fabric as disclosed above and shown in FIG. 5. In embodiments, a process 500 may include providing 505 corespun warp yarns and corespun weft yarns each having a stretchable core and an inelastic fiber sheath that may cover the stretchable core. In embodiments, the stretchable cores may comprise a first elastic fiber and a second fiber, wherein the second fiber may be less elastic than the first elastic fiber.

[0113] The process may further include weaving 510 the corespun warp yarns and the corespun weft yarns to create a fabric. The process may further include finishing 515 the fabric. In embodiments, the finishing 515 may provide the fabric with an elasticity in the warp direction of at least 25% and an elasticity in the weft direction of at least 25%.

[0114] In embodiments, the finishing 515 may provide the fabric with an elasticity in the warp direction of at least 30% and an elasticity in the weft direction of at least 30%.

[0115] In embodiments, the finishing 515 may provide the fabric with an elasticity in the warp direction of at least 40% and an elasticity in the weft direction of at least 40%.

[0116] In embodiments, the first fiber and second fiber may be connected together by at least one of intermingling, twisting, and coextrusion.

[0117] In embodiments, the elasticity of the fabric in the weft direction (E.sub.weft) may be greater than the elasticity of the fabric in the warp direction (E.sub.warp). In embodiments, the elasticity of the fabric in the warp direction (E.sub.warp) may be greater than the elasticity of the fabric in the weft direction (E.sub.weft).

[0118] In embodiments, the second fiber may be selected from the group of a PBT elastomultiester, a bicomponent PTT/PET, a PTT/PBT, and a nylon.

[0119] In embodiments, the first elastic fiber may be selected from the group of a polyolefin elastomer and a polyurethane elastomer.

[0120] FIG. 2 displays a woven fabric in accordance with embodiments. The woven fabric 50 may comprise warp yarns 51 and weft yarns 52. In embodiments, a first fiber 61 and a second fiber 62 (also referred to as core fibers 63 in embodiments) may be present in the core of the warp yarns 51. In embodiments, core fibers 63, including both first fibers 61 and second fibers 62, may be present in the core of the weft yarns 52.

[0121] In embodiments, the second fibers 62 may be less elastic than the first fibers 61.

[0122] FIG. 2 displays an embodiment of the woven fabric that may be a bi-directional stretch fabric. In embodiments, the fabric may be denim.

[0123] In embodiments, the bi-stretch fabric of the disclosure may be suitable to produce clothing articles comprising at least bi-stretch fabric. For example, clothing articles that may comprise the elastic woven fabric disclosed may be leggings, pants, T-shirts, sweaters, jackets, and any other garment. In embodiments, the bi-stretch fabric of the disclosure may be suitable to produce textiles other than clothing articles.

[0124] The following table may show the advantages of a fabric as described in an embodiment of the disclosure as far as growth of the fabric is concerned.

TABLE-US-00001 Required Elasticity % Growth for 80% elastic fabric (ASTM D3107) Growth for 50% elastic fabric (ASTM D3107) Growth for 20% elastic fabric (ASTM D3107) 10 1 1 1 20 1.5 3 6 30 2 4 - 40 3 5 - 50 4 7 - 60 5 - - 65 5.5 - - 70 5.8 - - 75 7.5 - - 80 10 - -

[0125] In the above table, the required elasticity may be the elasticity determined or measured as previously discussed, e.g., it may be known that the elasticity required for the fabric of a legging or skinny jeans is 20% when the actual fabric used has a 20% elasticity. The result may be a growth of the fabric with use and a bagging resulting at the knees. Additionally, any holding and shaping power of the fabric may be decreased with time.

[0126] If, in embodiments, for a leggings or jeans garment, the used fabric has an elasticity of 50%, the growth may be only 3 or 1.5 if a fabric having 80% elasticity is utilized.

[0127] If, in embodiments, a required elasticity of a fabric is 50%, the use of a 50% elastic fabric may result in a growth of 7% of the fabric compared to a growth of 4% of the fabric if a fabric having 80% elasticity is used.

[0128] In embodiments, a garment may be customized to the final user’s body structure. By measuring the required elasticity on a user’s body as previously mentioned it may be possible to select a garment, in embodiments, that may have an elasticity that more properly suits a user’s body and movement characteristics.

[0129] For the purposes of this disclosure, the term “inelastic fiber sheath” may refer to a sheath comprising one or more fibers that may envelop and/or cover at least a portion of a stretchable core of a yarn.

[0130] For the purposes of this disclosure, the terms “method” and “process” may be interchangeable.

[0131] In embodiments of any processes disclosed, the fabric, yarn, and/or fibers may comprise any disclosed characteristics.

[0132] In embodiments, suitable elastic core spun yarns may be those disclosed in WO2008/130563, which is hereby incorporated by reference in its entirety.

[0133] In embodiments, original polymers may be utilized. For the purposes of this disclosure, the term “original polymers” may refer to polymers that are utilized that are in their original form of when they had first been discovered. In embodiments, trademarked polymers may be utilized. It is noted that trademarked polymers may vary in characteristics from original polymers, such characteristics being, for example, molecular weight, branching, and density.

[0134] While this disclosure has been particularly shown and described with reference to preferred embodiments thereof and to the accompanying drawings, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit of this disclosure. Therefore, the scope of the disclosure is defined not by the detailed description but by the appended claims.