Patent Application
20170088985
The present disclosure relates to a chambray fabric, bedding articles including a chambray fabric, and related methods of manufacturing same.
A typical chambray fabric formed with a colored warp yarns and undyed weft yarns. In some cases, the weft yarns are dyed a color that is lighter than the color the warp yarns are dyed. The warp yarns may be package dyed or dyed on the warp beam and then woven into fabric with the undyed filling yarns to achieve the desired effect. Chambray fabric can also be made in reverse with undyed or white warp yarns and colored weft yarns. In either version, the warp and weft yarns are normally made of 100% cotton fibers. Coloring agents typically include reactive or vat dyes.
Typical chambray fabrics have poor colorfastness to ingredients common in consumer products, such as, for example, cosmetic or household products. There is a need for woven chambray fabrics and related bedding articles that are colorfast to one or more ingredients in cosmetic and/or household products. An embodiment of the present disclosure is a woven chambray fabric that includes a plurality of warp yarns with each warp yarn including natural fibers. The woven fabric includes a plurality of weft yarns interwoven with the plurality of warp yarns. Each weft yarn defines a weft yarn assembly that has a first weft yarn, a second weft yarn that extends alongside the first weft yarn, and a plurality of consolidation regions where the first weft yarn and the second weft yarn are coupled to each other. The first weft yarn is a spun staple yarn that includes natural fibers and the second weft yarn is a dyed continuous filament yarn. The second weft yarn is dyed a color that is different from a color of the first weft yarn and each warp yarn so as to define the woven chambray fabric.
Another embodiment of the present disclosure is a coordinated bedding system. The system includes a plurality of bedding articles that are formed from a woven chambray fabric. The bedding articles include one or more of a flat sheet, a fitted sheet, a pillow case, a sham, a comforter, a duvet, a bed-skirt, and/or a blanket.
Another embodiment of the present disclosure is a method of manufacturing a woven chambray fabric. The method includes forming a yarn assembly that includes a first yarn, a second yarn that extends alongside the first yarn, and a plurality of consolidation regions where the first yarns and the second yarns are coupled together. The first yarn is a spun staple yarn that includes natural fibers and the second yarn is a continuous filament yarn. The method includes weaving a plurality of warp yarns with a plurality of the yarn assemblies to form the woven fabric. The warp yarns include natural fibers. The method includes applying color to the second yarn. Applying color to the second yarn can occur before weaving. Alternatively, applying color to the second yarn can occur after weaving.
The foregoing summary, as well as the following detailed description of illustrative embodiments of the present application, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the present application, there is shown in the drawings illustrative embodiments of the disclosure. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown.
Embodiments of the present disclosure include a woven chambray fabric, bedding articles, and a coordinated bedding system comprising a plurality of bedding articles. A bedding article may be a flat sheet, a fitted sheet, a pillow case, a sham, a comforter, a duvet, a bed-skirt, and/or a blanket. The bedding articles include woven chambray fabrics 10 constructed in accordance with the present disclosure.
Turning to
The woven chambray fabric 10 is well suited for bedding applications. The presence of natural fibers (e.g. cotton) results in soft, supple fabrics with good hand and drape—characteristics that are desirable in bedding articles. The presence of continuous filament yarns in the weft can improve fabric durability, e.g. wash durability, which is also a desirable attribute in bedding articles. And the chambray color effect is not diminished by exposure to various ingredients found in consumer products. Rather, the woven chambray fabric 10 is colorfast against one or more ingredients found in cosmetic and household products. For example, the woven chambray fabric 10 is colorfast against cosmetics chemicals, such as benzoyl peroxide, retinol, and salicylic acid, as will described further below. The woven chambray fabric 10 is also colorfast against chlorine bleach and non-chlorine bleach. Thus, long-term use of bedding articles that include woven chambray fabric 10 should not result in color changes when exposed to these common household chemicals. Improved durability, in combination with the colorfast properties, extends the useful life bedding articles, decreasing the overall cost of use for the consumer.
The woven chambray fabric 10 can have wide range of designs. The woven chambray fabric 10 can have a number of different woven structures each having a woven design repeat. As used herein, a woven design repeat includes at least a first warp yarn 20a, a second warp yarn 20b, and at least one weft yarn 40. For example, a plain weave fabric has a woven design repeat that includes two adjacent warp yarns 20 and two adjacent weft yarns 40. Depending on the particular design, woven design repeats may repeat along: a) the weft direction 4; b) the warp direction 6; or c) both the weft direction 4 and warp directions 6. Some exemplary woven structures include, but are not limited to: plain weaves; basket weaves, rib weaves (e.g. 2×1 rib weave; 2×2 rib weave; or 3×1 rib weave) twill weaves; oxford weaves; percale weaves, satin weaves (e.g. satin dobby base, satin stripe satin 5/1, satin 4/1 satin; 4/1 satin base strip; 4/1 stain swiss dot; 4/1 down jacquard; 5/1 satins), or sateen weaves. In one example, the woven fabric is a plain weave. In another example, the woven fabric is a basket weave. In another example, the woven fabric is a rib weave. In another example, the woven fabric is a twill. In another example, the woven fabric is an oxford weave. In another example, the woven fabric is a satin weave. In another example, the woven fabric is a percale weave. Furthermore, a number of exemplary satin constructions are possible. For instance, in one satin weave example, the woven fabric is a 4/1 satin. In another example, the woven fabric is a 4/1 satin dobby diamond weave. In another example, the woven fabric is a 4/1 satin dobby stripe. In yet another example, the woven fabric is a 4/1 satin jacquard weave. In another example, the woven fabric is a 5/1 satin. In still another example, the woven fabric may be a 6/1 satin. In another example, the woven fabric is a 7/1 satin. In yet another example, the woven fabric is an 8/1 satin. In another example, the woven fabric is a 9/1 satin. And in another example, the woven fabric is a 10/1 satin.
The present disclosure can utilize co-insertion techniques to insert multiple weft yarns 40 along a weft insertion path 19 in a single weft insertion event during weaving, as will be further detailed below. The weft insertion path 19 of weft yarn 40 is shown in dashed lines in
The woven chambray fabric 10 has thread counts suitable for bedding applications. The thread count of the woven fabrics made in accordance with present disclosure are typically greater than about 100 and can be as high as about 1000 (or even higher). The thread count as used herein is the total number of yarns in square inch of fabric. Plied yarns are considered one yarn for the purpose of determining thread count.
The woven chambray fabric 10 can have a range of warp end densities that are suitable for bedding articles. In accordance with an embodiment of the present disclosure, the woven fabric has a warp end density between about 50 warp ends per inch and about 350 warp ends per inch. Warp end density may be referred to as ends per inch or EPI. In one example, the warp end density is between about 50 and 150 warp ends per inch. In another example, the warp end density is between about 150 and 250 warp ends per inch. In another example, the warp end density is between about 250 and 350 warp ends per inch.
The woven chambray fabric 10 can have a range of weft end densities suitable for bedding articles. In accordance with an embodiment of the present disclosure, the weft yarns are arranged to define a weft end density between about 50 weft yarns per inch and about 700 weft yarns per inch (or more). Weft end density may be referred to as picks per inch or PPI. In one example, the weft yarn density is between about 100 and about 700 weft yarns per inch. In one example, the weft yarn density is between about 100 and about 400 weft yarns per inch. In another example, the weft yarn density is between about 400 and about 500 weft yarns per inch. In another example, the weft yarn density is between about 500 and about 700 weft yarns per inch. The weft yarn density has used herein refers to the total number of separate weft yarns along a length of the woven fabric. For example, a weft yarn density of about 50 picks per inch refers the 50 total weft yarns per inch of woven fabric. If the weft yarn groups are inserted during a single weft insertion event and each group includes three (3) weft yarns, then there would be about 16 total weft yarn groups per inch of fabric and 48 picks per inch. In accordance with one embodiment of the present disclosure, the plurality of warp yarns define a warp end density between about 50 warp ends per inch to about 250 warp ends per inch, and the weft yarns 40 define a weft density between about 50 wefts per inch and about 150 wefts picks per inch.
The type and content of the warp yarns 20 and weft yarns 40 are described next. In accordance with an embodiment of the present disclosure, the warp yarns 20 may be spun staple yarns that include natural fibers, e.g. cotton fibers. For example, the weft yarns may be exclusively cotton fibers, a blend of cotton fibers and one or more other natural fibers, and/or synthetic fibers. For instance, other natural fibers include silk, linen, flax, bamboo, hemp, wool, and the like. Other synthetic fibers may include, but are not limited to, rayon fibers (e.g. Modal, Lyocell) or thermoplastic fibers could be used blend yarns, such as polyethylene terephthalate (PET) fiber, polylactic acid (PLA) fiber, polypropylene (PP) fibers, polyamide fibers, and microfiber staple fibers.
The warp yarns 20 can include any type of spun staple yarn. For example, the warp yarns can be ring spun yarns, open end yarns, rotor spun yarns, vortex spun yarns, core spun yarns, jet spun yarns, or compact spun yarns. In another embodiment, the warp yarns can be Hygrocotton® brand yarns marketed by Welspun India Limited. Furthermore, yarns can be formed as disclosed in U.S. Pat. No. 8,833,075, entitled “Hygro Materials for Use In Making Yarns And Fabrics,” (the 075 patent). The 075 patent is incorporated by reference into present disclosure. Preferred warp yarns are ring spun yarns. The warp yarn 20 can, however, be any type of spun yarn structure. In alternative embodiment, the warp yarn can be a continuous filament yarn.
The warp yarns 20 have a range of counts for the fiber and yarn types described above. For instance, the warp yarn 20 can have a count in the range between about 8 Ne (664 denier) to about 120 Ne (44.3 denier). In certain examples, the warp yarn count is between 20 Ne (266 denier) and about 120 Ne (44.3 denier). In one example, the warp yarn count is between 20 Ne (266 denier) and about 100 Ne (53.1 denier). In one example, the warp yarn count is between 20 Ne (266 denier) and about 60 Ne (88.6 denier). In another example, the warp yarn count is between 20 Ne (266 denier) and about 40 Ne (133 denier). In another example, the warp yarn count is 20 Ne (266 denier) and about 30 Ne (177 denier). In one example, the warp yarn is 2-ply yarn. In another example, the warp yarn is a 3-ply yarn.
Referring to
The first weft yarn 42 can be formed from primarily from natural fibers. In accordance with the illustrated embodiment, the natural fibers are cotton fibers. However, in alternative embodiments, the first weft yarn 42 can include cotton fibers blended with other natural or synthetic fibers. In such an example, the natural fibers could include silk, linen, flax, bamboo, hemp, wool, and the like. The first weft yarn can include cotton and synthetic fibers. Synthetic fibers include, but are not limited to, rayon fibers (e.g. Modal, Lyocell) or thermoplastic fibers, such as polyethylene terephthalate (PET) fiber, polylactic acid (PLA) fiber, polypropylene (PP) fibers, polyamide fibers, and microfiber staple fibers.
The first weft yarn 42 is a spun staple yarn. The first weft yarns 42 can be ring spun yarns, open end yarns, rotor spun yarns, vortex spun yarns, core spun yarns, jet spun yarns, or compact spun yarns. In one example, the first weft yarn can be a Hygrocotton® brand yarn. In one preferred embodiment, the first weft yarn 42 is a ring spun yarn formed from cotton fibers. However, the first weft yarn is not limited to ring spun yarns made exclusively from the cotton fibers.
The first weft yarn 42 can have a range yarn counts. For instance, the first weft yarn 42 can have a count in the range between about 8 Ne (664 denier) to about 120 Ne (44.3 denier). In certain examples, the first weft yarn count is between 20 Ne (266 denier) and about 120 Ne (44.3 denier). In one example, the first weft yarn count is between 20 Ne (266 denier) and about 100 Ne (53.1 denier). In one example, the first weft yarn count is between 40 Ne (133 denier) and about 100 Ne (53.1 denier). In one example, the first weft yarn count is between 40 Ne (133 denier) and about 80 Ne (66.4 denier). In one example, the first weft yarn count is between 40 Ne (133 denier) and about 60 Ne (88.6 denier). In one example, the first weft yarn count is between 60 Ne (88.6 denier) and about 80 Ne (66.4 denier). In one example, the first weft yarn count is between 60 Ne (88.6 denier) and about 100 Ne (53.1 denier). In one example, the first weft yarn count is between 20 Ne (266 denier) and about 60 Ne (88.6 denier). In another example, the first weft yarn count is between 20 Ne (266 denier) and about 40 Ne (133 denier). In another example, the first weft yarn count is 20 Ne (266 denier) and about 30 Ne (177 denier). In one example, the first weft yarn has a count of about 20 Ne (266 denier). In one example, the first weft yarn count is about 30 Ne (177 denier). In one example, the first weft yarn count is about 40 Ne (133 denier). In another example, the first weft yarn count is about 60 Ne (88.6 denier). In another example, the first weft yarn count is about 70 Ne (75.9 denier). In another example, the first weft yarn count is about 80 Ne (66.4 denier). In another example, the first weft yarn count is about 100 Ne (53.1 denier). In another example, the first weft yarn has a count of about 120 Ne (44.3 denier).
The second weft yarn 44 is a dyed continuous filament yarn. Continuous filament yarns are formed by typical melt-spinning processes. As such, the second weft yarn 44 can be textured with false twist imparted via air jet texturing apparatus as is known in the art. The second weft yarn 44 can be formed to have a range of filaments per yarn as well as a range denier per filament (dpf). In one example, the second weft yarn 44 is a dyed continuous filament yarn formed from polyethylene terephthalate (PET) filaments.
The dyed continuous filament yarn 44 (sometimes referred to as the “dyed yarn)”can have one of several different yarn types based on how color is applied to the yarn. The dyed continuous filament yarn 44 may be a “dope-dyed” yarn, a “package-dyed” yarn, or a “yarn-dyed” yarn. A “dope-dyed” yarn is yarn with dye molecules or pigments disposed uniformly throughout the internal morphology of the fibers (filaments). A dope dyed yarn is a yarn that has dyes applied in the masterbatch during filament extrusion. A “package-dyed” means yarns that have dyes applied after yarn formation and before fabric formation, yet have dye molecules disposed in the internal morphology of filament or fiber structure. The phrases “yarn dyed yarn,” “yarn dyed weft yarn” or “yarn dyed continuous filament yarn” means yarns that have dyes applied after fabric formation) yet have dye molecules within the internal morphology of filament or fiber structure. A dope-dyed yarn as used herein is a structural term that is distinguished from a “package dyed” yarn and a “yarn dyed yarn.” A dope-dyed yarn would have better and more uniform color penetration through the yarn cross-section and along the length of the yarn. In contrast, a package dyed yarn and a yarn-dyed yarn would have non-uniform color penetration through the yarn cross-section and along the length of the yarn. Accordingly, the second weft yarn 44 can be a dope-dyed continuous filament yarn that includes pigments. In another example, the second weft yarn 44 can be a package dyed yarn that includes disperse dyes applied to yarn via a package dyeing process (not shown). In another example, the second weft yarn 44 can be a yarn dyed yarn where color is applied after fabric formation with, for example, disperse dyes. It should be appreciated that a number of colorants can be used to form the dope-dyed yarn, the package dyed yarn, or the yarn-dyed yarn as described in the present disclosure.
The second weft yarn 44 can have a range of counts. In accordance with the illustrated embodiment, the second weft yarn 44 has count between 60 denier (88.6 Ne) to about 150 denier (55.4 Ne). In one example, the second weft yarn 44 has count between 60 denier (88.6 Ne) to about 120 denier (44.3 Ne). In another example, the second weft yarn 44 has count between 60 denier (88.6 Ne) to about 110 denier (48.3 Ne). In another example, the second weft yarn 44 has count between 60 denier (88.6 Ne) to about 100 denier (53.1 Ne). In another example, the second weft yarn 44 has count between 60 denier (88.6 Ne) to about 80 denier (66.4 Ne). In another example, the second weft yarn 44 has count between 80 denier (66.4 Ne) to about 120 denier (44.3 Ne). In another example, the second weft yarn 44 has count between 80 denier (66.4 Ne) to about 110 denier (48.3 Ne). In another example, the second weft yarn 44 has count between 90 denier (59.1 Ne) to about 110 denier (48.3 Ne). The second weft yarn can particular counts among the ranges described above. For instance, the second weft yarn 44 has a count of about 60 denier (88.6 Ne). In another example, the second weft yarn 44 has a count of about 70 denier (75.9 Ne). In another example, the second weft yarn 44 has a count of about 75 denier (70.9 Ne). In another example, the first weft yarn 42 has a count of about 80 denier (66.4 Ne). In another example, the second weft yarn 44 has a count of about 90 denier (59.1 Ne). In another example, the second weft yarn 44 has a count of about 100 denier (53.1 Ne). In another example, the second weft yarn 44 has a count of about 110 denier (48.3 Ne). In another example, the second weft yarn 44 has a count of about 120 denier (44.3 Ne). In another example, the second weft yarn 44 has a count of about 130 denier (40.9 Ne). In another example, the second weft yarn 44 has a count of about 140 denier (38 Ne). In another example, the second weft yarn 44 has a count of about 150 denier (35.4 Ne).
The warp yarns 20 and weft yarns 40 may be selected to achieve a desire fiber content. In accordance with an embodiment of the present disclosure, the warp yarns include natural fibers, the first weft yarn 42 includes natural fibers, and the second warp yarn is a dyed continuous filament yarn. In one example, the woven chambray fabric 10 is between 50% to about 80% by weight of natural fibers, with the balance comprising the synthetic fibers (based on dyed continuous filament yarn). In one preferred example, natural fibers are cotton fibers. In such an example, the woven chambray fabric 10 is between 50% to about 80% by weight of cotton fibers. In another preferred example, the woven chambray fabric 10 is between 60% to about 80% by weight of cotton fibers. In another preferred example, the woven chambray fabric 10 is between 70% to about 80% by weight of cotton fibers. The specified ranges are exemplary and indicate the fiber content of woven chambray fabrics that have desirable attributes. The fiber content could vary outside of the stated ranges and fall within the inventive concepts set forth in the present disclosure.
Turning to
Referring to
The winder 460 is a multiple yarn package winder 460 that supports a package core 462. The first and second yarns 42 and 44 are wound in a parallel relationship with respect to each other onto the package core 462 by the winder 460. The winder 460 is configured to wind the first and second yarns on the package core 462 within a predetermined range of wind angles so to define the multiple yarn package 420. The winder 460 can be a precision winder or a random winder as is known in art.
Referring to
Turning to
During yarn formation 210, the first weft yarn 42 can may be formed using similar yarn spinning systems used to form the warp yarns, where appropriate. The first weft yarn 42 can be formed using any spun spinning system, similar to the warp yarns 20 described above. As needed, the first weft yarn 42 may be a plied yarn. For instance, the first weft yarn 42 can be a 2-ply, 3 ply, or 4-ply yarn. The second weft yarn 44 is a continuous filament yarn formed using a melt spinning system.
During filament formation, polymer resins are melted and extruded through orifices at temperatures that approach the polymer melting temperature (Tm). From the orifices, the filaments may be slightly tensioned by passing over one or more godets before being wound onto desired yarn packages. Additional bulking or texturizing steps may be included to increase the bulk and impart “false twist” to the texture to the second weft yarns 44. The second weft yarn 44 may formed during filament formation 214. In some embodiments, colorants are added the to the masterbatch of the polymer resin. Colorant loaded polymer resin then extruded as dyed filaments. Thus, filament formation can form a dope dyed continuous filament yarn as described above. In one example, the second weft yarn 44 is a dope dyed PET yarn. In an alternative embodiment, filament yarn formation may include package dying the continuous filament yarn (e.g. if dope-dying is not used).
Following weft yarn spinning, a weft yarn assembly is prepared in winding 216 and consolidation 218 operations. Winding 216 includes use of a yarn winding apparatus 400 (
Warping 220 follows the yarn formation 210. Warping 220 is where warp yarn ends are removed from their respective yarn packages, arranged in a parallel form, and wound onto a warp beam. Warping 220 also includes a sizing step where a sizing agent is applied to each warp yarn to aid in fabric formation. Warping 220 results in a warp beam of warp yarns prepared for weaving. The warp beam can be positioned on a mounting arm of a weaving loom so that the warp yarns can be drawn through the loom components, as further described below.
Continuing with
During the formation phase of the weaving 240, the weft yarns 40 are interwoven with the warp yarns 20 to define the desired woven construction. The formation phase creates shed with the warp yarns 20 that the weft yarns 40 can be inserted through across the width direction of the machine to create the desired woven fabric construction. For instance, shedding motions can include cam shedding, dobby shedding, or jacquard shedding motions, each of which can cause the selective raising and lowering of warp ends to create an open shed for weft insertion. The formation phase can utilize different weft insertion techniques, includes air-jet, rapier, or projectile type weft insertion techniques. In each weft insertion event, one or composite yarns 40 are inserted through the shed. For instance, the weaving step can utilize a co-insertion so that multiple groups of weft yarn inserted through the shed during a single weft insertion event, as described above. The weaving step 240 can further include weaving one or more selvedge edges along a length L of the woven fabric. It should be appreciated that various woven constructions can made during weaving 240, including, but not limited to: plain weaves; basket weaves, satins; rib weaves; twill weaves, oxford weaves; percale weaves; and sateens.
After weaving 240, the woven fabric passes through desizing and bleaching 250. Desizing may be accomplished with enzymes as is known in the art. Bleaching may include typical bleaching agents, such as hydrogen peroxide bleaching. In the bleaching process the fabric may be treated with the exemplary composition shown in the table 1 below.
In accordance with the illustrated embodiment, such as when the warp yarn 20 and the first weft yarn 42 are cotton yarns, the bleaching process bleaches the cotton warp yarns 20 cotton weft yarns 42. The dyed continuous filament yarn 44 of weft yarn 40 remains as is in the woven fabric and gives final chambray color effect as described herein. Step 250 may also include an optional singing step.
Next, an optional fabric finishing 270 operation applies a composition including one or more of the functional agents to the woven fabric, such as a softener. In one example, the finish composition may contains micro silicone at about 5-20 gpl, a macro silicone at about 5-20 gpl, and/or a polyethylene emulsion at about 5-20 gpl. Functional finishes are optional. Finishing includes a drying phase that is used to remove excess moisture from the woven fabric and the composition. During the drying phase, the woven fabric is advanced through a heating machine. The drying phase may include convection, heated steam, infrared, hot air, surface rolls, hot oil can, through-air ovens and the like. After drying, the woven fabric may be optionally sanforized and calendared to adjust the hand and better control shrinkage.
After finishing 270, the woven chambray fabric 10 may be assembled 280 into bedding articles. Article assembly 280 may include material handling a roll goods to present to cutting, hemming, and or folding machines that are used to prepare the articles. In one example, article assembly 280 includes cutting a panel of woven chambray fabric to the appropriate length and width dimensions for the intended articles, such as the flat sheet or pillow case. The outer edges of the panel may be hemmed or surged to create finished edge. Secondary components can be attached to the panel at this stage. For example, ribbing, block hems, or binding can be sewn or otherwise attached to the panel. For fitted sheets, elastic materials are secured the at least the corner regions along the edge of the panel. For comforters can be cut to size and combined with desired batting or fill (e.g. fiber, feather, etc.). Accordingly, article assembly 280 includes forming one or more bedding articles of a bedding system. The bedding articles include at least one of a flat sheet, a fitted sheet, a pillow case, a sham, a comforter, a duvet, a bed-skirt, and a blanket.
After the assembling step, a packaging step 290 places the bedding article in suitable packaging for shipment. The packaging 290 may include automatically folding the formed articles, which are in panel form, into a folded configuration. The folded article is then placed in an outer package for shipment.
Turning to
After desizing and bleaching, coloring agents are applied to the woven fabric in dyeing operation 360. In accordance with the embodiment illustrated, the dyeing operation 360 applies color to the undyed continuous filament yarn, i.e. the second weft yarn 44 in the yarn assembly. The dyeing operation is carried out in such way that coloring agents are not applied or affixed to, the first weft yarn 42 or the warp yarns 20. For instance, in an example where the first weft yarn 42 and the warp yarns 20 made of spun staple yarns comprised of cotton fibers, and the continuous filament yarn is comprised of PET, the dyeing operation can use disperse dyes to apply color the PET continuous filament yarn. Because disperse dyes are suitable color agents for PET but not for cotton fibers, the dyeing operation does not apply color to the first weft yarn 42 and the warp yarns 20.
In accordance with the illustrated embodiment, the dyeing operation 360 used to apply color to the continuous filament yarn is a thermosol dyeing operation. A thermosol dying operation a) dye application, b) drying and pre-heating; c) thermo-fixing of the dyes to fabric, and d) after-treatment, which includes removing any un-fixed dyes from the fabric. Thermosol dying utilizes disperse dyes, as explained below.
Dye application includes pad-applying a dye composition onto to woven fabric using a pad-applicator. The composition includes disperse dyes and one or more auxiliaries. The auxiliaries may include, but are not limited to, a dispersing agent, a wetting agent, an anti-migrating agent, a pH stabilizer (e.g. a buffering salt, such as monosodium phosphate), and a diffusion accelerant.
The drying and pre-heating phase removes any excess water from the composition and the fabric and gradually dries the woven fabric.
The thermo-fixing phase exposes the woven fabrics to temperatures between 190° C. and 210° C. (or higher) thermosol machine. The thermo-fixing phase causes the internal morphology of the filaments to open so that disperse dye molecules can migrate into the fiber structure. The fabric is exposed to elevated temperatures for a limited period of time. A person of ordinary skill would understand that the time-temperature profile can be modified as needed based on the application and the shade requirements.
After the thermo-fixing phase, excess or unfixed dyestuffs can be removed via the washing or reduction clearing phase. In one example, a reduction clearing phase can use a composition that includes caustic soda (10-30 gpl) and sodium hydrosulphite (10-30 gpl) at predetermined temperatures, e.g. between 98105° C. The fabric is then dried again to remove any excess moisture applied during the after-treatment phase.
Dye operation 360 therefore applies color the continuous filament yarn 44 while the first weft yarn 42 and the warp yarns 20 remain white or bleached. Because color is applied the second weft yarn 42 and no color is applied to the first weft yarn 42 and the warp yarns 20 and remain white, the woven fabric provides a “Chambray” effect. The dying operation 360 applies color the woven fabric, and the second weft yarn 44, after fabric formation. Accordingly, the second weft yarn 44, when woven and then dyed, can be referred to as a “yarn dyed weft yarn” or “yarn dyed continuous filament yarn,” as those terms are described in the present disclosure. As described above, the phrases “yarn dyed yarn,” “yarn dyed weft yarn” or “yarn dyed continuous filament yarn” means yarns that have dyes applied after yarn formation (or fabric formation) yet have dye molecules disposed within the internal morphology of filament or fiber structure. In contrast method 200, utilizes dope dyed weft yarn 44, in which pigments are applied to masterbatch during filament extrusion.
Continuing with
The method 200 and method 300 as described above can be used to form woven chambray fabrics with the following exemplary constructions, noted as example A through example L below. In the examples A through L, each fabric construction includes one of several types of dyed weft yarns. In other words, for each example A-L shown below, the exemplary fabric was formed with second weft yarns 44 being either a) dope dyed, b) package dyed, or c) yarn dyed. This is noted in the examples with the parenthetical “(dope dyed/package dyed/yarn dyed yarn).” The examples A-L are suitable for bedding articles and colorfast to one or more household or cosmetic ingredients.
Several exemplary woven chambray fabrics made in accordance with the present disclosure were evaluated to determine their suitability for bedding uses. Table 2 below summarizes the structural attributes of these exemplary fabrics. In accordance with the present disclosure, it is believed that the woven chambray fabrics as described herein are durable, soft, and exhibit colorfast properties to various household and cosmetic compounds commonly found in a consumer's home. Exemplary woven chambray fabrics were tested to determine a) appearance changes (smoothness) due to repeated launderings using “Appearance of Apparel and Other Textile End Products after Repeated Home Laundering, AATCC Test Method 143-2006;” b) colorfastness to benzoyl peroxide; c) colorfastness to chlorine using “Quick Methods for Colorfastness to Chlorine and Non-Chlorine Bleach, AATCC TS-001;” d) colorfastness to non-chlorine bleach using “Quick Methods for Colorfastness to Chlorine and Non-Chlorine Bleach, AATCC TS-001;” and e) colorfastness to active cosmetic ingredients found in several cosmetic products. For all colorfastness data compiled herein, colorfastness was determined by assigning a value between 1.0 to 5.0 after the sample was subjected to the specified test condition, as is known to a person of skill in the textile arts. A rating of 1.0 means that there has been a significant shade change after the sample is subjected to the specified test condition. A rating of 5.0 indicates no or minimal shade change after the sample has been subjected to the specified test condition. Shade change ratings of 4.0 or higher are indicative more colorfast materials compared to samples where a shade change rating of 3.0 or lower is observed.
Table 2 includes woven construction, total thread count, warp yarn fiber type, weft yarn assembly construction, color, and % of total fiber in the fabric (by weight). For each example, the first weft yarn is spun staple yarn comprising cotton fibers, and the second weft yarns is dyed continuous filament yarn formed from PET. The second weft yarns in examples 1, 3, 5, 7, and 9 are dope dyed continuous filament yarns. The second weft yarns in examples 2, 4, 6, and 8 are yarn-dyed continuous filament yarns as that phrase is defined in the present disclosure. The color indicated is therefore the color applied to the second weft yarn in each example.
Table 3 below contains data for example 1. The impact of laundering on fabric appearance for example 1 was evaluated under AATCC 143-2006 (Test No. 1 (III) A (ii)). As shown in Table 3 below, after 5 washes a smoothness rating of 3.5-4.0 was observed. After 10 washes, a smoothness rating of 3.5-4.0 was observed. Colorfastness to benzoyl peroxide was determined by exposing the example to benzoyl peroxide for 8 hours. The shade change was observed at the conclusion of the 8 hour period. In this case, a shade change rating of 4-4.5 was observed for example 1. Example 1 was evaluated to determine colorfastness to chlorine bleach under test method AATCC TS-001. In this case, a shade change rating of 4.0 was observed for chlorine bleach. Finally, example 1 was also evaluated to determine colorfastness to non-chlorine bleach under test method AATCC TS-001. A shade change rating of 4.0/4.5 was observed for non-chlorine bleach. Example fabric 1 has suitable appearance to repeated laundering and was found to be colorfast to benzoyl peroxide, chlorine, and non-chlorine bleach.
Table 4 below contains data for examples 2-9 (summarized in table 2) related to colorfastness to active ingredients in various cosmetic products. Under this test, each exemplary fabric 2-9 was exposed to the cosmetic materials listed in the far left column in table 4 for 24 hours. After 24 hours of exposure, the shade change of each example was evaluated. As shown in table 4, a shade rating of at least 4.5 was observed for each example 2-9, for all cosmetic products evaluated. The shade change rating indicates that the exemplary woven chambray fabrics are colorfast to the cosmetic products and their active ingredients. Furthermore, it may be observed that the colorfastness to cosmetics ingredients is consistent across different embodiments of the yarn assembly. For instance, it would appear that woven fabrics are colorfast to cosmetic ingredients when the second weft yarn is a dope dyed continuous filament yarn. Alternatively, the woven chambray fabrics are colorfast to cosmetic ingredients when the second weft yarn is a yarn-dyed continuous filament yarn.
While the disclosure is described herein using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the disclosure as otherwise described and claimed herein. The precise arrangement of various elements and order of the steps of articles and methods described herein are not to be considered limiting. For instance, although the steps of the methods are described with reference to sequential series of reference signs and progression of the blocks in the figures, the method can be implemented in a particular order as desired.
The present application claims priority to, and the benefit of, U.S. Provisional Application No. 62/232,445, filed Sep. 25, 2015, the entire disclosure of which is incorporated by reference into this application.
| Number | Date | Country | |
|---|---|---|---|
| 62232445 | Sep 2015 | US |
