Patent Application
20190032273
Embodiments of the present disclosure relate to textile structures and their methods of manufacture thereof. More specifically, the present disclosure relates to textile structures for use in the hospitality industry.
Comfort is a pleasant state of psychological, physiological and physical harmony between the human being and the environment. The processes involved in human comfort are physical, thermophysiological, neuro-physiological and psychological. Thermo-physiological comfort is associated with the thermal balance of the human body, which strives to maintain a constant body core temperature of about 37° C. and a rise or fall of ˜±5° C. can be fatal. Hypothermia and hyperthermia may result, respectively, due to the deficiency or excess of heat in the body, which is considered to be a significant factor in limiting work performance.
In a regular atmospheric condition and during normal activity levels, the heat produced by the metabolism is liberated to the atmosphere by conduction, convection and radiation and the body perspires in vapor form to maintain the body temperature. However, at higher activity levels and/or at higher atmospheric temperatures, the production of heat is very high and for the heat transmission from the skin to the atmosphere to decrease, the sweat glands are activated to produce liquid perspiration as well. The vapor form of perspiration is known as insensible perspiration and the liquid form as sensible perspiration. When the perspiration is transferred to the atmosphere, it carries heat (latent as well as sensible) thus reducing the body temperature. Therefore, any textile structure that comes in contact with the human body should allow the perspiration to pass through, otherwise it will result in discomfort. The perception of discomfort in the active case depends on the degree of skin wetness. During sweating, if the clothing moisture transfer rate is slow, the relative and absolute humidity levels of the clothing microclimate will increase, suppressing the evaporation of sweat. This may increase body temperatures, resulting in heat stress.
It is also important to reduce the degradation of thermal insulation caused by moisture build-up. If the ratio of evaporated sweat and produced sweat is very low, moisture will be accumulated in the inner layer of the textile structure, thus reducing the thermal insulation and causing unwanted loss in body heat. Therefore, both in hot and cold weather and during normal and high activity levels, moisture transmission through fabrics plays a major role in maintaining the wearer's body at comfort. Hence, a clear understanding of the role of moisture transmission through textile structures in relation to body comfort is essential for designing high performance textile structures for specific applications.
Embodiments of the present disclosure relate to textile structures and their methods of manufacture thereof. More specifically, the present disclosure relates to textile structures for use in the hospitality industry.
Accordingly, one example embodiment is a textile structure including one or more layers of warp yarns interwoven with one or more layers of weft yarns, and a durable thermoregulating coating. The durable thermoregulating coating may include at least one of an adaptive agent, a cleaning agent, a fabric softener, an antistatic agent, and citric acid. The thermoregulating coating may include about 30-50 gram per liter of Adaptive AC-03, and about 1-10 gram per liter of Clean DEC, both supplied by HeiQ in Switzerland. The textile structure may further include a binder that may be selected from the group consisting of latex, elastomeric, acrylic binders, vinyl acrylic binders, vinyl acetate binders, styrene containing binders, butyl containing binders, starch binders, polyurethane binders, and polyvinylalcohol containing binders. The warp yarns have a warp density of about 100 to 120 epi, and may have a maximum linear mass density of at least about 75 denier with multiples of about 72 filaments per yarn. The weft yarns have a weft density of about 65 to 80 ppi, and may have a minimum linear mass density of at least about 150 denier with multiples of about 72 filaments per yarn. The number of filaments, however, is always more than the denier of each weft yarn.
Another example embodiment is a method for manufacturing a textile structure. The method includes weaving one or more layers of warp yarns with one or more layers or weft yarns to form a woven textile structure, and applying a durable thermoregulating coating to at least a portion of the textile structure. The method may also include brushing the textile structure at least two times, prior to applying the thermoregulating coating, to create a fuzzy and softer feel. Brushing increases the surface area for better absorption and adhesion of the thermoregulating coating on the fabric. The method may also include heat setting and curing the textile structure to fix the durable thermoregulating coating permanently onto the textile structure. The durable thermoregulating coating may include at least one of an adaptive agent, a cleaning agent, a fabric softener, an antistatic agent, and citric acid. The thermoregulating coating may include about 30-50 gram per liter of Adaptive AC-03, and about 1-10 gram per liter of Clean DEC, both supplied by HeiQ in Switzerland. The textile structure may further include a binder that may be selected from the group consisting of latex, elastomeric, acrylic binders, vinyl acrylic binders, vinyl acetate binders, styrene containing binders, butyl containing binders, starch binders, polyurethane binders, and polyvinylalcohol containing binders. The warp yarns have a warp density of about 100 to 120 epi, and may have a maximum linear mass density of at least about 75 denier with multiples of about 72 filaments per yarn. The weft yarns have a weft density of about 65 to 80 ppi, and may have a minimum linear mass density of at least about 150 denier with multiples of about 72 filaments per yarn. The number of filaments, however, is always more than the denier of each weft yarn.
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
The foregoing aspects, features, and advantages of embodiments of the present disclosure will further be appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing embodiments of the disclosure illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.
For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the discussion of the described embodiments of the invention. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present invention. Like reference numerals refer to like elements throughout the specification.
Example embodiments relate to a woven polyester structure that dynamically responds to body temperature to keep one cool when they feel hot and keeps them warm when they feel cold. The thermoregulating aspect of the disclosure may be used in bedding products such as flat sheets, fitted sheets, pillowcases, pillow protectors, shells of pillows, shells of comforters, etc.
Turning now to the figures,
After the woven textile structure is formed, at step 104, the structure is mechanically brushed at least two times at room temperature. This process may be carried out at about 30 m/min speed to create a fuzzy and softer feel on the fabric. In the next step 106, the fabric may be passed through an alkali refining process where the alkali solution may include an alkali (5-10% of fabric weight), such as NaOH, one or more cleaning agents (1-2% of fabric weight), hydrogen peroxide (1-5% of fabric weight), and a chelating agent of about 0.5 gram per liter of the solution. The cleaning agent may include a soil release agent and/or a wetting agent. The pH value of this solution may be about 8-9, and with a pick-up of about 90-100% the fabric is run through this solution at about 100 m/min at an elevated temperature of about 130° C. After the alkali refining step 106, the fabric is bleached, at step 108, using a bleaching solution including a brightening agent of about 16 gram per liter of the solution, and an alkali (about 1% of fabric weight), such as NaOH. The pH value of this solution may be about 8-9, and with a pick-up of about 90-100% the fabric is run through this solution at about 100 m/min at an elevated temperature of about 130° C. After the fabric is bleached, it enters a washing zone, at step 110, where a steamer at 70-80° C. temperature steams the fabric with a solution having a pH of about 7-7.5. The fabric may be run through this section at about a reduced speed of 40 m/min.
The method further includes, at step 114, applying a durable thermoregulating coating to at least a portion of the textile structure. The durable thermoregulating coating may include one or more polymers mixed in an aqueous solution. For example, the durable thermoregulating coating may include an adaptive agent (HeiQ Ac-03) in the amount of 30-50 gram per liter of the solution, a cleaning agent (HeiQ Clean DEC) in the amount of 1-10 gram per liter, a fabric softener of about 5 gram per liter, an antistatic agent of about 5 gram per liter, and a citric acid of about 0.05 gram per liter. The adaptive agent may include, among other things, 0.5-1% triisobutyl phosphate, and 0.2-0.5% ethoxylated and propoxylated alcohols. The cleaning agent may include a soil release agent and/or a wetting agent. The cleaning agent may include, among other things, 30-50% isotrideceth 12, 10-15% 2-(2-butoxyethoxy)ethanol, 2-3% N-(2-Ethylhexyl)isononan-1-amide, and 1-2% Poly(oxy-1,2-ethanediyl), a-butyl-uJ-hydroxy. The solution may have a pH of about 5-7, and the fabric may be run through this solution at a speed of about 60 m/min at an elevated temperature of 190-200° C.
The method may optionally include, at step 112, applying a binder prior to application of the durable thermoregulating coating. The binder may be selected from the group consisting of latex, elastomeric, acrylic binders, vinyl acrylic binders, vinyl acetate binders, styrene containing binders, butyl containing binders, starch binders, polyurethane binders, and polyvinylalcohol containing binders. The method may also include, at step 116, heat setting and curing the textile structure to fix the durable thermoregulating coating permanently onto the textile structure. After the fabric goes through the heat setting and the finishing process, the fabric may be vacuum cleaned at a speed of about 30-40 m/min, at step 118. The resulting fabric can be cut and sewn to form, among other things, a sheeting fabric for use in the hospitality industry. However, the thermoregulating aspect of the disclosure may be also used in other bedding products such as flat sheets, fitted sheets, pillowcases, pillow protectors, shells of pillows, shells of comforters, etc.
Accordingly, one example embodiment is a woven polyester structure that dynamically responds to body temperature to keep one cool when they feel hot and keeps them warm when they feel cold. The durable thermoregulating textile structure may be produced by weaving polyester microfilaments in an optimized ratio in warp and weft directions. Adaptive AC-03, a chemical from Swiss supplier HeiQ, may be used for finishing such a woven structure. It shows opposite, “non-Newtonian” behavior. The structure has high moisture affinity at low temperatures (moisture capture) and low moisture affinity at high temperatures (moisture release).
Durable thermoregulating textile structures according to example embodiments disclosed can withstand at least 100 commercial washes. A strong binder that molecularly bonds the polyester filaments to the AC-03 chemical may be used. The binder may be colorless and may not make the hand of the fabric stiff or rough.
The durable thermoregulating fabric may be woven with polyester yarns, which may include filaments or multifilaments, with a warp density of about 100 to 120 epi. Each polyester yarn may have a maximum linear mass density of at least about 75 denier with multiples of about 72 filaments per yarn. The durable thermoregulating fabric may also include polyester yarns, which may include filaments or multifilaments, in the weft direction. The weft density of the textile structure may be anywhere from about 65 to 80 ppi. Each polyester yarn may have a minimum linear mass density of at least about 150 denier with multiples of about 72 filaments per yarn. The number of filaments, however, is always more than the denier of each weft yarn. Warp and weft yarns may be interwoven in any known pattern, including but not limited to plain, twill, satin, and sateen. The woven textile structure may be brushed, using for example a mechanical process similar to napping, to create a fuzzy and softer feel. This process also minimizes the undesirable sheen inherent to most synthetic fibers.
After the fabric is padded through a solution of binder, the fabric may be run through the AC-03 solution. The binder may include any binder including but not limited to latex, elastomeric, and acrylic binders. Acrylic binders, vinyl acrylic binders, vinyl acetate binders, styrene containing binders, butyl containing binders, starch binders, polyurethane binders, and polyvinylalcohol containing binders are examples of binders that find utility in coating and finishing the fabric. Then the fabric is heat set and cured to fix the chemical permanently onto the fabric. The resultant polyester fabric is now a durable thermoregulating fabric.
Evaluation of the Textile Structure
Two fabric types were tested by the Textile Protection and Comfort Center (T-PACC) in the College of Textiles at North Carolina State University. An advanced sweating manikin system and thermal imaging camera were used to evaluate and compare the response of the two fabric types. Test samples were tested at the TPACC testing facility. A mattress was covered with two sheets split vertically down the middle and tested with the sweating thermal manikin system. Fabric types were identified as Control (untreated fabric) and Phasology (fabric treated with durable thermoregulating coating), respectively. No clothing was worn during testing. A comforter was used during testing. The comforter consisted of 95% white duck feathers/5% white duck down in a 100% polyester cover. The weight of the comforter was about 16.3 oz/yd2. The mattress cover was tested on a twin mattress in the test chamber.
The sweating manikin system is a “Newton” type instrument designed to evaluate heat and moisture management properties of clothing systems. This instrument simulates heat and sweat production making it possible to assess the influence of clothing on the thermal comfort process for a given environment. Simultaneous heat and moisture transport through the clothing system, and variations in these properties over different parts of the body can be quantified.
The manikin consists of several features designed to work together to evaluate clothing comfort and/or heat stress. Housed in a climate-controlled chamber, the manikin surface is divided into 34 separate sections, each of which has its own sweating, heating, and temperature measuring system. With the exception of a small portion of the face, the whole manikin surface can continuously sweat.
Using a pump, preheated water is supplied from a reservoir located outside of the environmental chamber. An internal sweat control system distributes moisture to 139 “sweat glands” distributed across the surface of the manikin. Water supplied to the simulated sweat glands is controlled by operator entry of the desired sweat rate. Each sweat gland is individually calibrated and the calibration values are used by the control software to maintain the sweat rate of each body section. Water exuding from each simulated sweat gland is absorbed by a custom made body suit. This specialty designed suit acts as the manikin's ‘skin’ during sweating tests. It is form-fitted to the manikin to eliminate air gaps and provides wicking action to evenly distribute moisture across the entire manikin surface.
Continuous temperature control for the 34 body segments is accomplished by a process control unit that uses analog signal inputs from separate Resistance Temperature Detectors (RTDs). These evenly distributed RTDs are used instead of point sensors because they provide temperature measurements in a manner such that all areas are equally weighted. Distributed over an entire section, each RTD is embedded just below the surface and provides an average temperature for each section. Software establishes any discrepancy between temperature set point and the input signal, and adjusts power to section heaters as needed. Temperature controls are adjustable, by the operator, for each heater control.
The Newton sweating manikin system combined with ManikinPC2 control system allows the manikin to simulate human metabolism and thermoregulation while performing a variety of activities. The software and manikin interact in real-time setting imitating the transient behavior of the human body and allowing for the most accurate predictions of human physiological responses that can be achieved without actual human trials. The ManikinPC2 model control system is used to predict human physiological response including average skin temperature, final temperature of each manikin section, predicted core body temperature, as well as other parameters.
The FLIR A325 Infrared Camera is used to record thermographic images with temperature measurement. These non-contact temperature measurements allow for surface temperature evaluation of test items without interfering with the test operation. ThermoVision ExaminIR Analysis Software is used to read and analyze thermal images.
The purpose of this test was to evaluate the effectiveness of Phasology treatment on sheeting fabric compared to an untreated control fabric. The response of the fabric was assessed by use of a thermal imaging camera and manikin measurements. The two fabric types were taped into a single split-fabric mattress cover. Simultaneous evaluation of the two fabric types was accomplished by having the split-fabric mattress cover design that the manikin could be equally exposed to each side. The excess fabric was folded over top the manikin and taped at the seam. The manikin was dressed in the typical sweating skin material to assist with sweat wicking and spreading as well as a water vapor permeable/liquid water impermeable suit to limit the amount of liquid water pooling into the mattress. Test protocols were determined that used physiological model control of the manikin in which the manikin responded to the test environment and simulated sleeping condition based on a human thermoregulation model. The test environment was relatively mild. The mattress was tested once (Control right side/Phasology left side) per Test Protocol 1 (See Table 2). Table 1 shows the testing conditions/parameters used.
Table 3 shows the average surface temperature and change in surface temperature from the defined Region of Interest (ROI). ΔT is defined as (T-Ti) and Time 0 is the time immediately after removing the manikin from the mattress.
Moisture Management Test (MMT)
The fabric was conditioned and tests were performed in the standard atmosphere laboratory condition of 70+3° F. (21° C.), 65+5% RH. The MMT is a system that can measure liquid transport properties of fabrics. A specific volume of electrically conductive fluid is injected onto the fabric surface at a controlled rate, and a series of conductive, copper rings monitor the movement of this fluid. The conductivity of the sample continuously changes as the fluid moves throughout the sample, and this data is recorded in order to determine the moisture management properties of the sample.
For the purpose of this test, the side of the fabric that contacts the skin is referred to as the “top surface,” and the other side is referred to as the “bottom surface.” The reported measurements include:
Wetting Time (s): WTT (top surface) and WTB (bottom surface)—period in which the top and bottom surfaces just start to get wetted
Absorption Rate (%/s): ART (top surface) and ARB (bottom surface)—the average moisture absorption ability of the top and bottom surfaces
Maximum Wetted Radius (mm): MWRT (top surface) and MWRB (bottom surface)—the maximum wetted ring radius at the top and bottom surface
Spreading Speed (mm/s): SST (top surface) and SSB (bottom surface)—the accumulative spreading speed from the center to the maximum wetted radius
The reported parameters calculated from the above measurements include:
One-way Transport Capability (%): R—the difference of the accumulative moisture content between the two surfaces of the fabric.
Overall Moisture Management Capacity: OMMC—an index to measure the overall capability of the fabric to manage the transport of liquid moisture based on three aspects of performance.
The results of these tests are summarized below (Table 4). Individual metrics were evaluated as well as two indices that quantify the moisture management properties of fabric, (One-way Transport Capability, and Overall Moisture Management Capacity). A higher value for either of these indices indicates a greater capability to effectively transport liquids. The results illustrate that even after 100 wash cycles, the overall moisture management capacity of the fabric is virtually unchanged.
A grading table is provided by SDL Atlas, manufacturers of the MMT device. These data, obtained under controlled laboratory conditions, characterize the moisture management properties of test sample responses in laboratory conditions.
Accordingly, one example embodiment is a textile structure including one or more layers of warp yarns interwoven with one or more layers of weft yarns, and a durable thermoregulating coating. The durable thermoregulating coating may include at least one of an adaptive agent, a cleaning agent, a fabric softener, an antistatic agent, and citric acid. The cleaning agent may include a soil release agent and/or a wetting agent. The thermoregulating coating may include about 30-50 gram per liter of Adaptive AC-03, and about 1-10 gram per liter of Clean DEC, both supplied by HeiQ in Switzerland. The textile structure may further include a binder that may be selected from the group consisting of latex, elastomeric, acrylic binders, vinyl acrylic binders, vinyl acetate binders, styrene containing binders, butyl containing binders, starch binders, polyurethane binders, and polyvinylalcohol containing binders. The warp yarns have a warp density of about 100 to 120 epi, and may have a maximum linear mass density of at least about 75 denier with multiples of about 72 filaments per yarn. The weft yarns have a weft density of about 65 to 80 ppi, and may have a minimum linear mass density of at least about 150 denier with multiples of about 72 filaments per yarn. The number of filaments, however, is always more than the denier of each weft yarn.
Another example embodiment is a method for manufacturing a textile structure. The method includes weaving one or more layers of warp yarns with one or more layers or weft yarns to form a woven textile structure, and applying a durable thermoregulating coating to at least a portion of the textile structure. The method may also include brushing the textile structure at least two times, prior to applying the thermoregulating coating, to create a fuzzy and softer feel. Brushing increases the surface area for better absorption and adhesion of the thermoregulating coating on the fabric. The method may also include heat setting and curing the textile structure to fix the durable thermoregulating coating permanently onto the textile structure. The durable thermoregulating coating may include at least one of an adaptive agent, a cleaning agent, a fabric softener, an antistatic agent, and citric acid. The thermoregulating coating may include about 30-50 gram per liter of Adaptive AC-03, and about 1-10 gram per liter of Clean DEC, both supplied by HeiQ in Switzerland. The textile structure may further include a binder that may be selected from the group consisting of latex, elastomeric, acrylic binders, vinyl acrylic binders, vinyl acetate binders, styrene containing binders, butyl containing binders, starch binders, polyurethane binders, and polyvinylalcohol containing binders. The warp yarns have a warp density of about 100 to 120 epi, and may have a maximum linear mass density of at least about 75 denier with multiples of about 72 filaments per yarn. The weft yarns have a weft density of about 65 to 80 ppi, and may have a minimum linear mass density of at least about 150 denier with multiples of about 72 filaments per yarn. The number of filaments, however, is always more than the denier of each weft yarn.
The Specification, which includes the Summary, Brief Description of the Drawings and the Detailed Description, and the appended Claims refer to particular features (including process or method steps) of the disclosure. Those of skill in the art understand that the invention includes all possible combinations and uses of particular features described in the Specification. Those of skill in the art understand that the disclosure is not limited to or by the description of embodiments given in the Specification.
Those of skill in the art also understand that the terminology used for describing particular embodiments does not limit the scope or breadth of the disclosure. In interpreting the Specification and appended Claims, all terms should be interpreted in the broadest possible manner consistent with the context of each term. All technical and scientific terms used in the Specification and appended Claims have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs unless defined otherwise.
As used in the Specification and appended Claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly indicates otherwise. The verb “comprises” and its conjugated forms should be interpreted as referring to elements, components or steps in a non-exclusive manner. The referenced elements, components or steps may be present, utilized or combined with other elements, components or steps not expressly referenced.
Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain implementations could include, while other implementations do not include, certain features, elements, and/or operations. Thus, such conditional language generally is not intended to imply that features, elements, and/or operations are in any way required for one or more implementations or that one or more implementations necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or operations are included or are to be performed in any particular implementation.
The textile structures and methods described herein, therefore, are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While example embodiments of the textile structure and method have been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications may readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the textile structure and method disclosed herein and the scope of the appended claims.
This non-provisional application claims priority of U.S. Provisional Patent Application No. 62/538,299, filed Jul. 28, 2017 and titled “Durable Thermoregulating Textile Structures and Methods of Manufacture,” the disclosures of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62538299 | Jul 2017 | US |
