Patent Application
20180080151
The present application claims the benefit under 35 U.S.C. § 119 of Indian Patent Application No. 201621031577, filed Sep. 15, 2016. The contents of which is incorporated by reference into the present application.
The present disclosure relates to performance fabrics, and in particular to a performance fabrics having multiple fiber.
Sheeting fabrics require a number of different end-use properties to achieve widespread market acceptance. Sheeting fabrics should be wrinkle resistant and/or have easy care characteristics while having the requisite softness, durability, color retention, and quick dry properties. Typical sheeting fabrics are formed primarily from cotton fibers. Chemical finishes are often applied to cotton sheeting fabrics to attain the desired wrinkle resistance/easy care attributes. Sheeting fabrics that comprise cotton and polyester fibers may have improved wrinkle resistance due in part to the presence of the polyester fibers in the structure. However, manufacturers still seek an adequate balance of the end-use properties at a price the market will accept. Development within such cost constraints in view of end-use requirements is difficult and not a predictable endeavor.
An embodiment of the present disclosure is a performance fabric. The performance fabric includes a plurality of warp yarns extending along a warp direction. The warp yarn includes a first warp yarn and a second warp yarn that is directly adjacent to the first warp yarn. The plurality of warp yarns are blended staple warp yarns each of which has cotton fibers and regenerated cellulosic fibers. The performance fabric includes a plurality of weft yarns interwoven with the plurality of warp yarns to define a woven fabric structure. The plurality of weft yarns include at least one yarns comprising thermoplastic fibers.
Another embodiment of the present disclosure is a performance fabric. The performance fabric includes a plurality of warp yarns extending along a warp direction. The warp yarns include a first warp yarn and a second warp yarn that is directly adjacent to the first warp yarn. The plurality of warp yarns are blended staple warp yarns each of which has cotton fibers and regenerated cellulosic fibers. The performance fabric includes a plurality of weft yarns interwoven with the plurality of warp yarns to define a woven fabric structure. The plurality of weft yarns includes at least one yarn comprising a blend of cotton fibers and regenerated cellulosic fibers.
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 also include flat woven fabrics that includes at least three fiber types to achieve desirable end-use properties. In various embodiments of the present disclosure, the woven fabric includes cotton fibers, regenerated cellulosic fibers, and/or various types of thermoplastic fibers, such as thermoplastic staple fibers or thermoplastic filaments. The cotton fibers provide a natural hand-feel and improved comfort. The regenerated cellulosic fibers (e.g. viscose rayon, lyocell, modal, and the line) enhance softness, luster, and brilliance to woven fabric. The thermoplastic fibers add strength, wrinkle resistance, and quick dry properties. The fiber combinations described herein may be implemented in a flat woven fabric or a terry woven fabric using a number of different yarn configurations.
The woven fabrics as described herein are suitable for home textile applications. Accordingly, the fabrics can be formed into one or more different bedding articles, such as a flat sheet, a fitted sheet, a pillow case, a sham, a comforter, a duvet, a bed-skirt, coverlet and/or a blanket. The fabrics can be formed into one or more different bath articles, such as a towels, hand towels, wash clothes, bath matts, bath robes, and the like.
Referring to
Continuing with
The woven fabric 10 as described herein may be defined by a number of different woven structures having a woven design repeat 18. As used herein, a woven design repeat 18 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 20a, 20b and two adjacent weft yarns 40a, 40b. Depending on the particular design, woven design repeats may repeat along: a) the weft direction 4; b) the warp direction 6; or both the weft direction 4 and warp directions 6. However, the design of the woven fabric 10 is not limited to a plain weave. For example, the woven fabric can have a number of exemplary woven structures including, 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 as shown in
Each of the woven fabrics described herein include warp yarns 20 that are blended staple yarns. The warp yarns may therefore be referred to as blended staple yarns formed from staple length fibers arranged in a twisted assembly using typical short staple yarn spinning systems as further described below. The blended staple yarns that include cotton fibers and regenerated cellulosic fibers. Any type of cotton fiber that is suitable for staple yarn manufacture may be used, such a Pima and/or Egyptian cotton fibers. Regenerated cellulosic fibers include rayon fibers in staple form and/or filament form. Rayon is considered a manufactured fiber composed of regenerated cellulose, as well as manufactured fibers composed of regenerated cellulose in which substituents have replaced not more than 15% of the hydrogens of the hydroxyl groups. A lyocell fiber is where the fiber is composed of cellulose precipitated from an organic solution in which no substitution of the hydroxyl groups takes place and no chemical intermediates are formed. Modal is a modified rayon fiber that has high tenacity and high wet modulus. Modal fibers are dimensionally stable and do not shrink or get pulled out of shape when wet like. Modal fibers are also wear resistant and strong while maintaining a soft, silky feel.
The blended warp yarns 20 may have range of cotton and cellulosic fiber content. The blended warp yarns may include between about 20% to about 80% by weight (of the yarn) of the cotton fibers and also between about 20% to about 80% by weight of the cellulosic synthetic fibers. In one example, the blended warp yarns have about 25% to about 45% by weight of the cotton fibers and about 55% to about 75% by weight of the cellulosic synthetic fibers. In yet another example, the blended warp yarns preferably have about 40% by weight of the cotton fibers and 60% by weight of the cellulosic synthetic fibers. In yet another example, the blended warp yarns preferably have about 30% to by weight of the cotton fibers and 70% by weight of the cellulosic synthetic fibers. It should be understood that the amount of cellulosic fiber content specified above include viscose rayon fibers, model fibers, and/or lyocell fiber.
The blended warp yarns 20 may have a range of linear densities that are suitable for bedding applications. For example, the blended warp yarn 20 can have a count 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 another 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 yet another example, the warp yarn count is 20 Ne (266 denier) and about 30 Ne (177 denier).
The blended warp yarns 20 may be single end yarns or plied yarns. For instance, the blended warp yarns may be plied yarn, such as a two ply yarn or a three-ply yarn. For plied yarns, at least one of the ends in the plied yarn is a blended yarn comprising cotton fiber and regenerated cellulosic fibers. However, each one of the yarns in the plied yarn structure is blended yarn that includes cotton fibers and regenerated cellulosic fibers.
The blended warp yarns may be any type of spun staple yarn structure. For example, the blended warp yarns may be ring spun yarns, open end yarns, rotor spun yarns, vortex spun yarns, core spun yarns, jet spun yarns, or compact spun yarns. Preferably, the blended warp yarns are ring spun yarns. The blended warp yarn can, however, be any type of spun yarn structure.
The woven fabrics as described herein may utilize number of different techniques to alter the overall thread count and vary the fiber blend. For instance, the woven fabric 10 as shown in
The warp yarns and weft yarns in the fabrics described herein are arranged to achieve desired warp and weft end densities, respectively, and thus desired thread count, for bedding applications. 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. 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 450 warp ends per inch. In another example, the warp end density is between about 450 and 350 warp ends per inch. Furthermore, 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). 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 300 weft yarns per inch. In another example, the weft yarn density is between about 300 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 weft yarn 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.
The woven fabrics 10, 210,310, and 510 as described herein have a number of different weft yarn constructions and arrangements to achieve the desired fabric fiber blend. For example, as shown in
Referring to
As shown in
The continuous filament weft yarns 145a-145d for fabric 110 may have a range of linear densities suitable for bedding applications. For instance, the continuous filament weft yarns have a linear density between 15 denier (354.3 Ne) to about 150 denier (55.4 Ne). In one example, the continuous filament weft has a count between 20 denier to about 150 denier. In one example, the continuous filament weft has a count between 25 denier to about 150 denier. In one example, the continuous filament weft has a count between 30 denier to about 150 denier. In one example, the continuous filament weft has linear density between 40 denier to about 150 denier. In one example, the continuous filament weft has linear density between 50 denier to about 150 denier. In one example, the continuous filament weft has linear density between 75 denier to about 150 denier. In one example, the continuous filament weft has linear density between 80 denier to about 150 denier. In one example, the continuous filament weft has linear density between 100 denier to about 150 denier. Preferably, the continuous filament yarns have a linear density between 50 denier and 100 denier. However, ranges outside of and within the stated ranges are possible.
The continuous filament weft yarns 145a-145d in fabric 110 may be single end yarns or plied yarns. For instance, the continuous filament weft yarns may be plied yarn, such as a two ply yarn or a three-ply yarn. For plied yarns, at least one of the ends in the plied yarn is a continuous filament weft yarns comprising synthetic filaments. However, each one of the yarns in the plied yarn structure comprising synthetic filaments.
As shown in
Another embodiment shown in
Continuing with
The spun weft yarn 245a may be any type of spun staple yarn structure. For example, the second weft yarn may be ring spun yarns, open end yarns, rotor spun yarns, vortex spun yarns, core spun yarns, jet spun yarns, or compact spun yarns. Preferably, the spun weft yarns 245a are ring spun yarns. The spun weft yarns 245a can, however, be any type of spun yarn structure. The spun weft yarn 245a may have a range of linear densities that are suitable for bedding applications. For example, the spun weft yarn 245a can have a count between 20 Ne (266 denier) and about 120 Ne (44.3 denier). In one example, the spun weft yarn count is between 20 Ne (266 denier) and about 100 Ne (53.1 denier). In another example, the spun weft yarn count is between 20 Ne (266 denier) and about 60 Ne (88.6 denier). In another example, the spun weft yarn count is between 20 Ne (266 denier) and about 40 Ne (133 denier). In yet another example, the spun weft yarn count is 20 Ne (266 denier) and about 30 Ne (177 denier). The spun weft yarns may be single end yarns or plied yarns. For instance, the spun weft yarns may be plied yarns, such as two ply yarns or three-ply yarns.
In the woven fabric 210, the second weft yarn type within the weft yarn groups 240a-240d are continuous filament yarns 245b-245d. The continuous filament weft yarns 245b-245d may be formed from polyester filaments. However, other filament types are possible. Each continuous filament yarn 245b-245d may have a linear density between 15 denier and 150 denier.
In accordance with such an embodiment shown in
Another embodiment shown in
The blended weft yarns 345a-345d may be any type of spun staple yarn structure. For example, the blended weft yarns may be ring spun yarns, open end yarns, rotor spun yarns, vortex spun yarns, core spun yarns, jet spun yarns, or compact spun yarns. Preferably, the blended spun weft yarns are ring spun yarns. The blended spun weft yarns 345a-345d can, however, be any type of spun yarn structure. The blended spun weft yarns 345a-345d may have a range of linear densities that are suitable for bedding applications. For example, the blended spun weft yarns can have a count between 20 Ne (266 denier) and about 120 Ne (44.3 denier). In one example, the blended spun weft yarn count is between 20 Ne (266 denier) and about 100 Ne (53.1 denier). In another example, the blended spun weft yarn count is between 20 Ne (266 denier) and about 60 Ne (88.6 denier). In another example, the blended spun weft yarn count is between 20 Ne (266 denier) and about 40 Ne (133 denier). In yet another example, the blended spun weft yarn count is 20 Ne (266 denier) and about 30 Ne (177 denier). The blended spun weft yarn may be single end yarns or plied yarns. For instance, the blended spun weft yarns may be plied yarns, such as two ply yarns or a three-ply yarns.
An alternative embodiment of the present disclosure is terry fabric 510 as shown in
As illustrated in
The terry fabric 510 may include a plurality of yarns as described above. For instance, the warp yarns 530 are blended staple warp yarns each of which has cotton fibers and regenerated cellulosic fibers. The weft yarns and/or the pile yarns may include at least one yarn comprising thermoplastic fibers. In another example, the weft yarns and/or the pile yarns may include at least one yarn comprising a blend of cotton fibers and regenerated cellulosic fibers.
Turning to
Following weft yarn spinning, a weft yarn may be prepared in winding 416 operation. Winding 416 may include use of a yarn winding apparatus (not shown) configured to wind separate yarns onto a multiple yarn packages.
Warping 420 follows the yarn formation 410 for woven and terry fabrics. Warping 420 is where warp yarn ends are removed from their respective yarn packages, arranged in a parallel form, and wound onto a warp beam. Warping 420 also includes a sizing step where a sizing agent is applied to each warp yarn to aid in fabric formation. Warping 420 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. Terry fabric production may include pile warp beam as in known in the art.
Continuing with
During the formation phase of the weaving 440, the weft yarns 40, 140, 240, 240 are woven withthe warp yarns 20 to define the desired woven construction. The formation phase creates shed with the warp yarns 20 that the weft yarns 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, yarns 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 440 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 440, including, but not limited to: plain weaves; basket weaves, satins; rib weaves; twill weaves, oxford weaves; percale weaves; and sateens.
After weaving 440, the woven fabric passes through desizing and bleaching 450. Desizing may be accomplished with enzymes as is known in the art. Bleaching may include typical bleaching agents, such as hydrogen peroxide.
After desizing and bleaching, coloring agents are applied to the woven fabric in dyeing operation 460. In accordance with the embodiment illustrated, the dyeing operation 460 applies color to any yarns, including any undyed continuous filament yarn and/or spun yarns, depending on the specific woven fabric construction. The dyeing operation is carried out in such way that coloring agents that are applied to the cotton fibers and or regenerated cellulosic fibers and/or the continuous filament yarns as the case may be. The dyeing operation may include sub operations depending on the fiber blends in the fabric. For instance, woven fabrics that include cotton fibers may involve application of reactive dyes. Woven fabrics that include continuous polyester filaments or staple length polyester fibers may include application of disperse dyes as is known persons of skill in the art.
Continuing with
After finishing 470, the fabrics may be assembled 480 into various textile articles. Article assembly 480 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 480 includes cutting a panel of woven 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, the fabrics can be cut to size and combined with desired batting or fill (e.g. fiber, feather, etc.). Accordingly, article assembly 480 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, coverlet and a blanket.
After the assembling step, a packaging step 490 places the bedding article in suitable packaging for shipment. The packaging 490 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.
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.
| Number | Date | Country | Kind |
|---|---|---|---|
| 201621031577 | Sep 2016 | IN | national |
