STRETCH WOVENS WITH A CONTROL YARN SYSTEM

• US 20150133017A1
• Filed: 03/26/2013
• Published: 05/14/2015
• Est. Priority Date: 03/30/2012
• Status: Active Grant

• Current Assignee: The Lycra Company, LLC
• Original Assignee: Invista North America Sarl (Invista)
• Inventors: Liao, Tianyi, Leung, Raymond S.P., Nefodov, Leonid
• Granted Patent: US 9,982,372 B2
• Time in Patent Office: Days
• US Class Current: 442/184
• CPC Class Codes: D02G 3/328 containing elastane
• CPC Class Codes: D03D 1/00 Woven fabrics designed to make specified articles
• CPC Class Codes: D03D 15/292 Conjugate, i.e. bi- or multicomponent, fibres or filaments
• CPC Class Codes: D03D 15/43 with differing diameters
• CPC Class Codes: D03D 15/47 multicomponent, e.g. blended yarns or threads multicomponent fibres or filaments D03D15/292
• CPC Class Codes: D03D 15/56 elastic
• CPC Class Codes: D10B 2201/01 Natural vegetable fibres
• CPC Class Codes: D10B 2321/02 polyolefins
• CPC Class Codes: D10B 2331/02 polyamides D10B2331/08 takes precedence
• CPC Class Codes: D10B 2331/04 polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2501/00 Wearing apparel
• CPC Class Codes: Y10T 442/3024 Including elastic strand or strip

Abstract

An article including a woven fabric comprising warp yarns and weft yarns, wherein at least one of either the warp yarns or the weft yarns includes: (a) a corespun elastic base yarn having a denier and including staple fiber and an elastic fiber core; and (b) a separate control yarn selected from the group consisting of a single filament yarn, a multiple filament yarn, a composite yarn, and combinations thereof; having a denier greater than zero to about 0.8 times the denier of the corespun elastic base yarn; wherein the woven fabric includes (1) a ratio of corespun base yarn ends to control yarn ends of up to about 6:1; or (2) a ratio of corespun base yarn picks to control yarn picks of up to about 6:1; or (3) both a ratio of corespun base yarn ends to control yarn ends of up to about 6:1; and a ratio of corespun base yarn picks to control yarn picks of up to about 6:1.

Claims

1. An article comprising a woven fabric comprising warp yarns and weft yarns, wherein at least one of either the warp yarns or the weft yarns includes:

(a) a corespun elastic base yarn having a denier and comprising staple fiber and an elastic fiber core; and

(b) a separate control yarn selected from the group consisting of a single filament yarn, a multiple filament yarn, a composite yarn, and combinations thereof;

having a denier greater than zero to about 0.8 times the denier of the corespun elastic base yarn;

wherein the woven fabric includes

(1) a ratio of corespun base yarn ends to control yarn ends of up to about 6;

1;

or

(2) a ratio of corespun base yarn picks to control yarn picks of up to about 6;

1;

or

(3) both a ratio of corespun base yarn ends to control yarn ends of up to about 6;

1; and

a ratio of corespun base yarn picks to control yarn picks of up to about 6;

1.

2. The article of claim 1, wherein the weft yarns include the corespun elastic base yarn and said separate control yarn.

3. The article of claim 1, wherein the warp yarns include the corespun elastic base yarn and said separate control yarn.

4. The article of claim 1, wherein both of the warp yarns and the weft yarns include the corespun elastic base yarn and said separate control yarn.

5. The article of claim 1, wherein at least one of either the warp yarns or the weft yarns has a ratio of the denier of the corespun base yarn to the denier of the separate control yarn of about 3:

1 to about 10;

1.

6. The article of claim 1, wherein the ratio of corespun base yarn ends or picks to control yarn ends or picks, respectively, of about 1:

1 to about 4;

1.

7. The article of claim 1, wherein the corespun base yarn comprises a fiber selected from the group consisting of wool, linen, silk, polyester, nylon, olefin, cotton, and combinations thereof.

8. The article of claim 1, wherein the amount of elastic fiber core in the corespun base yarn is about 0.5% to about 20% by weight of the warp or weft yarns.

9. The article of claim 1, wherein the elastic fiber core comprises spandex.

10. The article of claim 1, wherein the separate control yarn is a composite elastic yarn selected from the group consisting of air covered yarn, single wrapped yarn, double wrapped yarn and comprises a hard fiber and an additional elastic fiber.

11. The article of claim 1, wherein said control yarn is polyester bicomponent filament having a linear density of about 10 denier to about 450 denier.

12. The article of claim 1, wherein the control yarn is a filament yarn having a high shrinkage selected from the group consisting of fully drawn yarn, textured yarn, and partially oriented yarn.

13. The article of claim 1, wherein the fabric has a weaving pattern selected from the group consisting of plain, twill, satin, and combinations thereof.

14. The article of claim 13, wherein the fabric weaving pattern for the corespun base yarn and the control yarn is the same.

15. The article of claim 1, wherein the fabric has stretch in the weft direction of about 10% to about 45%.

16. The article of claim 1, wherein the elastic fiber core has a linear density of about 10 denier to about 300 denier.

17. The article of claim 1, wherein said article is a garment.

18. A method for making an article comprising a woven fabric comprising weaving warp yarns and weft yarns, wherein at least one of either the warp yarns or the weft yarns includes:

(a) a corespun elastic base yarn having a denier and comprising staple fiber and an elastic fiber core; and

(b) a separate control yarn selected from the group consisting of a single filament yarn, a multiple filament yarn, a composite yarn, and combinations thereof;

having a denier greater than zero to about 0.8 times the denier of the corespun elastic base yarn;

wherein the woven fabric includes

(1) a ratio of corespun base yarn ends to control yarn ends of up to about 6;

1;

or

(2) a ratio of corespun base yarn picks to control yarn picks of up to about 6;

1;

or

(3) both a ratio of corespun base yarn ends to control yarn ends of up to about 6;

1; and

a ratio of corespun base yarn picks to control yarn picks of up to about 6;

1.

19. The method of claim 18, wherein the corespun base yarn and the separate control yarn are joined during a warping process, a sizing process or during the weaving.

20. The method of claim 18, wherein the corespun base yarn is joined with the separate control yarn during the weaving through a co-insertion method.

21. The method of claim 18, where the fabric is finished in a piece dyeing or continuous dyeing process.

22. The method of claim 18, wherein said fabric is prepared in the absence of a heat setting process.

23. The method of claim 18 wherein said article is a garment.