STRETCH WOVENS WITH SEPARATED ELASTIC YARN SYSTEM

• US 20090191777A1
• Filed: 01/25/2008
• Published: 07/30/2009
• Est. Priority Date: 01/25/2008
• Status: Active Grant

• Current Assignee: The Lycra Company, LLC
• Original Assignee: Invista North America Sarl (Invista)
• Inventors: Liao, Tianyi
• Granted Patent: US 7,762,287 B2
• Time in Patent Office: Days
• US Class Current: 442/184
• CPC Class Codes: D02G 3/328 containing elastane
• CPC Class Codes: D03D 13/004 with weave pattern being non-standard or providing special effects
• CPC Class Codes: D03D 15/292 Conjugate, i.e. bi- or multicomponent, fibres or filaments
• 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 2211/04 Silk
• CPC Class Codes: Y10T 442/3024 Including elastic strand or strip

Abstract

In some embodiments are an article including a woven fabric having warp yarns and weft yarns. Either warp yarn or weft yarn or both warp and weft yarns have two separate systems of yarns. The systems of yarns include a hard yarn forming the main body of fabric and a composite covered elastic yarn with an elastic fiber core; wherein the fabric has an outer face side, a back side, and the fabric includes at least one of: (a) a weaving pattern where the composite yarn and at least one adjacent hard yarn pass over the same pick when the composite yarn is on the outer surface; (b) the ratio of hard yarn denier to composite yarn denier is at least 1:1; and (c) the composite yarn floats over no more than 5 picks on the outer face side.

Claims

1. An article comprising a woven fabric having warp yarns and weft yarns, wherein at least one of the warp yarns and weft yarns have two separate systems of yarns;

said systems of yarns include a hard yarn forming the main body of fabric and a composite covered elastic yarn with an elastic yarn core;

wherein the fabric has an outer face side, a back side, and includes at least one of;

(a) a weaving pattern where the composite yarn and at least one adjacent hard yarn pass over the same pick when the composite yarn is on the outer surface;

(b) the ratio of hard yarn denier to composite yarn denier is at least 1;

1; and

(c) the composite yarn floats over no more than 5 picks on the outer face side.

2. The article of claim 1, wherein the ratio of hard yarn denier to composite yarn denier is from about 2:

1 to about 10;

1.

3. The article of claim 1, wherein the yarn end ratio of the base yarn to the core yarn is from about 2:

1 to about 8;

1.

4. The article of claim 1, wherein the amount of elastic fiber present in the warp yarns is from about 0.1% to about 5% by weight of the warp yarns.

5. The article of claim 4, wherein the amount of elastic fiber is present in the weft yarns from about 0.1% to about 5% by weight of the weft yarns.

6. The article of claim 1, wherein the elastic yarn is spandex.

7. The article of claim 1, wherein the composite covered elastic yarn is selected from the group consisting of core spun yarn, air covered yarn, single wrapped yarn, double wrapped yarn, and combinations thereof.

8. The article of claim 1, wherein the hard yarn forming the main body of fabric is selected from staple spun yarn, filament yarn, and combinations thereof.

9. The article of claim 1, wherein the hard yarn forming the main body of fabric is selected from the group consisting of wool, linen, silk, polyester, nylon, olefin, cotton, and combinations thereof.

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

11. The article of claim 10, wherein the fabric weaving pattern for the hard yarn and the composite yarn is different.

12. The article of claim 1, wherein the fabric has stretch in the warp direction between about 10 and about 45%.

13. The article of claim 1, wherein the elastic fiber core has a denier from about 10 D to about 400 D.

14. The article of claim 1, wherein said fabric comprises a garment.

15. An article comprising a woven fabric having warp yarns and weft yarns, wherein at least one of the warp yarns or weft yarns have two separate systems of yarns;

said systems of yarns include a hard yarn forming the main body of fabric and a composite covered elastic yarn with an elastic yarn core;

wherein the fabric has an outer face side, a back side, and the fabric includes;

(a) a weaving pattern where the composite yarn and at least one adjacent hard yarn pass over the same pick when the composite yarn is on the outer surface;

(b) the ratio of hard yarn denier to composite yarn denier is at least 1;

1; and

(c) the composite yarn floats over no more than 5 picks on the outer face side.

16. A method of making an article comprising:

weaving a fabric having warp yarns and weft yarns, wherein at least one of the warp yarns or weft yarns have two separate systems of yarns;

said systems of yarns include a hard yarn forming the main body of fabric and a composite covered elastic yarn with an elastic yarn core;

wherein the fabric has an outer face side, a back side, and the fabric includes at least one of;

(a) a weaving pattern where the composite yarn and at least one adjacent hard yarn pass over the same pick when the composite yarn is on the outer surface;

(b) the ratio of hard yarn denier to composite yarn denier is at least 1;

1; and

(c) the composite yarn floats over no more than 5 picks on the outer face side.

17. The method of claim 16, wherein said composite covered elastic yarn includes the combination of a hard yarn with the elastic yarn core which are joined together during a warping process, a sizing process or the weaving process.

18. The method of claim 16, wherein the fabric is finished in a piece dyeing or continuous process.

19. The method of claim 16, wherein said fabric is prepared in the absence of a heat setting process.

20. The method of claim 16, wherein said article is a garment.