U.S. patent application number 13/009276 was filed with the patent office on 2011-07-21 for wool blend velour fabric.
Invention is credited to David Costello, Shawn Flavin, Charles Haryslak, Jane Hunter, Moshe Rock, Gadalia Vainer, Marcus Webster, James Zeiba.
Application Number | 20110177282 13/009276 |
Document ID | / |
Family ID | 44277775 |
Filed Date | 2011-07-21 |
United States Patent
Application |
20110177282 |
Kind Code |
A1 |
Rock; Moshe ; et
al. |
July 21, 2011 |
WOOL BLEND VELOUR FABRIC
Abstract
A wool blend velour fabric article (12) is formed of yarns (14,
16) consisting of wool fibers (17a, 17b) in a blend with
manufactured fibers (19a, 19b) (i.e., synthetic and/or regenerated
fibers). The wool and manufactured fibers are blended, i.e. spun,
together in a manner to control the distribution of the wool fibers
and of the manufactured fibers, across the cross-section of the
yarn such that each of the wool fibers is generally surrounded by
manufactured fibers, and thus shielded from interaction with other
ones of the wool fibers. The resulting velour fabric article
exhibits reduced shrinkage and felting.
Inventors: |
Rock; Moshe; (Brookline,
MA) ; Haryslak; Charles; (Marlborough, MA) ;
Zeiba; James; (Derry, NH) ; Webster; Marcus;
(Pelham, NH) ; Vainer; Gadalia; (Melrose, MA)
; Costello; David; (Marblehead, MA) ; Hunter;
Jane; (Manassas, VA) ; Flavin; Shawn;
(Sandown, NH) |
Family ID: |
44277775 |
Appl. No.: |
13/009276 |
Filed: |
January 19, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61296100 |
Jan 19, 2010 |
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Current U.S.
Class: |
428/91 ; 28/162;
66/194; 66/202; 87/8 |
Current CPC
Class: |
D04B 1/04 20130101; Y10T
428/2395 20150401; D10B 2211/02 20130101 |
Class at
Publication: |
428/91 ; 28/162;
66/194; 66/202; 87/8 |
International
Class: |
D06C 11/00 20060101
D06C011/00; D06C 23/02 20060101 D06C023/02; D04B 21/04 20060101
D04B021/04; D04C 1/02 20060101 D04C001/02 |
Claims
1. A wool blend velour fabric article comprising: a fabric body
having a technical face and a technical back, the fabric body
having a velour surface formed at one or both of the technical face
and the technical back, wherein the velour surface is formed of
yarn comprising a blend of wool and manufactured fibers, wherein
the wool and manufactured fibers are blended across a cross-section
of the yarn such that each wool fiber is generally surrounded by
manufactured fibers and thereby shielded from interaction with
other ones of the wool fibers.
2. The wool blend velour fabric article of claim 1, wherein the
wool fibers have an average diameter of 16 micron to about 36
micron.
3. The wool blend velour fabric article of claim 1, wherein the
wool fibers are not chemically treated by any oxidative
process.
4. The wool blend velour fabric article of claim 1, wherein the
manufactured fibers are selected from the group consisting of
polyester fibers, nylon fibers, acrylic fibers, modacrylic fibers,
polyolefin, polylactic acid, and rayon fibers.
5. The wool blend velour fabric article of claim 1, wherein the
manufactured fibers have an average thickness of less than 2 denier
per filament.
6. The wool blend velour fabric article of claim 1, wherein the
blend comprises at least 25 wt. % of the manufactured fibers, e.g.
at least 50 wt. % of the manufactured fibers.
7. The wool blend velour fabric article of claim 1, wherein the
yarn is a spun yarn.
8. The wool blend velour fabric article of claim 1, wherein the
manufactured fibers have flame retardant property.
9. The wool blend velour fabric article of claim 8, wherein the
manufactured fibers comprise modacrylic and/or flame retardant
rayon.
10. The wool blend velour fabric article of claim 1, wherein the
manufactured fibers comprise synthetic and/or regenerated
fibers.
11. The wool blend velour fabric article of claim 1, wherein the
wool fibers are treated with flame retardant chemical.
12. A method of forming a wool blend velour fabric, the method
comprising: joining a loop yarn and a stitch yarn to form a fabric
prebody, the stitch yarn forming a technical face of the fabric
prebody and the loop yarn forming a technical back of the fabric
prebody; and finishing at least one of the technical face and the
technical back of the fabric prebody to form a velour fabric body,
wherein at least one of the loop yarn and the stitch yarn comprises
a blend of wool and manufactured fibers, wherein the wool and
manufactured fibers are blended across a cross-section of the yarn
such that each wool fiber is generally surrounded by manufactured
fibers and thereby shielded from interaction with other ones of the
wool fibers.
13. The method of claim 12, wherein both the loop yarn and the
stitch yarn comprise blends of wool and manufactured fibers,
wherein the wool and manufactured fibers are blended across
respective cross-sections of the yarns such that each wool fiber is
generally surrounded by manufactured fibers and thereby shielded
from interaction with other ones of the wool fibers.
14. The method of claim 12, comprising finishing the technical face
and the technical back to form a double-face velour fabric
body.
15. The method of claim 12, further comprising subjecting the
fabric body to a dyeing process.
16. The method of claim 12, comprising finishing one of the
technical face and the technical back to form a single face velour
fabric body.
17. A method of forming a velour fabric, the method comprising:
joining a yarn comprising a blend of wool and manufactured fibers
to form a fabric prebody, the wool and manufactured fibers being
blended across a cross-section of the yarn such that each wool
fiber is generally surrounded by manufactured fibers and thereby
shielded from interaction with other ones of the wool fibers; and
finishing at least one surface of the fabric prebody to form a
velour fabric body.
18. The method of claim 17, further comprising subjecting the
fabric body to a dyeing process.
19. The method of claim 17, comprising finishing opposing surfaces
of the fabric prebody to form a double-face velour fabric body.
20. The method of claim 17, comprising finishing one of the
technical face and the technical back to form a single face velour
fabric body.
21. The method of claim 17, comprising: joining a yarn comprising a
blend of wool and manufactured fibers to form a fabric prebody
having a plaited construction; and finishing one of the technical
face and the technical back to form a plaited single face
fabric.
22. A wool blend velour fabric article comprising: a fabric body
having a technical face formed by a stitch yarn and a technical
back formed by a loop yarn, the fabric body having a velour surface
formed at one or both of the technical face and the technical back,
wherein one or both of the stitch yarn and the loop yarn comprises
a blend of wool and manufactured fibers, wherein the wool and
manufactured fibers are blended across a cross-section of the yarn
such that each wool fiber is generally surrounded by manufactured
fibers and thereby shielded from interaction with other ones of the
wool fibers.
23. The wool blend velour fabric article of claim 22, wherein the
wool fibers have an average diameter of 16 micron to about 36
micron.
24. The wool blend velour fabric article of claim 22, wherein the
wool fibers are not chemically treated by any oxidative
process.
25. The wool blend velour fabric article of claim 22, wherein the
manufactured fibers are selected from the group consisting of
polyester fibers, nylon fibers, acrylic fibers, modacrylic fibers,
polyolefin, polylactic acid, and rayon fibers.
26. The wool blend velour fabric article of claim 22, wherein the
manufactured fibers have an average thickness of less than 2 denier
per filament.
27. The wool blend velour fabric article of claim 22, wherein the
blend comprises at least 25 wt. % of the manufactured fibers, e.g.
at least 50 wt. % of the manufactured fibers.
28. The wool blend velour fabric article of claim 22, wherein the
yarn is a spun yarn.
29. The wool blend velour fabric article of claim 22, wherein the
stitch yarn comprises elastomer yarn and/or fibers.
30. The wool blend velour fabric article of claim 22, wherein the
manufactured fibers have flame retardant property.
31. The wool blend velour fabric article of claim 30, wherein the
manufactured fibers comprise modacrylic and/or flame retardant
rayon.
32. The wool blend velour fabric article of claim 22, wherein the
manufactured fibers comprise synthetic and/or regenerated
fibers.
33. The wool blend velour fabric article of claim 22, wherein the
wool fibers are treated with flame retardant chemical.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit from U.S. Provisional Patent
Application 61/296,100, filed Jan. 19, 2010.
TECHNICAL FIELD
[0002] This invention relates to wool blend velour fabrics, and
more particularly to wool blend velour fabrics having minimal
felting and shrinking
BACKGROUND
[0003] Velour is a fabric with a short, thick pile which makes the
fabric soft to the touch. Velour is usually made of wool or cotton
but can also be made from synthetic materials such as polyester.
Generally a velour fabric made of wool will "felt" (i.e., the wool
fibers will adhere and mat together through use and over time) and
the fabric will have high shrinkage during the dyeing process
and/or home laundering. It is known to overcome excess shrinkage
and felting by treating the wool fibers chemically, e.g., by
chlorination, or by ozonation, or by other oxidative process, all
of which are environmentally unfriendly.
SUMMARY
[0004] In general, this invention relates to wool blend velour
fabrics having minimal felting and shrinking
[0005] One aspect of the invention provides a wool blend velour
fabric article that includes a fabric body having a technical face
and a technical back. The fabric body having a velour surface
formed at one or both of the technical face and the technical back.
The velour surface is formed of yarn (e.g., a spun yarn) that
includes a blend of wool and manufactured fibers (e.g., synthetic
fibers such as polyester fibers, nylon fibers, acrylic fibers,
modacrylic fibers, polyolefin, and polylactic acid, and/or
regenerated fibers such as rayon fibers). The wool and manufactured
fibers (i.e., synthetic and/or regenerated fibers) are blended
across a cross-section of the yarn such that each wool fiber is
generally surrounded by manufactured fibers and thereby shielded
from interaction with other ones of the wool fibers.
[0006] Preferred implementations may include one or more of the
following additional features and/or steps. The wool fibers can
have an average diameter of 16 micron to about 36 micron, e.g.,
about 26 micron. In some embodiments, the wool fibers are not
chemically treated by any oxidative process. The manufactured
fibers can have an average thickness of less than 2 denier per
filament. The blend includes at least 25 wt. %, e.g., at least 50
wt. %, of the manufactured fibers. In some cases, the manufactured
fibers have flame retardant property. For example, the manufactured
fibers may include modacrylic and/or flame retardant rayon. The
wool fibers may be treated with flame retardant chemical.
[0007] Another aspect of the invention features a method of forming
a wool blend velour fabric. the method includes joining a loop yarn
and a stitch yarn to form a fabric prebody, the stitch yarn forming
a technical face of the fabric prebody and the loop yarn forming a
technical back of the fabric prebody; and finishing at least one of
the technical face and the technical back of the fabric prebody to
form a velour fabric body. At least one of the loop yarn and the
stitch yarn includes a blend of wool and manufactured fibers. The
wool and manufactured fibers are blended across a cross-section of
the yarn such that each wool fiber is generally surrounded by
manufactured fibers and thereby shielded from interaction with
other ones of the wool fibers.
[0008] Preferred implementations may include one or more of the
following additional features and/or steps. In some embodiments,
both the loop yarn and the stitch yarn include blends of wool and
manufactured fibers, and the wool and manufactured fibers are
blended across respective cross-sections of the yarns such that
each wool fiber is generally surrounded by manufactured fibers and
thereby shielded from interaction with other ones of the wool
fibers. In some embodiments, the fabric body is subjected to a
dyeing process.
[0009] According to another aspect, a method of forming a velour
fabric includes joining a yarn comprising a blend of wool and
manufactured fibers (i.e., synthetic and/or regenerated fibers) to
form a fabric prebody, the wool and manufactured fibers being
blended across a cross-section of the yarn such that each wool
fiber is generally surrounded by manufactured fibers and thereby
shielded from interaction with other ones of the wool fibers; and
finishing at least one surface of the fabric prebody to form a
velour fabric body.
[0010] Preferred implementations may include one or more of the
following additional features and/or steps. Methods can also
include finishing the technical face and the technical back to form
a double-face velour fabric body. In some embodiments, the fabric
body is subjected to a dyeing process. Methods may optionally
include finishing one of the technical face and the technical back
to form a single face velour fabric body, e.g., having plaited
jersey on one side.
[0011] In yet another aspect, a wool blend velour fabric article
includes a fabric body having a technical face formed by a stitch
yarn and a technical back formed by a loop yarn. The fabric body
has a velour surface formed at one or both of the technical face
and the technical back. One or both of the stitch yarn and the loop
yarn comprises a blend of wool and manufactured fibers (i.e.,
synthetic and/or regenerated fibers). The wool and manufactured
fibers are blended across a cross-section of the yarn such that
each wool fiber is generally surrounded by manufactured fibers and
thereby shielded from interaction with other ones of the wool
fibers.
[0012] Preferred implementations may include one or more of the
following additional features and/or steps. The wool fibers can
have an average diameter of 16 micron to about 36 micron, e.g.,
about 26 micron. In some embodiments, the wool fibers are not
chemically treated by any oxidative process. The manufactured
fibers can have an average thickness of less than 2 denier per
filament. The blend includes at least 25 wt. %, e.g., at least 50
wt. %, of the manufactured fibers. The stitch yarn may include
elastomeric material (e.g., elastomer yarn and/or fibers). The
manufactured fibers may have flame retardant property. For example,
the manufactured fibers may include modacrylic and/or flame
retardant rayon. The wool fibers may be treated with flame
retardant chemical.
[0013] Embodiments can include one or more of the following
advantages.
[0014] Forming a velour fabric from yarn that includes a blend of
wool and manufactured fibers, where each wool fiber is generally
surrounded by manufactured fibers, can help to shield the wool
fibers from interacting with each other and, as a result, can help
to inhibit felting and shrinking of the fabric.
[0015] Shielding the wool fiber from interaction with each other
can also allow for the formation of a velour fabric without the use
of environmentally unfriendly oxidative processes.
[0016] Other aspects, features, and advantages are in the
description, drawings, and claims.
DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a schematic end section view of a double-face
fabric prebody.
[0018] FIG. 2A is a detailed cross-sectional view of a spun loop
yarn.
[0019] FIG. 2B is a detailed cross-sectional view of a spun stitch
yarn.
[0020] FIG. 3 is a somewhat diagrammatic perspective view of a
double-face velour fabric article.
[0021] FIG. 4 is a perspective view of a segment of a circular
knitting machine.
[0022] FIGS. 5A-5G are sequential views of a cylinder latch needle
in a reverse plating circular knitting process.
[0023] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0024] A wool blend velour fabric article is formed of yarns
consisting of wool fibers in a blend with manufactured fibers
(i.e., synthetic and/or regenerated fibers). The wool and
manufactured fibers are blended, i.e. spun, together in a manner to
control the distribution of the wool fibers and of the manufactured
fibers, across the cross-section of the yarn, such that each of the
wool fibers is generally surrounded by manufactured fibers, and
thus shielded from interaction with other ones of the wool fibers.
The resulting velour fabric article exhibits reduced shrinkage and
felting.
[0025] FIG. 1, illustrates a fabric prebody 12 that is used to form
the velour fabric article 10 (FIG. 3) of the invention. The fabric
prebody is formed, e.g., in a knitting process, by joining a stitch
yarn 14 and a loop yarn 16. The stitch yarn 14 forms the technical
face 18 of the resulting fabric prebody 12 and the loop yarn 16
forms the opposite technical back 20, where it is formed into loops
22. The loop yarn 16 extends outwardly to overlie and cover the
stitch yarn 14 at the technical face 18.
[0026] The loop yarn 16 forming the technical back 20 of the fabric
body 12 is a spun yarn consisting of a blend of wool and at least
25 wt. % manufactured fibers. As illustrated in FIG. 2A, the wool
and manufactured fibers 17a, 19a of the loop yarn 16 are spun
(e.g., core-spun) together in a manner to control the distribution
of the wool fibers 17a and of the manufactured fibers 19a, across
the cross-section of the yarn such that each of the wool fibers 17a
is generally surrounded by manufactured fibers 19a, and thus
shielded from interaction with other ones of the wool fibers 17a.
The wool fibers 17a of the loop yarn 16 have an average fiber
diameter in the range of about 16 micron to about 36 micron, e.g.,
about 26 micron. Preferably, the wool fibers 17a are not treated by
chlorination, or by ozonation, or by any other oxidative processes.
The manufactured fibers 19a of the loop yarn 16 can be synthetic
fibers (e.g., polyester, nylon, acrylic, modacrylic, polyolefin,
and/or polylactic acid fibers) and/or regenerated fibers (e.g.,
rayon fibers). The manufactured fibers 19a are relatively finer
fibers having an average thickness of less than about 2 denier per
filament.
[0027] As illustrated in FIG. 2B, the stitch yarn 14 forming the
technical face 16 of the fabric body 12 can be also made of spun
yarn consisting of a blend of wool and at least 25 wt. %
manufactured (e.g., polyester, nylon, acrylic, modacrylic,
polyolefin, polylactic acid, and/or rayon) fibers. As in the case
of the loop yarn 16, the wool and manufactured fibers 17b, 19b of
the stitch yarn 14 are distributed such that each of the wool
fibers 17b is generally surrounded by the manufactured fibers 19b.
The manufactured fibers 19b shield the wool fibers 17b from
interaction with each other. The wool fibers of the stitch yarn 14
have an average fiber diameter in the range of about 16 micron to
about 36 micron, e.g., about 26 micron. As in the case of the loop
yarn 16, the wool fibers 17b of the stitch yarn 14 are preferably
left untreated by chlorination, or by ozonation, or by any other
oxidative processes. The manufactured fibers 19b have an average
thickness of less than about 2 denier per filament.
[0028] Referring to FIGS. 4 and 5A-5G, the fabric prebody is formed
(in a continuous web) by joining the stitch yarn 14 and the loop
yarn 16 in a standard reverse plating circular knitting (terry
knitting) process. This is principally a terry knit construction,
where segments 23 of the loop yarn 16 cover the stitch yarn 14 on
the technical face 18 and loops 22 of the loop yarn 16 form loops
22 at the technical back 20 of the fabric prebody 12.
[0029] The fabric prebody 12 is next subjected to finishing. During
the finishing process, the technical face and technical back
surfaces 18, 20, respectively, of the fabric prebody 12, with the
segments 23 of loop yarn 16 overlying the stitch yarn 14 at the
technical face surface 18 and the loops 22 formed at the technical
back surface 20, are subjected to a finishing process, e.g., such
as sanding, brushing and/or napping, to generate a velour 24, 26.
The yarn fibers are raised at one or both surfaces of the fabric
prebody 12, including the technical face 18 and the technical back
20, to form the velour 24, 26 at each face of the fabric body 30 of
the double-face velour fabric article 10 (FIG. 3) of the
invention.
[0030] The fabric article 10 may also be dyed, and heat may be
applied to the fabric body, e.g. dry heat and/or wet heat, such as
hot water or steam, e.g. during finishing or dyeing. Due at least
in part to the construction of the individual yarns, and, in
particular, the shielding of the wool fibers 17a, 17b (i.e., by the
manufactured fibers 19a,19b) from interaction with each other, the
velour fabric exhibits only minimal felting and shrinking as a
result of exposure to wet heat (e.g., during the dyeing or
finishing processes, and or regular home laundering).
Other Embodiments
[0031] While certain embodiments have been described above, other
embodiments are possible.
[0032] As an example, while an embodiment has been described in
which both the loop yarn and the stitch yarn consist of a spun yarn
that includes a blend of wool and manufactured fibers, in some
embodiments only the loop yarn or only stitch yarn includes such a
spun yarn.
[0033] While a circular knit velour fabric has been described, in
some embodiments the velour fabric can instead have warp knit
construction.
[0034] Although an embodiment of a double-face velour fabric has
been described in which both the technical face and technical back
surfaces of the fabric are finished as velour, in some embodiments,
only one of the surfaces (i.e., the technical back or the technical
face) is finished as velour. As an example, the wool blend velour
fabric can be finished as a single face velour and plaited jersey
on one side, opposite the velour.
[0035] Although a reverse plating circular knitting process has
been described, in some embodiments, the wool blend velour fabric
can be produced by other methods of knitting or forming.
[0036] In some cases, the fiber blend may have flame retardant
properties. For example, the manufactured fibers of the blend may
include modacrylic and/or flame retardant rayon. Alternatively or
additionally, the wool fiber can also be treated with flame
retardant chemical.
[0037] In some embodiments, the stitch yarn can include elastomeric
material (e.g., elastomer yarn and/or fibers) for enhanced stretch
and recovery.
[0038] In some cases, the yarn comprising the blend of wool and
manufactured fibers can be incorporated in a textile fabric having
single jersey construction, double knit construction, or 3-end
fleece knit construction.
[0039] Other embodiments are within the scope of the following
claims.
* * * * *