U.S. patent application number 13/717912 was filed with the patent office on 2013-07-18 for fabrics containing multi-groove fibers.
This patent application is currently assigned to MMI-IPCO, LLC. The applicant listed for this patent is MMI-IPCO, LLC. Invention is credited to Moshe Rock.
Application Number | 20130183480 13/717912 |
Document ID | / |
Family ID | 47505354 |
Filed Date | 2013-07-18 |
United States Patent
Application |
20130183480 |
Kind Code |
A1 |
Rock; Moshe |
July 18, 2013 |
Fabrics Containing Multi-Groove Fibers
Abstract
Fabric having a fabric body defines a first surface and an
opposite second surface, with at least one of the first and second
surfaces incorporating fibers having an axial core surrounded by a
multiplicity of radially extending, axially-elongated whiskers. The
whiskers are separated by axially-extending grooves. The fibers
have denier of about 0.3 dpf to about 10.0 dpf. Garments formed of
such fabric are also described.
Inventors: |
Rock; Moshe; (Brookline,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MMI-IPCO, LLC; |
Lawrence |
MA |
US |
|
|
Assignee: |
MMI-IPCO, LLC
Lawrence
MA
|
Family ID: |
47505354 |
Appl. No.: |
13/717912 |
Filed: |
December 18, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61587299 |
Jan 17, 2012 |
|
|
|
Current U.S.
Class: |
428/91 ;
2/69 |
Current CPC
Class: |
Y10T 428/2395 20150401;
A41D 1/00 20130101; D01D 5/253 20130101; D03D 15/0077 20130101 |
Class at
Publication: |
428/91 ;
2/69 |
International
Class: |
D03D 15/00 20060101
D03D015/00; A41D 1/00 20060101 A41D001/00 |
Claims
1. A fabric comprising a fabric body defining a first surface and
an opposite second surface, and at least one of the first surface
and the second surface incorporating fibers having an axial core
surrounded by a multiplicity of radially extending,
axially-elongated whiskers, separated by axially-extending grooves,
said fibers having denier of about 0.3 dpf to about 10.0 dpf.
2. The fabric of claim 1, wherein the first surface is a smooth
surface and incorporates said fibers.
3. The fabric of claim 1, wherein the first surface is a raised
surface and incorporates said fibers.
4. The fabric of claim 2 or claim 3, wherein the second surface
incorporates fibers other than said fibers.
5. The fabric of claim 3, wherein the second surface is a raised
surface and incorporates said fibers.
6. The fabric of claim 2 or claim 3, wherein the second surface
incorporates fibers other said fibers, and the fibers incorporated
in the second surface have denier relatively greater than the
denier of said fibers incorporated in the first surface.
7. The fabric of claim 3, wherein the fibers other than said fibers
incorporated in the second surface have denier of about 0.1 dpf to
about 3.0 dpf.
8. The fabric of claim 3, wherein the fabric has construction
selected from among has double needle bar warp knit (raschel),
circular terry sinker loop, cut loop terry sinker loop, and brushed
warp knit construction.
9. The fabric of claim 2, wherein the fabric has constructions
selected from among plaited single jersey, plaited jersey, double
knit, tricot, the jersey side of single face construction, 2-end
fleece, and 3-end fleece construction.
10. The fabric of claim 6, wherein the raised surface defines
pillars separated by intersecting channels, the pillars being
defined by discrete regions of relative high pile and the
intersecting channels being defined by discrete regions of
relatively lower pile or no pile.
11. The fabric of claim 6, wherein the raised surface defines
pockets, the pockets being defined by discrete regions of
relatively low pile or no pile arrayed among relatively higher
pile.
12. The fabric of claim 1, wherein the first and second surfaces
both incorporate said fibers.
13. The fabric of claim 1, wherein the fabric body further
comprises elastomeric fibers.
14. The fabric of claim 13, wherein the fabric body has 4-way
stretch.
15. The fabric of claim 1, wherein said fabric has construction
selected from woven construction, double weave construction, and
warp knit construction.
16. The fabric of claim 1, wherein the core and the whiskers of
said fibers consist of the same polymer or compatible polymers.
17. The fabric of claim 1, wherein the polymer of the core and/or
of the whiskers comprises polyethylene terephthalate (PET),
polypropylene (PP), polyamide 6 (PA 6), PA 66, or any of the
combinations.
18. The fabric of claim 1, wherein said fibers have about 3 to
about 200 whiskers within a cross-sectional surface of said
fibers.
19. The fabric of claim 1, wherein said axially-extending grooves
are nanogrooves or microgrooves.
20. The fabric of claim 1, wherein said whiskers have an average
radial length of about 2 nm to about 10 microns.
21. The fabric of claim 1, wherein the core has a denier of about
0.3 dpf to about 10.0 dpf.
22. The fabric of claim 1, wherein the whiskers have an average
length up to about 200% of a diameter of the core.
23. The fabric of claim 1, wherein the whiskers have an average
length down to about 0.01% of a diameter of the core.
24. The fabric of claim 1, wherein the whiskers have an average
length in the range of about 20% and to about 100% of a diameter of
the core, or about 0.1% to about 1.0% of a diameter of the
core.
25. A garment formed of the fabric of claim 1, claim 2, or claim 3,
wherein a raised surface of the fabric is an outer surface of the
garment, facing away from skin of a wearer.
26. A garment formed of the fabric of claim 1, claim 2, or claim 3,
wherein a raised surface of the fabric is an inner surface of the
garment, facing toward a skin surface of a wearer.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a non-provisional of U.S. Application
Serial No.: 61/587,299 filed Jan. 17, 2012, the entire content of
which is incorporated herein by reference.
TECHNICAL FIELD
[0002] This disclosure relates to fabrics consisting, at least in
part, of synthetic fibers having an axial core with multiple, axial
grooves defined between axially-elongated, axially arranged
whiskers.
BACKGROUND
[0003] Fine denier fibers, i.e. fibers having relatively reduced
weight per length, which can be achieved, e.g., through reduced
fiber diameter, are often used in fabrics, e.g. for garments and
the like, to provide a soft surface touch, e.g. to the wearer's
skin. However, low denier fibers typically generate only very low
bulk, i.e. thickness, e.g. when used as a terry knit yarn (in
circular knit) and subjected to a raising process, e.g. brushing,
napping, etc. Low denier fibers, e.g. less than about 0.3 to 1.0
denier per filament (dpf), incorporated into fabric yarns by direct
spinning or by island-in-the-sea construction (i.e. fine denier
fibers for the "islands") introduced in a larger denier fiber of
soluble or dissolvable polymer (the "sea" that is subsequently
removed leaving the fine denier fibers) tend to flatten out quite
readily under pressure, thus causing the fabric to lose its
desirable bulk (surface thickness).
[0004] High performance and other fabrics are also often designed
for enhanced water management performance, i.e. for removal of
sweat and other moisture from the fabric inner surface at the
wearer's skin by wicking through the fabric to the exposed outer
surface, where evaporation can occur. In fabric systems of this
nature, it is often desirable to provide a differential of denier
between fibers at the inner surface and fibers at the outer surface
of the fabric, with the inner surface fibers having relatively
higher denier, thereby to encourage enhanced wicking action. This
relationship of denier between fibers of the inner surface and
fibers of the outer surface thus limits the denier of the inner
surface, where enhanced fineness of the fibers would otherwise be
desirable, e.g. for increased comfort to the wearer's skin.
[0005] Referring to FIGS. 1A and 1B, raised surface fabrics 2, 4,
e.g. velour, fleece, shearling, etc., having a single raised
surface 5 (FIG. 1A) and two raised surfaces 6, 7 (FIG. 1B),
respectively, are also often desirable for their ability to entrap
air between raised surfaces fibers, thus to provide theimal
insulation. However, the air entrapped amongst the surface fibers
of these fabrics is quite easily removed by action of dynamic
conditions, i.e. blowing air or movement of the wearer, resulting
in rapid loss of insulation.
SUMMARY
[0006] In one aspect, the disclosure features a fabric comprising a
fabric body defining a first surface and an opposite second
surface. At least one of the first surface and the second surface
incorporates fibers having an axial core surrounded by a
multiplicity of radially extending, axially-elongated whiskers. The
whiskers are separated by axially-extending grooves. The fibers
have denier of about 0.3 dpf to about 10.0 dpf. In another aspect,
the disclosure features a garment formed of such a fabric.
[0007] Implementations of the fabric and/or the garment may include
one or more of the following features. The first surface is a
smooth surface and incorporates said fibers. The first surface is a
raised surface and incorporates said fibers. The second surface
incorporates fibers other than said fibers. The second surface is a
raised surface and incorporates said fibers. The raised surface of
the fabric is an inner surface of the garment, facing toward a skin
surface of a wearer. The second surface incorporates fibers other
said fibers, and the fibers incorporated in the second surface have
denier relatively greater than the denier of said fibers
incorporated in the first surface. The fibers other than said
fibers incorporated in the second surface have denier of about 0.1
dpf to about 3.0 dpf. The fabric has construction selected from
among has double needle bar warp knit (raschel), circular terry
sinker loop (plaited or reverse plaited), cut loop terry sinker
loop, and brushed warp knit construction. The fabric has
constructions selected from among plaited single jersey, plaited
jersey, double knit, tricot, the jersey side of single face
construction, 2-end fleece, and 3-end fleece construction. The
raised surface defines pillars separated by intersecting channels,
the pillars being defined by discrete regions of relative high pile
and the intersecting channels being defined by discrete regions of
relatively lower pile or no pile. The raised surface defines
pockets, the pockets being defined by discrete regions of
relatively low pile or no pile arrayed among relatively higher
pile. The first and second surfaces both incorporate said fibers.
The fabric body further comprises elastomeric fibers. The fabric
body has 4-way stretch. The fabric has construction selected from
woven construction, double weave construction, and warp knit
construction. The core and the whiskers of said fibers consist of
the same polymer or compatible polymers. The polymer of the core
and/or of the whiskers comprises polyethylene terephthalate (PET),
polypropylene (PP), polyamide 6 (PA 6), PA 66, or any of the
combinations. The fibers have about 3 to about 200, e.g., about 10
to about 200, whiskers within a cross-sectional surface of said
fibers. The axially-extending grooves are nanogrooves or
microgrooves. The whiskers have an average radial length of about 2
nm to about 10 microns, The core has a denier of about 0.3 dpf to
about 10.0 dpf. The whiskers may an average length of up to about
200% of the diameter of the core, e.g., for relatively longer
whiskers, or may have an average length of down to about 0.01% of a
diameter of the core, e.g. for relatively shorter whiskers. The
relatively longer whiskers may have an average length in the range
of about 20% to about 100% of a diameter of a core, and relatively
shorter whiskers may have an average length in the range of about
0.1% to about 1.0% of a diameter of a core, or about 200 nm to
about 2 microns.
[0008] Implementations of this disclosure may include one or more
of the following advantages. For example, fabrics incorporating
multi-groove fibers ("MGF"), e.g., multi-groove nano or micro
fibers, having a core from which extend, generally radially,
multiple axially-elongated whiskers separated by axially-extending
grooves can have an ultra-suede touch. The multi-groove fibers can
be incorporated into a raised surface, or surfaces, of a fabric
forming outer and/or inner surfaces of a garment.
[0009] The multi-groove fibers have a relatively fine denier
(weight per length), e.g. when compared to standard fibers of
similar diameter, but the multi-groove fibers are relatively
thicker (i.e. having relatively greater diameter) and provide more
bulk, e.g. as compared to fibers of standard cross-section and
similar denier. Loop yarn and/or pile surfaces including the
multi-groove fibers on the raised surface can have enhanced
thickness (bulk).
[0010] The multi-groove fibers diffuse light directed onto the
surface of a garment, providing the garment with fibers having
relatively shorter whiskers with the appearance of a dull or matte
finish, e.g. as compared to a reflectively shiny finish.
[0011] A raised surface fabric, whether single face or double face,
incorporating multi-groove fibers having relatively longer whiskers
in the raised surface(s), can provide improved thermal insulation
by entrapment and retention of air, and will resist release or
displacement of the entrapped air, e.g. as compared to standard
raised surface fabric, when exposed to dynamic conditions (movement
and/or blowing air). The fabric can have a single raised surface or
it can have two, opposite, raised surfaces. Under static
conditions, the raised surface of a fabric of the disclosure having
a raised surface formed of multi-groove fibers and the raised
surface of a fabric having a raised surface formed instead of
conventional fibers, without grooves or whiskers, both entrap a
similar amount of air to provide similar thermal insulation
properties to the fabric. However, air displacement in the raised
surface formed of the multi-groove fibers is reduced as compared to
a raised surface formed of conventional fibers, e.g., because of
the tortuosity effect caused by the multi-groove fibers. In
addition, under dynamic conditions, i.e., when the fabrics are in
motion, e.g. caused by wind or by movement of the wearer, movement
of multi-groove fibers on a raised surface of fabric of the
disclosure is more restricted, e.g. as compared to movement of
conventional fibers of a raised surface of a conventional fabric,
e.g. in particular in the case of relatively longer whiskers.
Accordingly, the fabric of the disclosure provides good thermal
insulation to the wearer under both static and dynamic
conditions.
[0012] A fabric incorporating multi-groove fibers can be foamed
into a garment having its raised surface facing the skin surface of
a wearer. The raised surface can be patterned, e.g., to define
grids, pillars, interconnected channels, pockets, or other surface
features, including to enhance thermal insulation, air circulation,
and water management capabilities.
[0013] The multi-groove fibers can also be incorporated into a
smooth surface of a fabric, e.g. for use as an outer surface of a
garment. The multi-groove fibers having relatively shorter whiskers
can be used on the technical face of plaited terry sinker loop, or
on the outer side of plaited jersey, double knit and tricot, to
provide enhanced water management and improved rate of drying.
[0014] In particular, a fabric incorporating the multi-groove
fibers having relatively shorter whiskers can have enhanced water
management performance. The grooves of the multi-groove fibers can
provide enhanced movement of water along or through the fabric by
flow of water along the grooves. The whiskers of the multi-groove
fibers cause the fibers to have relatively larger surface area,
resulting in increased water holding capacity and enhanced water
evaporation.
[0015] Plaited jersey or double knit with multi-groove fibers
having small denier can be used advantageously on the outer-facing
surface a garment in order to permit use of relatively coarse
denier down to smaller denier fibers on the inner-facing surface of
the garment, thereby maintaining the differential of higher to
lower denier between the inner-and outer-facing surfaces, as
required for effective wicking of fluid towards the outer surface,
and also providing enhanced comfort for the wearer with relatively
lower denier at the inner facing surface.
[0016] Dimensions of the multi-groove fibers, such as length and/or
density of the whiskers, can be selected to enhance desired
performance features of the fibers, of fabrics made of or
containing the fibers, and of garments formed of the fabrics.
[0017] All fabrics including the multi-groove fibers can also
include elastomeric yarns.
[0018] Other features, objects, and advantages will be apparent
from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0019] FIGS. 1A and 1B are schematic edge views of prior art
fabrics having a single raised surface and a double raised surface,
respectively.
[0020] FIG. 2A is a schematic edge cross-sectional view of a fabric
of this disclosure incorporating multi-groove fibers ("MGF") on the
technical face (jersey side) of, e.g., a single face or plaited
jersey raised fabric, where, in a garment, the raised surface of
the technical back would be directed toward a wearer's skin;
and
[0021] FIG. 2B is a similar schematic edge cross-sectional view of
another fabric of this disclosure incorporating multi-groove fibers
at one or both surfaces of, e.g., a fabric having a terry sinker
loop (reverse plaiting) construction, finished in double face, e.g.
velour/velour.
[0022] FIGS. 3A and 3B are end section and perspective side views,
respectively, of a multi-groove fiber, and
[0023] FIG. 3C is an end perspective view of a multi-groove fiber
as seen through a scanning electron microscope.
[0024] FIGS. 3D and 3E are end section views of other
implementations of multi-groove fibers having relative shorter
whiskers and having relatively longer whiskers, respectively.
[0025] FIG. 4 is a schematic cross-sectional representation of a
process for conversion of a precursor into a multi-groove fiber,
and
[0026] FIG. 4A is an end section view of an intermediate product
including a removable sheath during the process of making
multi-groove fibers.
[0027] FIGS. 5A through 5N are schematic views of other fabric
constructions of this disclosure implementing incorporation of
multi-groove fibers.
[0028] FIG. 6A is a schematic view of a garment segment formed of
fabric (e.g. plaited terry sinker loop fabric) of this disclosure
having a raised surface containing the multi-groove fibers.
[0029] FIG. 6B is s schematic view of another garment segment
formed of fabric of this disclosure having two raised surfaces,
each containing the multi-groove fibers.
DETAILED DESCRIPTION
[0030] Referring to FIG. 2A, in one implementation, a fabric 10 of
this disclosure has a fabric body 12 with a raised surface 14
formed of loop yarn or pile (e.g., velour) and an opposite smooth
surface 16 that incorporates fine denier multi-groove (nano or
micro or other) fibers("MGF"), which will be described in more
detail below. The multi-groove fibers in the smooth surface 16
include relatively shorter whiskers that facilitate water
management. As represented in the figure, the fabric 10, when
formed into a garment, has its raised surface 14 disposed to face
the skin surface, S, of a wearer.
[0031] Referring to FIG. 2B, in another implementation, a fabric
10' has a fabric body 12' with opposite raised surfaces 14', 16'
both formed of loop yarn or pile (e.g., velour/velour), with one or
both of the raised surfaces incorporating the fine denier
multi-groove fibers. The multi-groove fibers in the raised surfaces
can have relatively longer whiskers to provide good thermal
insulation.
[0032] Multi-groove fibers having relatively shorter whiskers, e.g.
as developed by Taiwan Textile Researched Institute ("TTRI"), are
described in Liu et al. U.S. Patent Publication No. 2010/0159241,
published Jun. 24, 2010 (assigned on its face to Taiwan Textile
Research Institute), the complete disclosure of which is
incorporated herein by reference. As will be described, whisker
fibers permit formation of fabrics, including raised surface velour
and velour/velour fabrics, with certain advantageous features,
including, but not limited to, ultra-suede touch, while still
generating appropriate thickness/bulk of the raised surface
fabric.
[0033] Referring to FIGS. 3A, 3B, and 3C, a multi-groove fiber 20
consists of an axially-elongated core 22 and multiple (e.g., 8-200)
grooves 26 defined and spaced apart by whiskers 24 that extend
generally radially from the core 22. The whiskers 24, e.g.,
axially-elongated whiskers, are separated by grooves 26, e.g.,
axially-elongated grooves, and can have an average radial length,
l, in the order of microns or nanometers. The core 22 can have any
desired mass density (i.e. denier or mass-per-length), e.g., a
coarse denier of about 1.5 dpf to about 10.0 dpf, or a fine denier
of about 0.3 dpf to about 1.5 dpf. In some implementations, the
total mass density of the fiber 20 is selected to be about 0.3 dpf
to about 1.5 dpf.
[0034] The core 22 is formed of a synthetic (polymeric) material,
e.g., selected from among, e.g. polyester, nylon, polypropylene,
and others. The whiskers 24 are formed of the same synthetic
material as the core 20. For example, both the core 20 and the
whiskers 24 are formed of polyester. Referring to FIGS. 3D and 3E,
other implementations of multi-groove fibers 20', 20'' are shown,
e.g. with whiskers of relatively shorter length and relatively
longer length, respectively. In some implementations, an average
radial length, l, of the whiskers 24' of multi-groove fibers 20' is
smaller than the diameter of the core 22'. An average radial
length, l, of the whiskers 24'' of the multi-groove fibers 20'' is
greater than the diameter of the core 22''. The whiskers may an
average length of up to about 200% of the diameter of the core,
e.g., for relatively longer whiskers, or may have an average length
of down to about 0.01% of a diameter of the core, e.g. for
relatively shorter whiskers. The relatively longer whiskers may
have an average length in the range of about 20% to about 100% of a
diameter of a core, and the relatively shorter whiskers can have an
average length in the range of about 0.1% to about 1.0% of a
diameter of a core, or about 200 nm to about 2 microns.
[0035] Referring also to FIG. 4, the multi-groove fibers may be
formed according to processes described in Liu et al. U.S. Patent
Publication No. 2010/0159241, as referenced above. Multi-groove
fibers may also be available commercially from TTRI. Similar fibers
may also be available from Hills, Inc. (Florida, USA). As shown in
FIG. 4, according to the patent publication of Liu et al.,
multi-groove fibers are formed initially as a precursor 40',
extruded from a spinneret die, the fiber precursor consisting of a
core 32 surrounded by an edge region 46. The edge region 46 is
formed of alternating materials 34, 36, e.g., polymeric materials,
respectively. The polymer 34 later forms whiskers over the core 32,
and the polymer 36 forms a removable, e.g., dissolvable, sheath
separating the polymer 34. In some implementations, as shown in
FIG. 4A, the sheath 36 extends beyond the whisker material 34 along
the radial direction. The surface of the edge region surrounding
the core 32 is formed of the sheath material 36. Upon removal of
the polymer sheath 36, grooves are formed among the whiskers.
[0036] The polymers 34, 36 can be in the form of alternating sheets
or webs extending along a longitudinal axis of the core 32. The
polymer 34 is the same as the synthetic material forming the core
32. The polymer 36 is different from the materials forming the core
32 and the polymer 34, and is dissolvable or otherwise removable.
The polymer 36 and the polymer 34 typically have surface energy
that is quite similar. Referring still to FIG. 4, the fiber
precursor 40' is next subjected to processing (arrow, P) for
removal of the sheath 36, thereby forming multiple grooves 38
disposed about and extending axially along the core 32 of the
multi-groove fiber 40, the grooves 38 being defined by and between
intervening "whiskers" 42 formed of the sheets of the first set
34.
[0037] Referring again to FIGS. 3A and 3B, and also to FIG. 3C,
fibers 20 have a core 22 and whiskers 24 separated by grooves 26
extending from the surface of the core. The fibers 20 can be
multi-groove nano fibers having a total (including the core and the
whiskers) average mass density of about 0.3 dpf to about 10.0 dpf.
The fibers 20 can also be multi-groove micro fibers. The whiskers
24 and grooves 26 cause the fibers 20 to have relatively low mass
density as compared to a relatively smaller diameter or thickness
for fibers in the indicated range of denier. For example, for
purposes of comparison, a conventional fiber without the grooves
and whiskers and formed of the same material would have a thickness
of about 2% to about 75% of the thickness of the fiber 20, in order
to have denier in the range indicated for the multi-groove fiber
20. In contrast, if a conventional fiber had a diameter in the
range indicated above for multi-groove fiber 20, and was formed of
the same material, such a conventional fiber would have denier in
the range of about 1.3 to about 50 times the denier of the fiber
20.
[0038] According to the present disclosure, the sizes, thicknesses,
and/or mass densities of the multi-groove fibers 20 can be selected
based on the desired features of the fibers 20, e.g., denier,
and/or other features of the raised surface(s) 14 or 14', 16'
(FIGS. 2A-2B). The whiskers 24 can have an average radial length,
l, of about 2 nm to about 10 microns, e.g., 200 nm to 2 microns,
and an average thickness, t, of about 100 rim to 1 micron, e.g.,
200 mu to 1 micron, or 250 nm. As mention above, the grooves can be
nano-size or micro-size, e.g., having an average width, w, of about
100 nm to 10 microns, e.g., 250 nm. The ratio of the average
diameter, D, of the core 22 to the average length, l, of the
whiskers 24 and/or the ratio of the average thickness, t, to the
average width, w, can be adjusted to obtain desired fiber
properties, e.g., by changing the materials for and/or processes of
making the multi-groove fibers 20 (discussed further below). In the
example shown in FIG. 3E, the ratio of core diameter to the average
length of the whiskers is 1:1.
[0039] In some implementations, each multi-groove fiber 20 has
about 3 to about 200 whiskers, e.g., about 10-200 whiskers, about
40-200 whiskers, or about 60-80 whiskers, extending generally
radially from the core. The grooves 26 extend the entire length of
the multi-groove fiber 20. In some implementations, the grooves 26
have substantially the same dimensions and/or are substantially
evenly distributed about and/or along a cross-sectional surface of
the multi-groove fiber 20. In other implementations, the grooves 26
may have different dimensions and/or may be distributed
irregularly. Although the core 22 and the multi-groove fibers 20
appearing in the figures are shown as having circular
cross-section, it is to be understood that the core 22 and the
multi-groove fibers 10 may have other cross-sectional shapes. In
some implementations, a fiber can include both relatively longer
whiskers and relatively shorter whiskers along its cross
section.
[0040] In some implementations, the multi-groove fibers 20 are
formed or consist of synthetic (polymeric) material. The core 22
and the whiskers 24 are typically formed of the same polymeric
material. Suitable polymeric materials for use in the core 22 and
the whiskers 24 include, e.g., polyethylene terephthalate (PET),
polypropylene (PP), polyamide 6 (PA 6), PA 66, and/or combinations
thereof.
[0041] Referring again to FIG. 4, multi-groove fibers 40, e.g.,
that are similar to or the same as the multi-groove fibers 20 of
FIGS. 3A and 3B, can be made by forming a polymer extrusion 30 of
three or more polymers 32, 34, 36 and removing one of the polymers
36 to form grooves 38 among whiskers 42 formed of the polymer 36.
The polymeric extrusion 30 includes a core region 44 formed of the
polymer 32 and an edge region 46 formed of polymers 34, 36. The
polymer 34 is the same as the polymer 32, and the whiskers are
separated by the sheath formed by the removable polymer 36, e.g.,
dissolvable polyester, polyvinyl alcohol (PVA), polybutylene
terephthalate (PBT), poly(lactic acid) or polylactide (PLA), or
others. The sheath can be removed by exposing the polymer extrusion
30 to water or caustic soda (NaOH). The polymer 36 can be removed
by heating or radiating the polymer extrusion 30 and dissolving the
polymer 36. Other removable polymers and removal mechanisms may
also be employed. The polymers 32, 34 can be the previously
discussed polymers for forming the core 22 and the whiskers 24.
[0042] Referring again to FIGS. 3D and 3E, the thickness, t, and
the length, l, of the whiskers 42 can be adjusted by modifying the
polymers 34, 36 or other related parameters and factors. For
example, the spinneret used for extruding the fibers and/or the
weight ratio of the whisker polymer 34 and the sheath polymer 36
can be controlled or adjusted to modify parameters of resulting
product. The feeding rate of each polymer, the spin head and the
spinning plates in the spinneret can also be modified. For example,
the weight ratio can be in the range of from 9/1 to 1/9. The
dimensional ratio of the core 44 to the edge 42 (FIG. 4) can also
be adjusted, e.g., to provide the desired fiber denier and
thickness. In some implementations, multi-groove fibers 20' (FIG.
3D) with relatively shorter and/or thicker edge segments, resulting
in relatively shorter and/or thinner whiskers 24', may be
desirable, e.g. to produce fabric having a matte appearance or
finish. Conversely, multi-groove fiber 20'' (FIG. 3E) with
relatively longer and/or thinner edge segments, resulting in
relatively longer and/or thicker whiskers 24'', may also be
desirable, e.g. to provide a softer touch to the fibers, and to the
fabric containing or made of the fibers, e.g. resembling
ultra-suede. The ratio of dissolvable and non-dissolvable segments,
as well as the ratio of edge and core dimensions, can also be
adjusted.
[0043] We refer to now to FIGS. 5A through 5N in describing
examples of other implementations of this disclosure.
[0044] Referring to FIG. 5A, a velour fabric 60 has a raised
surface 62 incorporating multi-groove fibers (or whisker fibers)
having a core and whiskers made of the same polymer. The raised
surface 62 has an ultra suede touch and still has standard
thickness/bulk.
[0045] Referring to FIG. 5B, a velour fabric 70 has a raised
surface 72 incorporating multi-groove fibers (or whisker fibers)
having a core and whiskers, that are relatively thinner and/or
longer as compared to FIG. 5A, resulting in relatively softer touch
resembling an ultra-suede feeling.
[0046] Referring to FIG. 5C, a raised surface and/or pile fabric 80
incorporating multi-groove fibers (or whisker fibers) yarns is
formed, e.g., with double needle bar warp knit (raschel), circular
terry sinker loop knit, cut terry sinker loop knit, brushed warp
knit, etc. construction.
[0047] Referring to FIG. 5D, a plaited construction fabric 90, e.g.
like plaited single jersey, plaited jersey, double knit, tricot,
the jersey side of single face construction, 2-end fleece, 3-end
fleece, etc., has multi-groove fibers (or whisker fibers)
incorporated on the smooth outer side 92 of a garment funned of the
fabric.
[0048] Referring to FIG. 5E, in a fabric 100 of a plaited
construction, employed, e.g., in a garment 102 (FIG. 5F) for
improved water management, i.e. moving liquid sweat from the inner
(skin surface) side 104 to the outer side 106, relatively coarser
denier fibers are used on inner side 104 (next to skin) and
relatively finer denier fibers are used on outer side 106 (away
from skin). Use of the multi-groove fibers (or whisker fibers) as
the relatively finer denier fiber on the outer side 106 permits use
of very fine fibers on inner side 104 (0.1 to 1.0 dpf), while still
maintaining, or improving, water management. Referring also to
FIGS. 3A-3E and 4, the configuration of the fibers 20, 20', 20',
and 40' can enhance the soft touch and water management capability
of the fabric 100. In some implementations, the whiskers having a
relatively longer radial length, l, e.g., longer than the diameter
of the core, provides a still further enhancement of the soft touch
to a surface of the fabric 100 and to the garment 102. Whiskers
having a relatively shorter length, l, e.g., 200 nm to 10 microns,
can provide good water management by allowing water to move along
the grooves 26, 38 among the whiskers. The whiskers 24, 42 and the
grooves 26, 38 also increase the total surface area of the fibers
20, 40, so that the fibers 20, 40 have a relatively larger capacity
to hold liquid and water evaporation can be enhanced. In some
implementations, the fibers 20, 40 can have any size core (i.e.,
any denier) with a desired length of whiskers selected to provide a
desired fiber property, e.g., denier and/or water management.
[0049] Referring to FIG. 5G, a single faced raised fabric 110
formed into a garment (not shown) has multi-groove fibers (or
whisker fibers) incorporated on technical face (jersey (smooth)
side) 112, while the raised surface on technical back 114 is facing
the wearer's skin to enhance further water management. As shown in
the figure, the single face fabric 110 can have surface
construction with raised pillars 116 separated by intersecting
channels 118. This single face fabric 110 can also include
elastomeric yams, e.g., for enhancement of stretch/recovery. The
fabric 110 can also include elastomeric yarn, e.g., yarn containing
or made of spandex, to provide stretch. In some implementations,
the fabric body 110 can have 2-way stretch or 4-way stretch, which
can facilitate, e.g., thermal insulation and water management.
[0050] Referring to FIG. 5H, a fabric 120 with terry sinker loop
construction (reverse plaited knit construction) has multi-groove
fibers (or whisker fibers) used in different proportions. For
example, the multi-groove fibers (or whisker fibers) may be used at
every end, or at every second end, or at every third end, or . . .
at every X end (where "X" is any integer). Multi-groove fibers (or
whisker fibers) can also be used in different proportions (e.g. at
every X end) of the jersey side (technical face, outer side of
terry sinker loop in single face plaited construction), or in
single jersey or double knit constructions. The fabric 120 can also
include elastomeric yarn.
[0051] Referring to FIGS. 5I and 5J, a terry sinker loop fabric 130
in single face 132 (FIG. 5I) or a terry sinker loop fabric 140 in
double face 142, 144 (FIG. 5J) can have a patterned design (e.g.,
grid, pile out, jacquard, etc.) with multi-groove fibers (or
whisker fibers) incorporated therein. For example, referring to
FIG. 5I, the raised surface 132 can include plaited terry sinker
loop pile and can be on the technical back of the fabric 130. The
raised surface 132 is patterned to enhance wearer comfort with the
raised loops or pile forming discrete pillars 134 separated by
channels, e.g., intersecting channels 136, formed by region of
relatively low pile or no pile. During wearer activity, the
intersected channels 136 allow air to flow between the wearer's
skin and the fabric 130 to facilitate evaporation of the sweat from
the wearer's skin. In contrast, during wearer inactivity, the
intersecting channels 136 entrap the air between the wearer's skin
and the fabric to provide enhanced thermal insulation. The pillars
134 and the channels 136 can be arranged in any desired pattern or
at random. The pillars 134 can have any desired cross-sectional
sizes and/or shapes, e.g., such as square, circular, triangular, or
others. Referring next to FIG. 5J, the fabric 140 defines pockets
148 formed in the raised surface 142. The raised surface 142 can be
plaited terry sinker loop pile on the technical back of the fabric
140. The pockets 148 do not extend the entire thickness of the
fabric 140 and are formed by regions of relatively low pile or no
pile. Similar to the intersecting channels 136 of FIG. 5I, the
pockets 148 can entrap air during wearer inactivity, to provide
enhanced thermal insulation. The pockets 148 can be arranged in any
pattern or at randomly upon the raised surface 142, and the pockets
can have any desired sizes and/or cross-sectional shapes, e.g.,
square, triangular, circular, or others.
[0052] Referring to FIG. 5K, a fabric 150 of other constructions,
e.g. woven construction, double weave construction, or warp knit
construction, can have multi-groove fibers (or whisker fibers)
incorporated therein.
[0053] Referring to FIGS. 5L and 5M, a single face fabric 160 (FIG.
5L) and a plaited jersey fabric 170 (FIG. 5M) have multi-groove
fibers (or whisker fibers) incorporated on the outer surface 162,
172, respectively (away from skin when formed into a garment).
[0054] Referring to FIG. 5N, a terry sinker loop (reverse plaiting)
fabric 180, finished in double face (velour/velour) 182, 184 has
multi-groove fibers (or whisker fibers) incorporated on both
sides.
[0055] The multi-groove fibers 20, 40 can be used in one or more
raised surfaces of a fabric to provide thermal insulation,
particularly in dynamic conditions. Referring to FIGS. 6A, a
segment of a garment 200 formed of single-faced fabric has a raised
surface 204, e.g., in the form of pile and a smooth surface 208 on
a fabric body 202. The raised surface 204 contains, or is formed
of, multi-groove fibers 206, e.g., the same as or similar to the
fibers 20, 40, having relatively longer whiskers. When the fabric
is incorporated into garment 200, the raised surface 204 can be an
outer surface facing an environment or an inner surface facing
towards skin of a wearer. Under static conditions, the raised
surface 204 of a fabric 202 (FIG. 6A) of the disclosure, fainted of
multi-groove fibers 206, and the raised surface 5 of a fabric 2
(FIG. 1A), formed instead of conventional fibers, without grooves
or whiskers, both entrap similar volumes of air to provide similar
thermal insulation properties to the respective fabrics. However,
air displacement in the raised surface formed of the multi-groove
fibers is reduced as compared to a raised surface formed of
conventional fibers, e.g., because of the tortuosity effect caused
by the multi-groove fibers. In addition, under dynamic conditions,
i.e., when the fabrics 2, 202 are in motion relative to surrounding
air, e.g. caused by wind movement or by wearer motion, movement of
multi-groove fibers 206 on a raised surface 204 of fabric 202 of
the disclosure is more restricted, e.g. as compared to movement of
conventional fibers of a raised surface 5 of a conventional fabric
2, e.g. in particular, in the case of relatively longer whiskers.
Accordingly, the fabric 202 of the disclosure provides thermal
insulation, or enhanced thermal insulation, to the wearer under
both static conditions and dynamic conditions. Referring to FIG.
6B, a segment of a garment 210 formed of a double-faced fabric has
two opposite, raised surfaces 214, 218 on a fabric body 212, each
raised surface containing or formed of multi-groove fibers 218,
220, e.g., similar to or the same as fibers 20, 40. The
multi-groove fibers 218, 220 on different surfaces can be the same
or can be different, e.g., having different denier. Similar to the
surface 204 of FIG. 6A, the surfaces 214, 216 can also provide good
thermal insulation to the garment 210 under static and/or dynamic
conditions. In some implementations, fabric of this disclosure can
form an entire garment or it can form selected portions of a
garment.
[0056] In some implementations, the fabrics and garment segments
discussed above, e.g., in FIGS. 2A-2B, 5A-5N and 6A-6B,
particularly the fabric 130 of FIG. 5I and the fabric 140 of FIG.
5J, can be used as a component of a fabric laminate, with the
fabric of the disclosure on the inner side, the outer side, or on
both the inner side and the outer side of the fabric laminate. The
fabric laminate can include a breathable membrane.
[0057] Other embodiments are within the scope of the following
claims.
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