U.S. patent application number 15/870437 was filed with the patent office on 2018-07-26 for woven brushed elastic fabric and method of making the same.
The applicant listed for this patent is SINGTEX INDUSTRIAL CO., LTD.. Invention is credited to Li-Hsun CHANG, Chih-Wei CHEN, Kuo-Chin CHEN, Chia-Cheng CHOU, Sung-Yun HUANG.
Application Number | 20180209079 15/870437 |
Document ID | / |
Family ID | 61022149 |
Filed Date | 2018-07-26 |
United States Patent
Application |
20180209079 |
Kind Code |
A1 |
CHEN; Kuo-Chin ; et
al. |
July 26, 2018 |
WOVEN BRUSHED ELASTIC FABRIC AND METHOD OF MAKING THE SAME
Abstract
A woven brushed elastic fabric includes a fabric blank and a
plurality of yarn segments. The fabric blank is formed by
interweaving a plurality of first yarns and composite yarns. Each
composite yarn is composed of a second yarn and an elastic yarn.
The second yarn is wound around the elastic yarn. The fabric blank
has a first side, and a second side opposite to the first side and
formed with a plurality of yarn loops. The yarn loops are formed by
the interweaving of the first yarns and the composite yarns in a
skip manner along a first direction or a second direction
transverse to the first direction. The yarn segments are formed on
the second side of the fabric blank by breaking at least some of
the yarn loops.
Inventors: |
CHEN; Kuo-Chin; (New Taipei
City, TW) ; HUANG; Sung-Yun; (New Taipei City,
TW) ; CHOU; Chia-Cheng; (New Taipei City, TW)
; CHEN; Chih-Wei; (New Taipei City, TW) ; CHANG;
Li-Hsun; (New Taipei City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SINGTEX INDUSTRIAL CO., LTD. |
New Taipei City |
|
TW |
|
|
Family ID: |
61022149 |
Appl. No.: |
15/870437 |
Filed: |
January 12, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D03D 27/00 20130101;
D06C 3/08 20130101; D03D 15/08 20130101; A41D 31/102 20190201; D04B
21/16 20130101; D10B 2403/0241 20130101; D03D 2700/0103 20130101;
D04B 21/18 20130101; D06M 17/10 20130101; D04B 21/202 20130101 |
International
Class: |
D04B 21/18 20060101
D04B021/18; D04B 21/20 20060101 D04B021/20; D04B 21/16 20060101
D04B021/16 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 26, 2017 |
TW |
106103175 |
Claims
1. A woven brushed elastic fabric comprising: a fabric blank formed
by interweaving a plurality of first yarns and a plurality of
composite yarns, each of said composite yarns being composed of a
second yarn and an elastic yarn said second yarn being wound around
said elastic yarn, said fabric blank having a first side, and a
second side opposite to said first side and formed with a plurality
of yarn loops, said yarn loops being formed by the interweaving of
said first yarns and said composite yarns in a skip manner along a
first direction or a second direction transverse to the first
direction; and a plurality of yarn segments formed on said second
side of said fabric blank by breaking at least some of said yarn
loops.
2. The woven brushed elastic fabric as claimed in claim 1, wherein
each of said yarn segments has a length at least 1.5 times larger
than a thickness of said fabric blank.
3. The woven brushed elastic fabric as claimed in claim 1, wherein
each of said yarn segments has a length larger than or equal to a
thickness of said fabric blank when a portion of an end of each of
said yarn segments is cut off.
4. The woven brushed elastic fabric as claimed in claim 1, wherein
each of said first and second yarns is one of a draw textured yarn
made of synthetic fiber, a high oriented yarn, a fully draw yarn
and a natural fiber.
5. The woven brushed elastic fabric as claimed in claim 1, wherein
said elastic yarn is made of polyurethane fiber.
6. The woven brushed elastic fabric as claimed in claim 1, wherein
said yarn segments are formed after carding and shearing said
broken yarn loops.
7. The woven brushed elastic fabric as claimed in claim 6, wherein
said yarn segments further undergo heat setting.
8. A method of making a woven brushed elastic fabric, comprising:
(A) preparing a fabric blank, the fabric blank being formed by
interweaving a plurality of first yarns and a plurality of
composite yarns, each of the composite yarns being composed of a
second yarn and an elastic yarn the second yarn being wound around
the elastic yarn, the fabric blank having a first side, and a
second side opposite to the first side and formed with a plurality
of yarn loops, the yarn loops being formed by the interweaving of
the first yarns and the composite yarns in a skip manner along a
first direction or a second direction transverse to the first
direction; and (B) breaking at least some of the yarn loops so that
each of the broken yarn loops is formed with two yarn segments.
9. The method as claimed in claim 8, further comprising a step (A1)
between step (A) and step (B), in which the fabric blank is heated
so as to shrink the fabric blank, to reduce the gaps among the yarn
loops and to enlarge the yarn loops.
10. The method as claimed in claim 9, further comprising a step (C)
after step (B), in which the yarn segments are carded such that
each of the yarn segments is straightened along a direction away
from the fabric blank.
11. The method as claimed in claim 10, wherein each of the yarn
segments has a length at least 1.5 times larger than a thickness of
the fabric blank.
12. The method as claimed in claim 10, further comprising a step
(D) after step (C), in which a portion of the end of each of the
yarn segments is cut off.
13. The method as claimed in claim 12, wherein, after the portion
of the end of each of the yarn segments is cut off, each of the
yarn segments has a length larger than or equal to a thickness of
the fabric blank.
14. The method as claimed in claim 12, further comprising a step
(E) after step (D), in which the yarn segments are heated so that
the yarn segments are hardened and set to shape.
15. The method as claimed in claim 8, wherein each of the first and
second yarns in step (A) is one of a draw textured yarn made of
synthetic fiber, a high oriented yarn, a fully draw yarn and a
natural fiber.
16. The method as claimed in claim 15, wherein each of the first
and second yarns is made of synthetic fiber selected from one of
polyester, polyamide, polypropylene, and polyethylene.
17. The method as claimed in claim 16, wherein the synthetic fiber
is polyester.
18. The method as claimed in claim 15, wherein each of the first
and second yarns is made of natural fiber selected from one of
cotton, linen, wool, silk, viscose, rayon, lyocell, animal fiber,
and plant fiber.
19. The method as claimed in claim 8, wherein each of the first and
second yarns in step (A) is a high oriented yarn made of polyester
fiber.
20. The method as claimed in claim 9, wherein the number of the
yarn loops in step (A1) is between 15 and 1000 per square
centimeter.
21. The method as claimed in claim 12, wherein the denier per
filament (d/f) of each of the yarn segments in step (D) is between
0.1 and 5.
22. The method as claimed in claim 8, wherein in step (B), a brush
finishing is used to break the at least some of the yarn loops so
as to form the yarn segments.
23. The method as claimed in claim 12, wherein in step (D), a
shearing machine is used to cut off the portion of the end of each
of the yarn segments.
24. The method as claimed in claim 8, wherein each of the composite
yarns is further composed of a third yarn wound around the elastic
yarn in a direction opposite to that in which the second yarn is
wound around the elastic yarn.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of Taiwanese Patent
Application No. 106103175, filed on Jan. 26, 2017.
FIELD
[0002] The disclosure relates to a fabric, more particularly to a
woven brushed elastic fabric and a method of making the same.
BACKGROUND
[0003] A common method of making a fabric includes weaving and
knitting. Fabric made from weaving has characteristics, such as
light weight, high density, abrasion resistance, waterproof and
windproof. Fabric made from knitting has characteristics, such as
elasticity, softness and breathability.
[0004] However, the clothing structure made from weaving has a high
density, is rigid and is not elastic, so that a user may feel
discomfort after using it for a long time. On the other hand, the
clothing structure made from knitting has a low density and a loose
surface, is not windproof, is not abrasion resistance, and is prone
to damage when hooked to an object.
[0005] A method of making a fabric having the advantages of the
fabrics made from the weaving and knitting methods is an issue to
be pursued by the textile industry.
SUMMARY
[0006] Therefore, an object of the present disclosure is to provide
a woven brushed elastic fabric that has the advantages of the
fabrics made from the weaving and knitting methods and a method of
making the same.
[0007] According to one aspect of this disclosure, a woven brushed
elastic fabric comprises a fabric blank and a plurality of yarn
segments. The fabric blank is formed by interweaving a plurality of
first yarns and a plurality of composite yarns. Each composite yarn
is composed of a second yarn and an elastic yarn. The second yarn
is wound around the elastic yarn. The fabric blank has a first
side, and a second side opposite to the first side and formed with
a plurality of yarn loops. The yarn loops are formed by the
interweaving of the first yarns and the composite yarns in a skip
manner along a first direction or a second direction transverse to
the first direction. The yarn segments are formed on the second
side of the fabric blank by breaking at least some of the yarn
loops.
[0008] According to another aspect of this disclosure, a method of
making a woven brushed elastic fabric comprises the steps of: (A)
preparing a fabric blank, the fabric blank being formed by
interweaving a plurality of first yarns and a plurality of
composite yarns, each of the composite yarns being composed of a
second yarn and an elastic yarn, the second yarn being wound around
the elastic yarn, the fabric blank having a first side, and a
second side opposite to the first side and formed with a plurality
of yarn loops, the yarn loops being formed by the interweaving of
the first yarns and the composite yarns in a skip manner along a
first direction or a second direction transverse to the first
direction; and (B) breaking at least some of the yarn loops so that
each of the broken yarn loops is formed with two yarn segments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other features and advantages of the disclosure will become
apparent in the following detailed description of the embodiment
with reference to the accompanying drawings, of which:
[0010] FIG. 1 is a flow diagram, illustrating the steps involved in
a method of making a woven brushed elastic fabric according to the
embodiment of the present disclosure;
[0011] FIG. 2 illustrates a composite yarn of the embodiment being
composed of an elastic yarn and a second yarn wound around the
elastic yarn;
[0012] FIG. 3 is an enlarged fragmentary schematic view of a fabric
blank of the embodiment;
[0013] FIGS. 4A to 4E are fragmentary schematic views, illustrating
the steps involved in the method of the embodiment;
[0014] FIG. 5 illustrates an alternative form of the composite yarn
of the embodiment;
[0015] FIG. 6 is a graph, illustrating a comparison of the
insulation value in Clo per g/m.sup.2 between the woven brushed
elastic fabric of this embodiment and a knitted brushed elastic
fabric at a same weight of 210 g/m.sup.2;
[0016] FIG. 7 is a graph, illustrating a comparison of the
windproof value in cfm between the woven brushed elastic fabric of
this disclosure and the knitted brushed elastic fabric at a same
weight of 210 g/m.sup.2;
[0017] FIG. 8 is a graph, illustrating a comparison of the pilling
grade between the woven brushed elastic fabric of this disclosure
and the knitted brushed elastic fabric; and
[0018] FIG. 9 is a graph, illustrating a comparison of pass rain
test (PRT) between the woven brushed elastic fabric of this
disclosure and the knitted brushed elastic fabric at a same weight
of 210 g/m.sup.2.
DETAILED DESCRIPTION
[0019] Referring to FIG. 1, a method of making a woven brushed
elastic fabric according to the embodiment of the present
disclosure is shown to comprise steps (S1) to (S6). The steps of
the embodiment will be described in detail below with reference to
FIGS. 2, 3 and 4A-4E.
[0020] In step (S1), a fabric blank 1 is made and prepared. A
plurality of first yarns 2 and a plurality of composite yarns 4 are
interwoven to form the fabric blank 1, as shown in FIG. 3. Each
composite yarn 4 is composed of an elastic yarn 42 and a second
yarn 41 wound around the elastic yarn 42, as shown in FIG. 2. The
winding of the yarns may be accomplished using an air covering or
single covering (not shown) method, so that the second yarn 41
covers the elastic yarn 42 to form the composite yarn 4 into an air
covering yarn (ACY) or single covering yarn (SCY). The fabric blank
1 has a first side 11, and a second side 12 opposite to the first
side 11 and formed with a plurality of yarn loops 5, as shown in
FIG. 4A. The yarn loops 5, as shown in FIG. 3, are formed by the
interweaving of the first yarns 2 and the composite yarns 4 in a
skip manner along a first direction (D1) or a second direction (D2)
transverse to the first direction (D1). The number of the skipped
yarns exemplified in this embodiment is two, but is not limited
thereto.
[0021] In this embodiment, each of the first and second yarns 2, 41
is a draw textured yarn made from synthetic fiber (such as
polyester, polyamide, polypropylene, polyethylene), preferably
polyester. However, it may also be a high oriented yarn, a fully
draw yarn, or a natural fiber (such as cotton, linen, wool, silk,
viscose, rayon, lyocell, animal fiber, plant fiber, etc.), and is
not limited to what is disclosed herein. The elastic yarn 42 is
made of polyurethane fiber.
[0022] In an alternative form of this embodiment, each composite
yarn 4 may further be composed of a third yarn 43 wound around the
elastic yarn 42 in a direction opposite to that in which the second
yarn 41 is wound around the elastic yarn 42, as shown in FIG. 5, so
that the second and third yarns 41, 43 cover the elastic yarn 42 to
form the composite yarn 4 into a double covering yarn (DCY).
Through the presence of the third yarn 4, the structure of the
composite yarn 4 can be strengthened.
[0023] The third yarn 4 may be made of a material similar to that
of the first and second yarns 2, 41, or a material having
functions, such as water repellent, deodorization, anti-bacterial,
fire retardant, etc.
[0024] In step (S2), the fabric blank 1 is heated so as to shrink
the fabric blank 1, to reduce the gaps among the yarn loops 5 and
to enlarge the yarn loops 5. This step can increase the density of
the yarn loops 5, and the number of the yarn loops 5 is between 15
and 1000 per square centimeter.
[0025] In step (S3), some of the yarn loops 5 are broken so that
each broken yarn loop 5 is formed with two yarn segments 51, as
shown in FIG. 4B. It should be noted herein that, although not all
of the yarn loops 5 are broken in this embodiment, in other
embodiments, all of the yarn loops 5 may be broken. However, this
will result in higher production costs. In this embodiment, a brush
finishing is used to capture and break the yarn loops 5 so that
each broken yarn loop 5 is formed with the two yarn segments 51.
This is done by feeding the fabric blank 1 to a conveyor belt of
the brushing device, and a plurality of needle bars of the brushing
device are hooked to the yarn loops 5 to break the same, so that
each broken yarn loop 5 is formed with the two yarn segments 51.
Each of the yarn segments 51 has a length (L1) at least 1.5 times
larger than a thickness (T) of the fabric blank 1.
[0026] In step (S4), the yarn segments 51 are carded using a
carding machine such that each yarn segment 51 is straightened
along a direction away from the fabric blank 1, so that the
appearance of the second side 12 of the fabric blank 1 is neat, as
shown in FIG. 4C.
[0027] In step (S5), a portion of the end of each yarn segment 51
is cut off, so that the distance of the end of each yarn segment 51
(B) from the second side 12 of the fabric blank 1 is the same, as
shown in FIG. 4D. In this step, a shearing machine (not shown) is
used to cut off the portion of the end of each yarn segment 51 so
that the length (L2) of each yarn segment 51 is larger than or
equal to the thickness (T) of the fabric blank 1 and the second
side 12 of the fabric blank 1 is smooth. The denier per filament
(d/f) of each yarn segment 51 after this step is between 0.1 and
5.
[0028] In step (S6), the yarn segments 51 are heated so that the
yarn segments 51 are hardened and set to shape, as shown in FIG.
4E. In this embodiment, the yarn segments 51 are heated at a
temperature lower than 180 degrees. The making of the woven brushed
elastic fabric of this disclosure is thus completed, and the woven
brushed elastic fabric of this disclosure has a feel similar to
that of a fleece.
[0029] The woven brushed elastic fabric of this disclosure can be
used to make clothings, such as a shirt, a blouse, pants, etc. When
a user wears the clothing made from the fabric of this disclosure,
his/her skin will contact the yarn segments 51 heated and set to
shape in step (S6), so that a space for retaining air is formed
between the user's skin and the yarn segments 51. Since air is a
poor conductor of heat, the woven brushed elastic fabric of this
disclosure can provide the function of warm-keeping. The clothing
insulation value of the woven brushed elastic fabric of this
disclosure obtained after intrinsic thermal resistance testing
(ASTMD1518-11a) is greater than 0.6 of Clo value. FIG. 6 compares
the insulation value in Clo per g/m.sup.2 between the woven brushed
elastic fabric of this disclosure and a knitted brushed elastic
fabric at a same weight of 210 g/m.sup.2. It is shown that the
woven brushed elastic fabric of this disclosure has a value of
0.00286 Clo/g/m.sup.2 which is higher than a value of 0.00095
Clo/g/m.sup.2 of the knitted brushed elastic fabric. Hence, the
woven brushed elastic fabric of this disclosure has a better
insulation in clothing than the knitted brushed elastic fabric.
[0030] The fabric blank 1 of the woven brushed elastic fabric of
this disclosure is made by weaving. Thus, the clothing made from
the woven brushed elastic fabric of this disclosure has
characteristics, such as high density, abrasion resistance,
waterproof and windproof. The windproof value is lower than 20 cfm
(cubic feet per minute) by using ASTM D737 testing method. FIG. 7
compares the windproof value in cfm between the woven brushed
elastic fabric of this disclosure and the knitted brushed elastic
fabric at the same weight of 210 g/m.sup.2. It is shown that the
woven brushed elastic fabric of this disclosure has a value of 6.43
cfm which is quite lower than a value of 100 cfm of the knitted
brushed elastic fabric. Hence, the woven brushed elastic fabric of
this disclosure has a better windproof in clothing than the knitted
brushed elastic fabric.
[0031] The woven brushed elastic fabric of this disclosure has an
abrasion resistance rating falling between grade 4 (minimum
pilling) and grade 5 (no pilling) of the classification by using
ASTM D4970 testing method. FIG. 8 compares the pilling test between
the woven brushed elastic fabric of this disclosure and the knitted
brushed elastic fabric. It is shown the woven brushed elastic
fabric of this disclosure has grade 4.5 which is better than grade
3.5 of the knitted brushed elastic fabric. Hence, the woven brushed
elastic fabric of this disclosure has a better abrasion resistance
in clothing than the knitted brushed elastic fabric.
[0032] Further, when the woven brushed elastic fabric of this
disclosure is first covered by a weighed water-absorbent paper, and
then runs the rain test for two minutes under the water pressure of
600 mm according to AATCC 35 pass rain testing (PRT) method, the
weight of the water-absorbent paper after testing is only increased
by less than one (1) gram. FIG. 9 compares the PRT test between the
woven brushed elastic fabric of this disclosure and the knitted
brushed elastic fabric at the same weight of 210 g/m.sup.2. It is
shown that the woven brushed elastic fabric of this disclosure has
a PRT value of 0.4 g which is better than a PRT value of 18 g of
the knitted brushed elastic fabric. Hence, the woven brushed
elastic fabric of this disclosure has a better rain resistance in
clothing than the knitted brushed elastic fabric.
[0033] Moreover, when a water repellent agent is used on the woven
brushed elastic fabric of this disclosure, the rating of the water
repellence (AATCC 22) before washing is five (5), while the rating
of the water repellence after washing (50 times) is four (4). It
should be noted herein that step (S2), step (S4), step (S5) and
step (S6) may be dispensed herewith. That is, the woven brushed
elastic fabric may be made by just using step (S1) and step (S3) of
this disclosure. However, the addition of step (S2), step (S4),
step (S5) and step (S6) can greatly improve the quality of the
woven brushed elastic fabric of this disclosure.
[0034] The construction of the conventional knitted brushed fabric
belongs to a plain fabric, using a yarn plats on a ground yarn in
the knitting process. During the process, ground yarn will form
long loops, and after being destroyed through the brushing finish,
loop lengths are formed. In contrast with the construction of woven
fabric in the weaving process, weft yarns interweave through the
warp yarns. Ground yarn under the weaving point must need the
shrinkage of an elastic yarn to form long loops, after which a
brushing finish should be executed.
[0035] In sum, the method of making the woven brushed elastic
fabric of this disclosure uses the fabric blank 1 which is made by
weaving and which has characteristics, such as good abrasion
resistance, windproof and waterproof. Moreover, the gaps among the
yarn segments 51 can accommodate air to provide the warm-keeping
function. Hence, the object of this disclosure can indeed be
achieved.
[0036] While the disclosure has been described in connection with
what is considered the exemplary embodiment, it is understood that
this disclosure is not limited to the disclosed embodiment but is
intended to cover various arrangements included within the spirit
and scope of the broadest interpretation so as to encompass all
such modifications and equivalent arrangements.
* * * * *