U.S. patent application number 16/600981 was filed with the patent office on 2020-02-06 for fibers, woven fabrics including the fibers, and methods of manufacturing the same.
This patent application is currently assigned to INDO COUNT INDUSTRIES LTD.. The applicant listed for this patent is INDO COUNT INDUSTRIES LTD.. Invention is credited to Mohit Kumar JAIN.
Application Number | 20200040490 16/600981 |
Document ID | / |
Family ID | 66542482 |
Filed Date | 2020-02-06 |
![](/patent/app/20200040490/US20200040490A1-20200206-D00000.png)
![](/patent/app/20200040490/US20200040490A1-20200206-D00001.png)
![](/patent/app/20200040490/US20200040490A1-20200206-D00002.png)
![](/patent/app/20200040490/US20200040490A1-20200206-D00003.png)
![](/patent/app/20200040490/US20200040490A1-20200206-D00004.png)
![](/patent/app/20200040490/US20200040490A1-20200206-D00005.png)
![](/patent/app/20200040490/US20200040490A1-20200206-D00006.png)
![](/patent/app/20200040490/US20200040490A1-20200206-D00007.png)
![](/patent/app/20200040490/US20200040490A1-20200206-D00008.png)
![](/patent/app/20200040490/US20200040490A1-20200206-D00009.png)
![](/patent/app/20200040490/US20200040490A1-20200206-D00010.png)
View All Diagrams
United States Patent
Application |
20200040490 |
Kind Code |
A1 |
JAIN; Mohit Kumar |
February 6, 2020 |
FIBERS, WOVEN FABRICS INCLUDING THE FIBERS, AND METHODS OF
MANUFACTURING THE SAME
Abstract
Fibers, yarns, woven fabric including the yarns and fibers, and
methods of manufacturing the same are disclosed. Fibers can include
base material staple fibers and dissolvable or water-soluble fibers
that are mixed together to define an ultra-homogenous yarn
comprising base material and dissolvable material, which is
provided in at least the warp direction to form a woven fabric
having a 7-end, 8-end or 10-end sateen weave. A processing step
provides for the removal of the dissolvable fibers to produce a
yarn defining a plurality of pores that are uniformly distributed
throughout the structure of the yarn. The woven fabric has a thread
count between 450-1200. The woven fabric is thermally-insulative,
breathable and moisture-wicking.
Inventors: |
JAIN; Mohit Kumar;
(Maharashtra, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
INDO COUNT INDUSTRIES LTD. |
Thane (West) |
|
IN |
|
|
Assignee: |
INDO COUNT INDUSTRIES LTD.
Thane (West)
IN
|
Family ID: |
66542482 |
Appl. No.: |
16/600981 |
Filed: |
October 14, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
16346279 |
|
|
|
|
PCT/IN2019/050307 |
Apr 15, 2019 |
|
|
|
16600981 |
|
|
|
|
62678148 |
May 30, 2018 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D03D 13/00 20130101;
D01D 5/11 20130101; D10B 2401/02 20130101; D10B 2401/04 20130101;
D03D 1/0017 20130101; D10B 2503/06 20130101; D02G 3/406
20130101 |
International
Class: |
D03D 13/00 20060101
D03D013/00; D03D 1/00 20060101 D03D001/00; D01D 5/11 20060101
D01D005/11 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 16, 2018 |
IN |
201821014465 |
Claims
1. A process for making a breathable, moisture-wicking and
thermal-insulating fabric, comprising: mixing cleaned cotton
slivers comprising cleaned cotton fibers with cleaned water-soluble
slivers comprising cleaned water-soluble fibers at a blow-room
stage to produce one or more homogenously-blended slivers; drawing
the homogenously-blended slivers on a draw frame to produce a
twice-mixed ultra-homogenous sliver; spinning the twice-mixed
ultra-homogenous sliver using low twist multipliers which produces
a twice-mixed ultra-homogenous yarn with a bulkier surface; using
the twice-mixed ultra-homogenous yarn in preparatory to make beam;
and weaving the twice-mixed ultra-homogenous yarn into a greige
fabric for better thermal comfort, the greige fabric comprising a
7-end, 8-end or 10-end sateen weave.
2. The process of claim 1, further comprising dissolving the
water-soluble fiber to form a plurality of micro passageways in the
yarn of the greige fabric, the plurality of micro passageways
extending from a plurality of locations at an outer surface of the
twice-mixed ultra-homogenous yarn to a central core portion
thereof.
3. The process of claim 1, wherein the fabric has a thread count
from about 450 thread count to about 1200 thread count.
4. The process of claim 1, wherein the step of weaving the
twice-mixed ultra-homogenous yarn includes orienting the
twice-mixed ultra-homogenous yarn in the warp direction of the
fabric.
5. The process of claim 4, wherein the step of weaving the
twice-mixed ultra-homogenous yarn further includes orienting more
of the twice-mixed ultra-homogenous yarn in the weft direction of
the fabric to produce maximum thermal comfort.
6. The process of claim 2, further comprising crosslinking to fix
up the micro passageways produced from the dissolved water-soluble
fibers, wherein the crosslinking provides durability to the micro
passageways such that they maintain their shape and resist
shrinking throughout the lifetime of the fabric.
7. The process of claim 1, wherein the water-soluble fiber is a
fine PVA fiber, about 0.9 Dn to about 1.2 Dn, with a 38 mm staple
length, which helps uniform mixing at the blow-room stage.
8. The process of claim 1, wherein the step of mixing with
water-soluble fiber includes mixing a PVA fiber in an amount of
about 10% to about 25% by weight in the yarn.
9. The process of claim 1, wherein the step of spinning includes
spinning the cotton fiber with water-soluble fiber using an S or Z
twist only.
10. The process of claim 1, wherein the step of spinning includes
spinning the twice-mixed ultra-homogenous sliver using a low twist
multiplier of about 3.2 to about 4.0 depending upon yarn count.
11. The process of claim 1, wherein the woven fabric is thermally
insulative, breathable and moisture-wicking.
12. The process of claim 1, wherein the woven fabric comprises a
warp float size of at least 1 millimeter.
13. The process of claim 1, wherein the woven fabric comprises a
warp float size of 2 millimeters or less.
14. A thermally-insulating and moisture-wicking woven,
high-thread-count fabric having superior breathability and
performance, the woven fabric comprising at least one specialized
yarn, the specialized yarn comprising a plurality of base material
fibers and a plurality of micro passageways extending from a
plurality of positions along an outer surface of the at least one
specialized yarn and to within a central core portion thereof, the
micro passageways being uniformly distributed throughout the
structure of the yarn so as to define an ultra-homogenous blend of
base material fibers and micro passageways for permitting air
ventilation and the absorption of heat and moisture from a user
covering at least a portion thereof with the woven fabric, wherein
the woven fabric comprises a thread count of between 450-1200.
15. The woven fabric of claim 14, wherein the woven fabric
comprises a 7-end, 8-end or 10-end sateen weave.
16. The woven fabric of claim 15, wherein the 7-end sateen weave
can comprise move numbers of 2, 3, 4 or 5, the 8-end sateen weave
can comprise move numbers of 3 or 5, and the 10-end sateen weave
can comprise move numbers of 3 or 7.
17. The woven fabric of claim 14, wherein the at least one
specialized yarn is single ply.
18. The woven fabric of claim 14, wherein the at least one
specialized yarn is 2-ply or 3-ply.
19. The woven fabric of claim 14, wherein the at least one
specialized yarn is provided in the warp direction of the
fabric.
20. The woven fabric of claim 14, wherein the specialized yarn is
provided in the warp and weft directions of the fabric.
21. The woven fabric of claim 14, wherein the woven fabric
comprises a warp float size of between 1-2 millimeters.
22. The woven fabric of claim 14, wherein the plurality of base
material fibers can be selected from a group consisting of cotton,
silk, bamboo, sea shell, sea weed, cupro, wool, milk, modal,
acrylics, poly(trimethylene terephthalate), Lyocell, silver,
charcoal, viscose or other cellulosic fibers, a blend of cotton and
polyester, a blend of polyester and viscose, a blend of
poly(trimethylene terephthalate) and cotton, a blend of cotton and
TENCEL, a blend of Lyocell and cotton, a blend of cotton and
bamboo, a blend of cotton and sea weed, a blend of cotton and
silver, a blend of cotton and charcoal, and a blend of cotton and
modal and/or any combination thereof.
23. The woven fabric of claim 14, wherein the dissolvable fibers
comprise polyvinyl alcohol.
24. The woven fabric of claim 14, wherein the dissolvable fibers of
the specialized yarn are between about 10%-25% of the weight of the
sum of the dissolvable fibers and the base material fibers.
25. The woven fabric of claim 15, wherein the woven fabric
comprises an EPI value of between about 100-260, a PPI value of
between about 1100-940, a yarn count ranging from between about 60
s-120 s for warp and between about 60 s-160 s for weft, a warp
crimp and weft crimp value between about 1.40% to about 5.97%, and
a fabric thickness between about 0.18 millimeters to about 0.37
millimeters.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
Non-Provisional patent application Ser. No. 16/346,279 filed Apr.
30, 2019, which is a U.S. National Phase Patent Application of
PCT/IN2019/050307 filed Apr. 15, 2019, which claims priority to
U.S. Provisional Patent Application Ser. No. 62/678,148 filed May
30, 2018 and Indian Provisional Patent Application Serial No.
201821014465 filed Apr. 16, 2018, the entireties of which are
hereby incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates generally to the field of
woven fabrics and textiles, and more particularly to yarn forming
flat bedding products such as sheets that are thermally insulating,
breathable, moisture-wicking, and soft, as well as methods of
making the same.
BACKGROUND
[0003] There are many thermal-insulation bed sheets and related
flat bedding products available in the marketplace and made using
various materials and techniques. One example includes injecting a
phase-change material into viscose fibers, mixing the resulting
viscose fibers with cotton fibers, and using the resulting
specialized fibers to make fabric having better thermal insulation
properties. Another example includes making a synthetic yarn having
a hollow core structure and using this yarn to make fabric, for
instance the synthetic yarn can be polyester, nylon, or the like.
These products provide enhanced insulation properties, but they
have their drawbacks, for example, related to viscose fabric
strength and customers preferring natural/cotton fibers for
bedding.
[0004] To address this, bedding products have been developed using
yarn fibers made by mixing cotton fiber with PVA fiber (polyvinyl
alcohol) at different stages in the yarn spinning. The PVA
dissolves at (and over) 90 degrees C. thereby creating air pockets
in the spaces occupied by the dissolved PVA. These air pockets
provide for enhanced thermal-insulation properties of the fabric,
but they still have their drawbacks, for example, related to
improper PVA mixing, desizing from conventional spinning, and
fabric dimensional stability.
[0005] U.S. Published Patent Application No. 2007/0087162 to
Mandawewala discloses a PVA core yarn, for example, where the yarn
defines a single continuous free air space channel at the core of
the yarn to provide for a hollow yarn core structure (see FIGS. 1A
& 1C). Mandawewala discloses that the PVA core yarn can be
provided by either using the core-spinning machine for feeding PVA
roving in the path of cotton roving in the drafting zone of the
ring frame, or for example, that the PVA roving is introduced in
the path of cotton roving on the roving machine. In either case,
Mandawewala discloses that the PVA fibers are to be positioned in
the middle of the cotton sliver or roving such that the resulting
yarn comprises a single continuous free air space channel at the
core of the yarn. As shown in FIG. 1A, a cross section of
Mandawewala's yarn structure is shown and includes a central core
having a plurality of PVA fibers 12 and an outer ring of cotton
fibers 14 surrounding the central core. Once the PVA fibers are
dissolved, the yarn comprises an outer ring of cotton fiber 14
defining the single continuous free air space channel 12' at the
core thereof (see FIG. 1C).
[0006] And U.S. Pat. No. 10,196,763 to Debnath discloses a yarn
comprising cotton slivers and PVA slivers are blended together in a
draw frame of a cotton spinning system. As shown in FIG. 1B, a
cross section of Debnath's yarn structure 20 includes an uneven
distribution of PVA fibers 22 and cotton fibers 24 which lack both
uniformity and homogeneity. According to the disclosure of Debnath,
the resulting blended draw frame sliver is the first time the PVA
is blended with the cotton. Typically, during drafting there is
little lateral movement of fibers, and wherein little improvement
in fiber intermingling is provided during condensing the slivers
into one sliver, for example, as each sliver tends to retain its
entity. Other drawbacks of initially blending on the draw frame
include the required longer process and average quality of
blending, required additional equipment and time, the blend
variation being at least about 3% and inconsistent quality of the
blended slivers. Typically, sliver-to-sliver blending also presents
drawbacks such as being vertically porous, for example, wherein
vertical voids are formed due to blending larger fiber portions
(e.g., slivers). For example, FIG. 1D shows a side cross-sectional
view of Debnath's yarn 20, which depicts a plurality of cotton
fibers 24 non-uniformly positioned along the length of the yarn 20,
and wherein a plurality of vertical voids 22' are unevenly and
non-homogenously provided along random portions of the yarn due to
the larger PVA fiber sliver portions remaining together throughout
drawing process (e.g., and being dissolved after forming and
weaving the yarn).
[0007] Furthermore, it is commonly known that it is difficult to
attain a homogenous arrangement of fibers in the cross section by
blending the slivers on a draw frame, for example, as even multiple
draw frame passages only provide up to about 80% homogenous blend
of cotton and PVA fibers. For example, FIG. 2 shows an example
first passage of a draw frame wherein a plurality of slivers enter
the draw frame (see A) and a plurality of slivers exiting the draw
frame (see B). As shown at the entrance A, seven slivers are shown
being fed into the draw frame, for example, wherein about five of
the slivers are cotton slivers 24S and about two of the slivers are
PVA slivers 22S. And as depicted at the draw frame exit B, the
spread-apart sliver substantially lacks homogeneity, for example,
as the slivers are only capable of being vertically blended with
little to no lateral movement of the fibers of the slivers. Even
with additional draw frame passages, the resulting sliver will
still only be up to about 80% homogenous.
[0008] Moreover, due to the inconsistent quality and lack of
homogenous blend of cotton and PVA fibers provided by multiple draw
frame passages, further complications can include less effective
and productive dyeing, for example, as the dissolved PVA fibers can
cause uneven porosity in the yarn which can cause variation in dye
saturation or pickup. For example, referring back to FIG. 10, the
voids 22' yarn 20 are substantially likely to cause a large
variation in dye saturation such that multiple dyeing treatments
would be required to be effective.
[0009] As such, only providing an air space at the core of the yarn
(e.g., Mandawewala) limits the thermal properties of the yarn as
the air space is not capable of directly communicating with the
absorbable air and moisture. And by only blending cotton and PVA
together in sliver form (e.g., Debnath) substantially limits the
resulting homogeneity of the cotton and PVA, for example, capable
of only being about 80% homogenous. Furthermore, draw frame
blending is strictly sliver-to-sliver blending of larger fiber
groupings (e.g. slivers). Thus, even performing a plurality of draw
frame passages still results in larger fiber groupings of cotton
and PVA, for example, whereby the dissolving of the PVA fibers
results in the presence of a plurality of non-uniform and uneven
voids 22' along the length of the yarn 20. In some known cases, the
resulting non-uniform and uneven voids 22' can likely cause
portions of the yarn 20 to be substantially weak, thereby lessening
the strength and durability of a fabric woven by the yarn 20.
[0010] Additionally, higher thread count sheets, which are
typically about 450 thread count and above (generally termed
"luxury sheets") commonly lack attributes or characteristics such
as being thermally insulating, moisture-wicking, and breathable.
Typically, one or more of these lacking attributes or
characteristics can be found in lower thread count sheets, however,
higher thread count sheets typically have a greater number of
"threads per square inch" and undesired weave structures which in
turn prevents air from being transmitted/trapped between the
threads of the sheet (or fabric), and thus, limits the sheet from
being thermally insulating, moisture wicking and/or breathable.
[0011] Accordingly, it can be seen that needs exist for
improvements in fibers, sheets made of fibers, and methods of
making the fibers and sheets, to provide enhanced thermal
insulation properties for better sleep without the drawbacks of the
prior art. It is to the provision of solutions meeting these and
other needs that the present invention is primarily directed.
SUMMARY
[0012] The present invention relates to improved yarns,
thermal-insulating fabrics made from the yarns, flat bedding
products made from the fabric, and methods of making the yarns,
fabrics, and products. The resulting thermal-insulation flat
bedding products can include sheets, pillow cases, comforters,
blankets, duvets, and duvet covers, and even mattress covers,
mattress pads and skirts.
[0013] In example embodiments, the yarns are made of a cotton fiber
and a specialized fiber mixed together at a blow-room stage for
ultra-homogenous mixing. For example, the specialized fiber can be
a water-soluble fiber such as polyvinyl alcohol (PVA) or another
water-soluble synthetic polymer. The PVA fiber can be fine, about
0.9 Dn to about 1.2 Dn, with a 38 mm staple length, which helps
uniform mixing. Also, the PVA fiber can be present in an amount of
about 10% to about 25% by weight in the yarn.
[0014] In addition, the cotton fiber and the specialized fiber are
spun into the yarn using a relatively low twist multiplier to get
maximum thermal comfort in the flat woven fabric. For example, the
twist multiplier can be about 3.2 to about 4.0, which results in
the fabric being relatively bulkier but still relatively light in
weight, which makes for improved thermal-resistance properties.
Also, the cotton and specialized fibers can be spun using an S or Z
twist only. The mixing at the blow-room stage and the low twist
multipliers produces outer air voids and inner air voids in the
yarn.
[0015] The fabric is weaved with the yarns oriented in the warp
direction (and sometimes in the weft direction). Also, the
specialized fiber in the yarn is dissolved in a controlled way
(e.g., in water) that does not damage the cotton fiber, with the
vacated locations where the specialized fiber was dissolved from
now forming air voids (e.g., homogenous in size, shape, and
location) throughout in the yarn, which results in excellent
thermal insulation in the fabric soft handle and better
breathability of the fabric. For example, the fabric can be hot
washed (e.g., after desizing it) at about 98 degrees Celsius for
about 15 minutes on a jigger machine or other conventional dyeing
machine to provide increased contact time of the water-soluble
fiber and water. Also, the method can include crosslinking to fix
up the air pockets for the lifetime of the fabric.
[0016] The resulting woven fabric typically is a greige fabric and
can have a thread count from about 80 thread count to about 1200
thread count, a thermal resistance index of about 0.024 C.degree.
M.sup.2/W to about 0.350 C.degree. M.sup.2/W at about 23 degrees
Celsius ambient temperature, a total insulation value of about 0.12
Clo to about 0.20 Clo, and a dry heat flux of about 100 W/m.sup.2
to about 161 W/m.sup.2. The other steps of making the yarns,
fabrics, and flat bedding products can all be of a conventional
type well-known in the art.
[0017] In one aspect, the invention relates to an improved process
for making a thermal-insulating fabric including mixing cleaned
cotton slivers containing cleaned cotton fibers with cleaned
water-soluble slivers containing cleaned water-soluble fibers at a
blow-room stage to produce one or more homogenously-blended
slivers; drawing the homogenously-blended slivers on a draw frame
to produce a twice-mixed ultra-homogenous sliver; spinning the
twice-mixed ultra-homogenous sliver using low twist multipliers
which produces a twice-mixed ultra-homogenous yarn with a bulkier
surface; using the twice-mixed ultra-homogenous yarn in preparatory
to make beam; and weaving the twice-mixed ultra-homogenous yarn
into a greige fabric for better thermal comfort.
[0018] In example embodiments, the process further includes
dissolving the water-soluble fiber to form a plurality of micro
passageways in the yarn of the greige fabric, the plurality of
micro passageways extending from a plurality of locations at an
outer surface of the twice-mixed ultra-homogenous yarn to a central
core portion thereof. In example embodiments, the fabric has a
thread count from about 80 thread count to about 1000 thread count.
In example embodiments, the step of weaving the twice-mixed
ultra-homogenous yarn includes orienting the twice-mixed
ultra-homogenous yarn in the warp direction of the fabric. In
example embodiments, the step of weaving the twice-mixed
ultra-homogenous yarn further includes orienting more of the
twice-mixed ultra-homogenous yarn in the weft direction of the
fabric to produce maximum thermal comfort. In example embodiments,
the process further includes hot washing the greige fabric, after
desizing it, at about 98 degrees Celsius for about 15 minutes on a
jigger machine or other dyeing machine to provide increased contact
time of the water-soluble fiber with water. In example embodiments,
the process further includes crosslinking to fix up the micro
passageways produced from the dissolved water-soluble fibers,
wherein the crosslinking provides durability to the micro
passageways such that they maintain their shape throughout the
lifetime of the fabric. In example embodiments, the water-soluble
fiber is a fine PVA fiber, about 0.9 Dn to about 1.2 Dn, with a 38
mm staple length, which helps uniform mixing at the blow-room
stage. In example embodiments, the step of mixing with
water-soluble fiber includes mixing a PVA fiber in an amount of
about 10% to about 25% by weight in the yarn. In example
embodiments, the step of spinning includes spinning the cotton
fiber with water-soluble fiber using an S or Z twist only. In
example embodiments, the step of spinning includes spinning the
twice-mixed ultra-homogenous sliver using a low twist multiplier of
about 3.2 to about 4.0 depending upon yarn count. In some example
embodiments, the woven fabric has a thermal resistance index of
about 0.024 C.degree. M.sup.2/W to about 0.030 C.degree. M.sup.2/W
at about 23 degrees Celsius ambient temperature. In example
embodiments, the woven fabric has a total insulation value of about
0.12 Clo to about 0.20 Clo. In example embodiments, the woven
fabric has a dry heat flux of about 100 W/m.sup.2 to about 140
W/m.sup.2.
[0019] In another aspect, the present invention relates to a method
of forming a twice-blended ultra-homogenous specialized yarn
including mixing a plurality of base material staple fibers,
cleaning the base material staple fiber, carding the base material
staple fiber and forming a cleaned base material staple sliver;
mixing a plurality of dissolvable fibers, cleaning the dissolvable
fiber, carding the dissolvable fiber and forming a cleaned
dissolvable sliver; combining the cleaned base material staple
sliver and the cleaned dissolvable sliver for mixing in a blow room
to produce a homogenous blend of base material staple fibers and
dissolvable fibers; cleaning the homogenous blend of base material
staple fibers and dissolvable fibers; carding the homogenous blend
of base material staple fibers and dissolvable fibers; forming a
homogenously-blended sliver comprising a homogenous blend of base
material staple fibers and dissolvable fibers; drawing the
homogenously-blended sliver on a draw frame; and spinning the
homogenously-blended sliver to produce the twice-blended
ultra-homogenous specialized yarn, the twice-blended
ultra-homogenous specialized yarn having an ultra-homogenous blend
of base material staple fibers and dissolvable fibers that are
evenly and uniformly distributed throughout the cross section
thereof.
[0020] In example embodiments, each of the plurality of base
material staple fibers can be selected from a group consisting of
cotton, silk, modal, acrylics, a blend of cotton and polyester, a
blend of polyester and viscose, a blend of poly(trimethylene
terephthalate) and cotton, a blend of Lyocell and cotton, a blend
of cotton and bamboo, a blend of cotton and sea weed, a blend of
cotton and silver, a blend of cotton and charcoal, and a blend of
cotton and modal or any combination thereof. In example
embodiments, the dissolvable fibers are polyvinyl alcohol. In
example embodiments, the polyvinyl alcohol fibers are between about
0.9 Dn-1.2 Dn with a staple length of about 38 mm.
[0021] In example embodiments, the method further includes
producing an ultra-homogenous blended roving on the roving machine
after drawing the homogenously-blended sliver on the draw frame. In
example embodiments, the method further includes spinning the
ultra-homogenous blended roving on a ring frame to produce the
twice-blended ultra-homogenous specialized yarn, the twice-blended
ultra-homogenous specialized yarn having an ultra-homogenous blend
of base material staple fibers and dissolvable fibers that are
evenly and uniformly distributed throughout the cross section
thereof. In example embodiments, the method further includes
weaving a fabric from the twice-blended ultra-homogenous
specialized yarn. In example embodiments, the twice-blended
ultra-homogenous specialized yarn is provided in the warp direction
of the fabric. In example embodiments, the twice-blended
ultra-homogenous specialized yarn is provided in both the warn and
weft directions of the fabric. In example embodiments, the method
further includes dissolving the dissolvable fibers of the
twice-blended ultra-homogenous specialized yarn so as to form a
plurality of pores in the twice-blended ultra-homogenous
specialized fiber, the pores being uniformly distributed throughout
the structure of the yarn so as to provide a plurality of micro
passageways extending from a plurality of positions along an outer
surface thereof and to within a central core portion of the
twice-blended ultra-homogenous specialized yarn.
[0022] In yet another aspect, the present invention relates to a
specialized yarn having an ultra-homogenous blend of base insoluble
fibers and dissolvable fibers, the dissolvable fibers being
uniformly distributed and evenly dispersed throughout the structure
of the yarn, the base insoluble fibers and dissolvable fibers being
first homogenously and intimately mixed together in a blow room and
then cleaned and carded so as to form one or more
homogenously-blended slivers having base insoluble fibers and
dissolvable fibers, and wherein the one or more
homogenously-blended slivers are mixed again on a draw frame to
produce an ultra-homogenous blended sliver.
[0023] In example embodiments, the specialized yarn further
includes producing an ultra-homogenous roving by passing the
ultra-homogenous sliver through a roving machine. In example
embodiments, the specialized yarn further includes spinning the
ultra-homogenous roving using an S or Z twist to produce the
specialized yarn. In example embodiments, the spinning includes
spinning the homogenously-blended roving on a ring frame at a low
twist multiplier. In example embodiments, the twist multiplier is
between about 3.2 to about 4.0. In example embodiments, the
specialized yarn further includes weaving a fabric having a
plurality of yarns, and wherein at least one of the yarns includes
the specialized yarn. In example embodiments, the fabric includes
at least one specialized yarn in the warp direction and at least
one specialized yarn in the weft direction.
[0024] In yet another example embodiment, the present invention
relates to a woven fabric including at least one specialized yarn,
the specialized yarn having a plurality of base material fibers and
a plurality of micro passageways extending from a plurality of
positions along an outer surface of the at least one specialized
yarn and to within a central core portion thereof, the micro
passageways being uniformly distributed throughout the structure of
the yarn so as to define an ultra-homogenous blend of base material
fibers and micro passageways for permitting the absorption of heat
and moisture from a user covering at least a portion thereof with
the woven fabric.
[0025] In example embodiments, the plurality of micro passageways
are formed by a plurality of dissolvable fibers, the base material
fibers and the dissolvable fibers being first homogenously mixed
together in a blow room to produce at least one
homogenously-blended sliver, and wherein the at least one
homogenously-blended sliver is further blended together on a draw
frame to produce a twice-mixed ultra-homogenous sliver having a
plurality of base material fibers and dissolvable fibers uniformly
distributed throughout the structure of the sliver. In example
embodiments, the twice-mixed ultra-homogenous sliver is further
passed through a roving machine to produce a twice-mixed
ultra-homogenous roving. In example embodiments, the twice-mixed
ultra-homogenous roving is spun on a spinning machine to produce a
twice-mixed ultra-homogenous yarn having an ultra-homogenous blend
of base material fibers and dissolvable fibers, the dissolvable
fibers being distributed ultra-homogenously throughout the base
material fibers.
[0026] In example embodiments, the twice-mixed ultra-homogenous
yarn is provided for weaving the fabric, the twice-mixed
ultra-homogenous yarn being used in the warp and/or weft
directions. In example embodiments, the fabric including the
twice-mixed ultra-homogenous yarn in the warp and/or weft
directions is processed through a hot bath at least once so as to
dissolve the dissolvable fiber to form the plurality of micro
passageways extending from a plurality of positions along an outer
surface of the at least one specialized yarn and to within a
central core portion thereof.
[0027] In example embodiments, at least one micro passageway,
extending from a plurality of positions along an outer surface of
the at least one specialized yarn and to within a central core
portion thereof, is provided about every 0.5-15 degrees around the
entire 360 degrees of the outer surface of the specialized yarn. In
example embodiments, the plurality of base material staple fibers
can be selected from a group consisting of cotton, silk, modal,
acrylics, a blend of cotton and polyester, a blend of polyester and
viscose, a blend of poly(trimethylene terephthalate) and cotton, a
blend of Lyocell and cotton, a blend of cotton and bamboo, a blend
of cotton and sea weed, a blend of cotton and silver, a blend of
cotton and charcoal, and a blend of cotton and modal or any
combination thereof. In example embodiments, the dissolvable fibers
are polyvinyl alcohol.
[0028] According to yet another aspect, the present invention
relates to a method of forming a twice-blended ultra-homogenous
specialized yarn including mixing a plurality of base material
staple fibers, cleaning the base material staple fiber, carding the
base material staple fiber and forming a cleaned base material
staple web; providing a plurality of dissolvable fibers; combining
the cleaned base material staple web and the plurality of
dissolvable fibers for mixing in a blow room to produce a
homogenous blend of base material staple fibers and dissolvable
fibers; cleaning the homogenous blend of base material staple
fibers and dissolvable fibers; carding the homogenous blend of base
material staple fibers and dissolvable fibers; forming a
homogenously-blended sliver comprising a homogenous blend of base
material staple fibers and dissolvable fibers; drawing the
homogenously-blended sliver on a draw frame to produce a
twice-blended ultra-homogenous sliver; and spinning the
twice-blended ultra-homogenous sliver to produce the twice-blended
ultra-homogenous specialized yarn, the twice-blended
ultra-homogenous specialized yarn comprising an ultra-homogenous
blend of base material staple fibers and dissolvable fibers that
are evenly and uniformly distributed throughout the cross section
thereof.
[0029] In example embodiments, the method further includes mixing
the plurality of dissolvable fibers, cleaning the dissolvable
fibers, carding the dissolvable fibers and forming a cleaned
dissolvable fiber web, and wherein the cleaned base material staple
web and the dissolvable fiber web are combined in the blow room and
intimately mixed together to produce a homogenous blend of base
material staple fibers and dissolvable fibers.
[0030] According to another aspect, the present invention relates
to a process for making a breathable, moisture-wicking and
thermal-insulating fabric including mixing cleaned cotton slivers
including cleaned cotton fibers with cleaned water-soluble slivers
including cleaned water-soluble fibers at a blow-room stage to
produce one or more homogenously-blended slivers; drawing the
homogenously-blended slivers on a draw frame to produce a
twice-mixed ultra-homogenous sliver; spinning the twice-mixed
ultra-homogenous sliver using low twist multipliers which produces
a twice-mixed ultra-homogenous yarn with a bulkier surface; using
the twice-mixed ultra-homogenous yarn in preparatory to make beam;
and weaving the twice-mixed ultra-homogenous yarn into a greige
fabric for better thermal comfort, the greige fabric including a
7-end, 8-end or 10-end sateen weave.
[0031] In example embodiments, the process further includes
dissolving the water-soluble fiber to form a plurality of micro
passageways in the yarn of the greige fabric, the plurality of
micro passageways extending from a plurality of locations at an
outer surface of the twice-mixed ultra-homogenous yarn to a central
core portion thereof. In example embodiments, the fabric has a
thread count from about 450 thread count to about 1200 thread
count. In example embodiments, the step of weaving the twice-mixed
ultra-homogenous yarn includes orienting the twice-mixed
ultra-homogenous yarn in the warp direction of the fabric.
[0032] In example embodiments, the step of weaving the twice-mixed
ultra-homogenous yarn further includes orienting more of the
twice-mixed ultra-homogenous yarn in the weft direction of the
fabric to produce maximum thermal comfort. In example embodiments,
the process further includes crosslinking to fix up the micro
passageways produced from the dissolved water-soluble fibers,
wherein the crosslinking provides durability to the micro
passageways such that they maintain their shape and resist
shrinking throughout the lifetime of the fabric. In example
embodiments, the water-soluble fiber is a fine PVA fiber, about 0.9
Dn to about 1.2 Dn, with a 38 mm staple length, which helps uniform
mixing at the blow-room stage. In example embodiments, the step of
mixing with water-soluble fiber includes mixing a PVA fiber in an
amount of about 10% to about 25% by weight in the yarn. In example
embodiments, the step of spinning includes spinning the cotton
fiber with water-soluble fiber using an S or Z twist only.
[0033] In example embodiments, the step of spinning includes
spinning the twice-mixed ultra-homogenous sliver using a low twist
multiplier of about 3.2 to about 4.0 depending upon yarn count. In
example embodiments, the woven fabric is thermally insulative,
breathable and moisture-wicking. In example embodiments, the woven
fabric includes a warp float size of at least 1 millimeter. In
example embodiments, the woven fabric includes a warp float size of
2 millimeters or less.
[0034] In yet another aspect, the present invention relates to a
thermally-insulating and moisture-wicking woven, high-thread-count
fabric having superior breathability and performance. In example
embodiments, the woven fabric includes at least one specialized
yarn, the specialized yarn including a plurality of base material
fibers and a plurality of micro passageways extending from a
plurality of positions along an outer surface of the at least one
specialized yarn and to within a central core portion thereof. In
example embodiments, the micro passageways are uniformly
distributed throughout the structure of the yarn so as to define an
ultra-homogenous blend of base material fibers and micro
passageways for permitting air ventilation and the absorption of
heat and moisture from a user covering at least a portion thereof
with the woven fabric. In example embodiments, the woven fabric
includes a thread count of between 450-1200.
[0035] In example embodiments, the woven fabric includes a 7-end,
8-end or 10-end sateen weave. In example embodiments, the 7-end
sateen weave can comprise move numbers of 2, 3, 4 or 5, the 8-end
sateen weave can comprise move numbers of 3 or 5, and the 10-end
sateen weave can comprise move numbers of 3 or 7. In example
embodiments, the at least one specialized yarn is single ply. In
example embodiments, the at least one specialized yarn is 2-ply or
3-ply. In example embodiments, the at least one specialized yarn is
provided in the warp direction of the fabric. In example
embodiments, the specialized yarn is provided in the warp and weft
directions of the fabric. In example embodiments, the woven fabric
includes a warp float size of between 1-2 millimeters.
[0036] In example embodiments, the plurality of base material
fibers can be selected from a group consisting of cotton, silk,
bamboo, sea shell, sea weed, cupro, wool, milk, modal, acrylics,
poly(trimethylene terephthalate), Lyocell, silver, charcoal,
viscose or other cellulosic fibers, a blend of cotton and
polyester, a blend of polyester and viscose, a blend of
poly(trimethylene terephthalate) and cotton, a blend of cotton and
TENCEL, a blend of Lyocell and cotton, a blend of cotton and
bamboo, a blend of cotton and sea weed, a blend of cotton and
silver, a blend of cotton and charcoal, and a blend of cotton and
modal and/or any combination thereof. In example embodiments, the
dissolvable fibers are polyvinyl alcohol. In example embodiments,
the dissolvable fibers of the specialized yarn are between about
10%-25% of the weight of the sum of the dissolvable fibers and the
base material fibers. In example embodiments, the woven fabric
includes an EPI value of between about 100-260, a PPI value of
between about 1100-940, a yarn count ranging from between about 60
s-120 s for warp and between about 60 s-160 s for weft, a warp
crimp and weft crimp value between about 1.40% to about 5.97%, and
a fabric thickness between about 0.18 millimeters to about 0.37
millimeters.
[0037] In example embodiments, the woven fabric comprises a thread
count from about 450 thread count to about 1200 thread count, a
thermal resistance index of about 0.024 C.degree. M.sup.2/W to
about 0.350 C.degree. M.sup.2/W at about 23 degrees Celsius ambient
temperature, a total insulation value of about 0.12 Clo to about
0.30 Clo, and a dry heat flux of about 100 W/m.sup.2 to about 161
W/m.sup.2.
[0038] These and other aspects, features, and advantages of the
invention will be understood with reference to the drawing figures
and detailed description herein, and will be realized by means of
the various elements and combinations particularly pointed out in
the appended claims. It is to be understood that both the foregoing
general description and the following brief description of the
drawings and detailed description of example embodiments are
explanatory of example embodiments of the invention and are not
restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1A is an end cross section view of a prior art yarn,
the yarn including a hollow central core.
[0040] FIG. 1B is an end cross section view of another prior art
yarn, the yarn including random pores passing through portions
thereof.
[0041] FIG. 1C is a side cross-sectional view of the prior art yarn
of FIG. 1A taken along line 1C-1C.
[0042] FIG. 1D is a side cross-sectional view of the prior art yarn
of FIG. 1B taken along line 1D-1D.
[0043] FIG. 2 is a plan view of a prior art drawing process for
blending slivers to produce the yarn of FIGS. 1B and 1D.
[0044] FIG. 3A is a flow diagram of a pre-spinning process for
manufacturing a specialized yarn according to an example embodiment
of the present invention.
[0045] FIG. 3B is a flow diagram of a spinning process for
manufacturing a specialized yarn according to an example embodiment
of the present invention.
[0046] FIG. 4 is a flow diagram of a pre-spinning process and an
initial portion of a spinning process for manufacturing a
specialized yarn according to another example embodiment of the
present invention.
[0047] FIG. 5 is a flow diagram of a weaving process and a
finishing process for manufacturing a specialized fabric from the
specialized yarn according to an example embodiment of the present
invention.
[0048] FIG. 6 shows an end cross section of the specialized yarn
produced from the spinning process of FIG. 4.
[0049] FIG. 7A shows the end cross section of the specialized yarn
of FIG. 6, and showing pores formed thereby after the dissolvable
or water-soluble fibers have been dissolved therefrom.
[0050] FIG. 7B shows a side cross-sectional view of the specialized
yarn of FIG. 7A taken along lines 7B-7B.
[0051] FIGS. 8A-B show a woven fabric including the specialized
yarn of FIG. 7A according to an example embodiment of the present
invention.
[0052] FIGS. 9A-B show a woven fabric including a specialized yarn
of FIG. 7A according to an example embodiment of the present
invention.
[0053] FIGS. 10A-D show a woven fabric including a specialized yarn
of FIG. 7A according to an example embodiment of the present
invention.
[0054] FIGS. 11A-B show a woven fabric including a specialized yarn
of FIG. 7A according to an example embodiment of the present
invention.
[0055] FIGS. 12A-B show a woven fabric including a specialized yarn
of FIG. 7A according to an example embodiment of the present
invention.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0056] The present invention may be understood more readily by
reference to the following detailed description of example
embodiments taken in connection with the accompanying drawing
figures, which form a part of this disclosure. It is to be
understood that this invention is not limited to the specific
devices, methods, conditions, or parameters described and/or shown
herein, and that the terminology used herein is for the purpose of
describing particular embodiments by way of example only and is not
intended to be limiting of the claimed invention. Any and all
patents and other publications identified in this specification are
incorporated by reference as though fully set forth herein.
[0057] Also, as used in the specification including the appended
claims, the singular forms "a," "an," and "the" include the plural,
and reference to a particular numerical value includes at least
that particular value, unless the context clearly dictates
otherwise. Ranges may be expressed herein as from "about" or
"approximately" one particular value and/or to "about" or
"approximately" another particular value. When such a range is
expressed, another embodiment includes from the one particular
value and/or to the other particular value. Similarly, when values
are expressed as approximations, by use of the antecedent "about,"
it will be understood that the particular value forms another
embodiment.
[0058] In example embodiments, the present invention relates to a
specialized yarn and to methods of making and using the specialized
yarn. In example embodiments, the specialized yarn is preferably
porous and provides for excellent thermal insulation properties,
and thus, provides for greater thermal insulation compared to known
yarns. In example embodiments, as will be described below, the
specialized yarn comprises an ultra-homogenous blend of insoluble
fibers (e.g., base material staple fibers) and dissolvable (or
water-soluble) fibers. According to one example embodiment, the
insoluble fiber comprises cotton and the dissolvable fibers
comprise polyvinyl alcohol (PVA). Preferably, after producing the
yarn or after the yarn is used for weaving a fabric, the
dissolvable yarns are exposed to a treatment process, for example,
such that they dissolve and disappear, thereby causing a plurality
of pores to form in the specialized yarn. Accordingly, the
specialized yarn preferably defines a plurality of insoluble yarns
(comprising pores defined by the dissolved fibers) that are
homogenously and uniformly distributed through the cross section
thereof. According to example embodiments, the plurality of pores
throughout the structure of the yarn defines a plurality of micro
passageways extending from a plurality of positions along an outer
surface of the specialized yarn and to within a central core
portion thereof. In example embodiments, one or more fabrics can be
woven from the specialized yarn. Preferably, fabric that is woven
from the specialized fabric is preferably thermally-insulating and
highly absorbent, for example, so as to provide for improved heat
and moisture absorbency properties. According to some example
embodiments, the fabric produced by at least one of the specialized
yarns comprises a thread count of between about 80-1000. According
to some example embodiments, the fabric comprises a thread count of
between 80-500. According to other example embodiments, the fabric
comprises a thread count of between 450-1000.
[0059] With reference now to the drawing figures, wherein like
reference numbers represent corresponding parts throughout the
several views, FIG. 3A shows a pre-spinning process 100 for
manufacturing a specialized yarn according to an example embodiment
of the present invention. In example embodiments, the pre-spinning
process 100 includes providing a cotton fiber 102 (e.g., base
material staple fibers) and a PVA fiber 112 for example a
water-soluble or dissolvable fiber such as polyvinyl alcohol (PVA),
raw wool and/or other dissolvable fibers as desired. In alternate
embodiments, the cotton fiber 102 can comprise various other
insoluble fibers or mixtures such as a cotton/poly blend, or other
blends including bamboo, linen, silk, wool, milk, poly
(trimethylene terephthalate), acrylics, Lyocell, sea weed, silver,
charcoal, viscose, modal, TENCEL or other cellulosic fibers, and/or
other conventional fibers. According to example embodiments, the
cotton fiber 102 is mixed at a blow-room stage 104, followed by a
cleaning stage 106 and a carding stage 108 to result in producing a
cotton sliver 110. Similarly, PVA fiber 112 is mixed at a blow-room
stage 114, followed by a cleaning stage 116 and a carding stage 118
to result in producing a PVA sliver 120.
[0060] According to example embodiments, the cotton and PVA fibers
102, 112 are typically first introduced to the pre-spinning process
100 as bales, for example, which are presented to the bale opener
and further carried to the blow-room stage 104, 114, followed by
cleaning 106, 116, carding 108, 118, to produce cotton and PVA
slivers 110, 120. According to example embodiments, a processing
line can be provided for each of the cotton and PVA materials, for
example, such that the cotton and PVA fibers are independently
processed to produce, for example, one or more cotton slivers 110
on a first processing line and one or more PVA slivers 120 on a
second processing line. For example, according to one example
embodiment, at least a first bale opener and blow room can be
provided for the pre-spinning processing of the cotton and at least
a second bale opener and blow room can be provided for the
pre-spinning processing of the PVA. In alternate example
embodiments, a single bale opener and blow room can be configured
for processing both the cotton and PVA, for example, so long as
they are processed independently to produce a clean cotton sliver
110 and a clean PVA sliver 120.
[0061] According to example embodiments, the dissolvable fibers are
between about 0.9 Dn-1.2 Dn with a staple length of about 38 mm.
According to one example embodiment, the dissolvable fibers have a
denier of between 0.9-1.2 and a staple length of 38 mm. According
to another example embodiment, the PVA fibers are between 0.5
Dn-2.5 Dn with a staple length that is equal to or more than 28 mm
and equal to or shorter than 55 mm. In other example embodiments,
the PVA fibers can preferably comprise a desired denier and
length.
[0062] As depicted in FIG. 3B, once the cotton and PVA fibers are
independently cleaned and formed into slivers, the spinning process
200 can begin. In example embodiments, the cotton sliver 110 and
the PVA sliver 120 are returned to the blow-room stage 202 to be
mixed together in desirable proportions to produce a homogenous
mixture of cotton and PVA fibers (see stage 204). Accordingly, the
independently cleaned and prepared cotton and PVA slivers 110, 120
are broken down back into cotton and PVA fibers 102, 112, however,
the broken-down cotton and PVA fibers 102, 112 have been thoroughly
cleaned, and thus any contaminants, trash, and/or other impurities
have been removed from the broken-down cotton and PVA fibers 102,
112. Accordingly, it is clean cotton fibers and clean PVA fibers
that are homogenously mixed together at the blow-room stage 202.
According to example embodiments, the mixture of the clean cotton
fibers and clean PVA fibers produced by the blow room is at least
about 97% homogenous, for example, at least about 99% homogenous
according to some example embodiments. According to one example
embodiment, the mixture is 97% homogenous. According to another
example embodiment, the mixture is 98% homogenous. According to
another example embodiment, the mixture is 99% homogenous.
[0063] Next, the homogenous mixture of cotton and PVA fibers
proceed with a cleaning stage 206 and a carding stage 208 to result
in producing a homogenously blended cotton/PVA sliver 210.
According to example embodiments, the mixture can be varied so as
to contain a desired amount of PVA fiber mixed with the cotton
fiber (as will be described below).
[0064] The spinning process 200 then includes a series of steps to
complete the making/spinning of the specialized yarn 228. For
example, the spinning process 200 can include conventional steps
using conventional equipment as are known to persons of ordinary
skill in the art. For example, the depicted spinning process 200
includes steps using equipment related to a sliver and ribbon lap
former at 214 and 216 (optionally using a unilap), combing at 218,
drawing at 220, speed frame/roving at 222, spinning at 224
(optionally ring frame with low twist multiplier (TM)), and auto
coner at 226, to produce the specialized yarn 228. The specialized
yarn 228 can then be packaged for example in a carton for
transporting to a weaving location.
[0065] According to example embodiments, during drawing at 220, two
or more homogenously blended cotton/PVA slivers 210 are drawn
together in the draw frame of a spinning system and output as a
single, ultra-homogenous cotton/PVA sliver. Thus, according to
preferred example embodiments of the present invention, the cotton
and PVA fibers are first blended together at the blow room stage
202 to produce the homogenous mixture of cotton/PVA fibers, for
example, which is carded at 208 to produce the homogenously blended
cotton/PVA sliver at 210. Then, at the drawing step 220, two or
more of the homogenously blended cotton/PVA slivers 210 are further
blended together (drawn together in draw frame) to form an
ultra-homogenous cotton/PVA sliver, for example, such that the
cotton and PVA fibers are uniformly distributed throughout the
sliver and thereby resulting in the specialized yarn 228 comprising
an ultra-homogenous and uniformly-blended structure defining cotton
and PVA fibers 102, 112.
[0066] Preferably, by both mixing/blending together at the blow
room stage 202 and then further mixing/blending at drawing stage
220, an ultra-homogenous yarn structure of uniformly distributed
cotton and PVA fibers is achievable (e.g., specialized yarn 228).
In example embodiments, by initially mixing/blending the cotton and
PVA fibers 102, 112 in the blow room stage 202, intimate mixing of
fibers 102, 112 is achievable so as to produce a 97%-99% homogenous
mixture of the cotton and PVA fibers 204. This is quite different
from the prior art yarns as shown in FIGS. 1-2, for example, where
only the core of the yarn comprises the dissolvable fibers (e.g.,
defining an air space channel at the core of the yarn--no
homogeneity) or where an uneven distribution of cotton and PVA
fibers (lacking uniformity and homogeneity--only up to 80%
homogenous) are produced by only blending at the draw frame.
[0067] According to one example embodiment, in the step for
spinning at 224, a roving formed from the roving step of 222
(comprising an ultra-homogenous mixture of cotton and PVA fibers
102, 112) is spun on a ring frame using a relatively low TM (aka
twist factor) to form the yarn. For example, the TM can be about
3.2 to about 4.0. In other embodiments, the TM is about 3.2 to
about 3.7, and in yet other embodiments the TM is about 3.2 to
about 3.3. The specific TM selected can be based on the yarn count.
This results in providing a relatively bulkier surface without
adding any extra weight to the yarn, which provides improved
thermal comfort in the resulting fabric. This is because lower
density and greater mass result in better thermal insulation
because there is a larger volume of air pockets throughout the yarn
(similarly to for example wool).
[0068] Thus, according to example embodiments of the present
invention, finer yarns of higher counts can be produced by spinning
on a ring frame at a low TM, for example, as described above. In
example embodiments, the ring frame can be configured for accepting
a homogenous sliver or roving. In some example embodiments, coarser
yarns of lower counts can be produced by spinning on an open end
spinning machine. In some example embodiments, the open end machine
is configured for accepting a homogenously blended and uniformly
distributed sliver comprising base staple fibers and dissolvable
fibers.
[0069] According to another example embodiment, the pre-spinning
process 100 and at least an initial portion of the spinning process
200 can be altered as desired. For example, FIG. 4 shows a
pre-spinning process 100' and an initial portion of a spinning
process 200'. According to example embodiments, the resulting
homogenously-blended cotton/PVA sliver 210, 210' is the same,
however, the pre-spinning and spinning processes 100', 200' are
altered with respect to the pre-spinning and spinning processes
100, 200.
[0070] Starting with the pre-spinning process 100', cotton fiber
102' is provided in bale form, which is drawn by a bale opener to
be opened and mixed at a blow-room stage 104', followed by a
cleaning stage 106' and a carding stage 108' to result in producing
a cotton web 110'. Preferably, additional equipment or processes
including conventional steps using conventional equipment as are
known to persons of ordinary skill in the art can be provided so as
to produce the cotton web 110'. According to example embodiments,
the cotton web 110' can be moved along a conveyor or other
transportation means so as to be directed to a blow room 202' for
mixing with a PVA fiber 120'.
[0071] For example, after producing the cotton web 110', the cotton
web 110' and PVA fiber 120' are homogenously mixed together in the
blow room 202' in a desired proportion (e.g., the PVA fiber not
being more than about 25% of the entire weight of the combination
of cotton fibers and PVA fibers). Thus, rather than introducing
cotton slivers 110 and PVA slivers 120 in the blow room 202 of the
spinning process 100 for mixing the same, a cotton web 110' and PVA
fibers 120' are introduced in the blow room 202' and are
homogenously mixed together. Thereafter, the spinning process 200'
is generally similar to the spinning process 200, for example,
wherein the blow room 202' produces a homogenous blend of
cotton/PVA fibers 204'. The homogenous blend of cotton/PVA fibers
204' then proceed through a cleaning stage 206', and then are
carded at carding stage 208', which produces a homogenously-blended
cotton/PVA sliver 210'. The homogenously-blended cotton/PVA sliver
210' can then be processed as similarly described above, including
processing the homogenously-blended cotton/PVA sliver 210' through
a sliver and ribbon lap former at 214 and 216 (optionally using a
unilap), combing at 218, drawing at 220, speed frame/roving at 222,
spinning at 224 (optionally ring frame with low twist multiplier
(TM)), and auto coner at 226, to produce the specialized yarn
228.
[0072] Accordingly, as depicted in FIG. 4, the cotton fiber 102' is
opened, cleaned, carded and formed into a web (e.g., cotton web
110') before being mixed together in the blow room 202' with the
PVA fiber 120'. According to one alternate example embodiment,
rather than introducing the cotton web 110' and PVA fiber 120' in
the blow room 202', the PVA fiber 120' can go through a
pre-spinning process similar to the pre-spinning process 100', for
example, wherein the PVA fiber 120' is processed through a blow
room, cleaned and carded to produce a PVA web. Accordingly, in some
example embodiments, rather than introducing the cotton web 110'
and PVA fiber 120' in the blow room 202', the cotton web 110' and a
PVA web are introduced in the blow room 202' to be homogenously
mixed together.
[0073] Accordingly, according to example embodiments of the present
invention, the base staple material and dissolvable material can be
processed in various ways so as to produce the specialized yarn
228. As described above, according to one example embodiment,
cotton and PVA fibers are opened and mixed independently from each
other to produce cotton slivers and PVA slivers, for example, which
are then returned to the blow room for mixing together in desired
proportions. According to another example embodiment, a cotton
sliver can be returned to the blow room for mixing together with
PVA fibers. According to another example embodiment, a cotton web
can be returned to the blow room for mixing with PVA fibers.
According to another example embodiment, a cotton web and a PVA web
can be returned to the blow room for mixing together in desired
proportions. Thus, according to example embodiments of the present
invention, preferably the base staple material is at least cleaned
independently before being returned to the blow room to be mixed
with the dissolvable fibers. In some examples, the base staple
material is opened, cleaned, carded and formed into a sliver. In
other examples, the base staple material is opened, cleaned and
formed into a web. The base staple material sliver or web is then
mixed together in the blow room with the raw PVA fibers, or for
example, the PVA fibers can be introduced into the blow room in the
form of a sliver or web.
[0074] FIG. 5 shows a weaving process 300 for manufacturing a
specialized fabric 420 according to an example embodiment of the
present invention. According to one example embodiment, the
specialized fabric is woven from the specialized yarn 228 that is
formed by the spinning process 200. As will be described below, the
specialized yarn 228 can be woven in the warp and/or weft
directions, and for example, can be single ply or multiple ply.
[0075] In example embodiments, the weaving process 300 can include
conventional steps using conventional equipment as are known to
persons of ordinary skill in the art. For example, the depicted
weaving process 300 includes steps using equipment related to
special yarn storage at 302, special yarn issue to weaving at 304,
setting up special yarn at 306, sizing at low temperature at 308,
and weaving at 310, to produce the unfinished raw fabric 312. The
greige fabric 312 is typically inspected for quality control
purposes.
[0076] Preferably, the step of setting up special yarn at 306
includes setting up the special yarn 228 in the warp direction for
weaving at 310. Using the special yarn 228 in the warp direction
results in yarn coverage in the flat bedding product (e.g., bed
sheets) with increased surface area contact with the user, so that
when the user sleeps, more of their released body heat is trapped
in the air pockets for enhanced thermal properties. Typically, the
special warp yarns 228 are woven together with conventional yarns
(e.g., 100 percent cotton, cotton/poly blend, or other blends
including bamboo, linen, silk, wool, milk, TENCEL or other
cellulosic fibers, and/or other conventional fibers) in the weft
direction to make the fabric. To weave some fabrics, the special
yarn 228 is also used in the weft direction for weaving at 310, for
example for sateen weave fabrics for which users tend to touch the
warp surface of the fabric, including for fitted sheets and flat
sheets. According to alternate example embodiments, the
conventional yarns can be selected from a group consisting of
modal, acrylics, a blend of polyester and viscose, a blend of
poly(trimethylene terephthalate) and cotton, a blend of Lyocell and
cotton, a blend of cotton and bamboo, a blend of cotton and sea
weed, a blend of cotton and silver, a blend of cotton and charcoal,
and a blend of cotton and modal or any combination thereof.
[0077] FIG. 5 shows a finishing process 400 for the specialized
woven fabric according to an example embodiment of the present
invention. The finishing process 400 can include conventional steps
using conventional equipment as are known to persons of ordinary
skill in the art. For example, the depicted finishing process 400
includes steps using equipment related to fabric issue to
processing at 402, desizing with enzyme at 404, rotation at 406,
hot wash (to dissolve the PVA fiber 112, 120' to create the hollow
pores) at 408, bleaching at 410, dyeing at 412, finishing at
stenter at 414, sanforizing at 416, and calenering at 418, to
produce the finished fabric 420. According to some example
embodiments, an additional step can be added to the finishing
process 400, for example, such as crosslinking so that that the
plurality of pores resulting from the dissolved PVA are durable and
maintain their shape throughout the lifetime of the fabric. Thus,
according to example embodiments, the finishing process 400 can
further include the step of crosslinking the fabric, for example,
so as to set or fix up the porosity of the pores to remain therein
throughout the life of the fabric. As such, the fabric comprising
the specialized yarn is preferably configured so as to not be
affected by one or more washes or other process or actions that the
fabric may go through during its lifetime, for example, such that
the pores of the specialized yarn are prevented from shrinking over
time.
[0078] The finished fabric 420 can then be made into flat bedding
products such as sheets, pillow cases, comforters, blankets,
duvets, mattress covers and skirts, and the like. Such flat bedding
products can be made from the finished fabric 420 using
conventional steps using conventional equipment as are known to
persons of ordinary skill in the art. For example, according to
some example embodiments, one or more cutting/stitching routines
can be performed such as length cutting, length stitching, cross
cutting, cross stitching, and/or other various routines to produce
desired flat bedding products.
[0079] FIG. 6 shows a cross section of the specialized yarn 228
according to an example embodiment of the present invention. As
shown, the specialized yarn 228 preferably comprises an
ultra-homogenous blend of cotton fibers 102 and PVA fibers 112, for
example, which provides for the uniform distribution of PVA fibers
112 throughout the structure of the specialized yarn 228. According
to example embodiments, the ultra-homogenous blend is attainable by
a combination of 1) first mixing/blending the cotton and PVA fibers
at the blow-room stage 202 to produce a homogenously blended
cotton/PVA sliver 210; and 2) further mixing/blending one or more
homogenously blended cotton/PVA slivers 210 on the draw frame of
the drawing stage 220 (see FIG. 4). Furthermore, according to some
example embodiments as depicted in FIG. 3A, the cotton fibers 102
and PVA fibers 112 can be first independently mixed, cleaned and
carded to produce the clean cotton sliver 110 and clean PVA sliver
120. Thereafter, the clean cotton sliver 110 and clean PVA sliver
120 can be combined together (in desired proportions) in the
blow-room stage 202, for example, such that the clean cotton sliver
110 and clean PVA sliver 120 are broken back down into a homogenous
blend of cotton/PVA fibers 204. Furthermore, as described above,
the cleaned cotton web 110' and PVA fibers 120' can be mixed
together in the blow-room stage 202', or for example, the cleaned
cotton web 110' and a cleaned PVA web can be mixed/blended together
in the blow-room stage 202', both of which result in a homogenous
mixture or blend of cotton/PVA fibers 204, 204' for producing a
homogenous mixture/blend cotton/PVA sliver 210, 210'.
[0080] FIG. 7A shows a cross section of a processed specialized
yarn 228', for example, wherein the PVA fibers 112 have been
dissolved to define a porous yarn structure comprising a plurality
of hollow pores, channels or conduits P uniformly distributed
throughout the cotton fibers 102. In example embodiments, pores P
are provided throughout the yarn structure such that pores P are
present at an outer surface or periphery of the yarn 228' and
proximal the central core thereof, for example, so as to provide a
plurality of channels or conduits for permitting fluid
communication from an outer surface of the yarn 228' to the central
core thereof. As depicted in FIG. 7B, the yarn 228' comprises a
homogenous distribution (between 97%-99%) of cotton fibers 102 and
pores P (e.g., formed form the PVA fibers 112) provided throughout
the length of the yarn 228'. In some example embodiments, the pores
P can be configured so as to permit fluid communication from a
first outer surface of the yarn, through the central core thereof,
and to a second outer surface of the yarn, for example, wherein the
first and second outer surfaces of the yarn are generally on
opposite or at least partially different outer side surfaces of the
yarn.
[0081] According to one example embodiment, at least one micro
passageway (e.g., defined by a plurality of interconnected or
spaced-apart pores P), extending from a plurality of positions
along an outer surface of the at least one specialized yarn and to
within a central core portion thereof, is provided at least about
every 1-30 degrees around the entire 360 degrees of the outer
surface of the processed specialized yarn 228'. According to
another example embodiment, at least one micro passageway
(extending from an outer surface to the central core) is provided
every 0.5-15 degrees around the entire 360 degrees of the outer
surface of the processed specialized yarn 228' (see FIG. 7A).
[0082] FIGS. 8A-9B show woven fabrics according to example
embodiments of the present invention. According to one example
embodiments, the woven fabrics can comprise the specialized yarn
incorporated therein, for example, in only the warp direction, or
for example, in both the warp and weft direction. For example, FIG.
8A shows a woven fabric 500 defining a 3-move sateen weave
comprising a plurality of warp and weft yarns 502, 504. As
depicted, the warp yarns 502 comprise the specialized yarn 228 and
the weft yarn 504 comprises a desired yarn, for example, 100%
cotton, cotton/poly blend, and/or other yarn as desired. According
to some example embodiments, the weft yarn 504 comprises two or
more yarns, for example, as provided by multi-pick insertion. As
shown in FIG. 8B, the woven fabric 500 defines a top side 510 and a
bottom side 512. Preferably, the sateen weave structure is such
that the top side 510 of the fabric 500 comprises a plurality of
the specialized yarns 228 exposed thereon, and thus, provides for
more contract with the skin of a user, for example, when the fabric
500 is a sheet that is being used for covering (or contacting) the
user while sleeping. According to example embodiments, with the
specialized yarn 228 being exposed to the user's skin, the pores P
preferably help absorb body heat and moisture from the user.
[0083] FIG. 9A shows a woven fabric 600 defining a 3-move, 5-end
sateen weave comprising a plurality of warp and weft yarns 602,
604. As depicted, both the warp yarn 602 and the weft yarns 604
comprise the specialized yarn 228. According to some example
embodiments, the weft yarn 604 can comprise two or more yarns, for
example, as provided by multi-pick insertion. As shown in FIG. 9B,
the woven fabric 600 defines a top side 610 and a bottom side 612,
and wherein both the top and bottom sides 610, 612 comprise the
specialized yarn 228 exposed thereon. According to alternate
example embodiments, other sateen weave configurations are
possible, for example, a 2-move, 5-end sateen weave. In further
example embodiments, the specialized yarn 228 can be used for
making fabrics of other weaves or configurations as desired. For
example, according to some example embodiments, a 6-end, 7-end,
8-end or 10-end sateen weave fabric can be woven wherein at least
one of the yarns comprises the specialized yarn 228. According to
some example embodiments, the specialized yarn 228 is provided for
making a fabric comprising a 5-move, 7-end sateen weave fabric, for
example, with the thread count being between about 450-1200 (as
described below). According to some example embodiments, multi-pick
insertion can be provided in either of the warp and/or weft
directions. According to alternate example embodiments, at least
one of the specialized yarns 228 can be provided for making fabrics
comprising other weaves such as a plain weave, an oxford weave, a
basket weave or a twill weave. Optionally, other weaves can be
provided as desired.
[0084] According to the depicted example embodiments, the
specialized yarn 228 is a single ply yarn, and for example, can be
woven together with another specialized yarn 228, or for example,
can be woven with another conventional yarn comprising cotton, a
cotton/poly blend, or for example, a desired material and/or
composition. According to some example embodiments, the specialized
yarn can comprise a 2-ply yarn, or for example, a 3-ply yarn. In
such a case, preferably two or three single ply specialized yarns
can be twisted together, for example, using an S or Z twist such
that additional bulk, strength and/or absorbency can be provided in
the finished fabric. According to some example embodiments, the
warp and/or weft yarn can comprise a 2-ply or 3-ply yarn comprising
a combination of one or more specialized yarns 228 and one or more
conventional yarns. Accordingly, according to some example
embodiments, a fabric can comprise at least one of a warp or weft
yarn that is at least 2-ply or 3-ply, for example, wherein at least
one of the yarns of the 2-ply or 3-ply yarns comprises the
specialized yarn 228.
[0085] According to another example embodiment, the warp and/or
weft yarns of the fabric can comprise a 3-ply parallel specialized
yarn 228 configuration, for example, wherein three specialized
yarns 228 run parallel with respect to each other in either of the
warp and/or weft directions. According to example embodiments, by
providing three specialized yarns 228 (e.g., 3-ply parallel warp
and/or weft), a greater amount of surface area of the specialized
yarns 228 (and thus pores P) are exposed to the skin of the user,
and thus, a greater amount of heat and moisture absorbency is
attainable. On alternate example embodiments, a 4-ply, 5-ply or
6-ply parallel yarn configuration can be provided, for example, for
providing even greater heat and moisture absorbency.
[0086] Referring back to FIG. 5, additional details of example
preparatory and weaving settings to perform the weaving process 300
are included in Tables 1-3. In particular, Table 1 relates to
special yarn warping at 306, Table 2 relates to sizing at 308, and
Table 3 relates to weaving at 310. In addition, Table 4 highlights
some typical/representative machine settings in the warping at 306,
sizing at 308 and the weaving at 310 for making the unfinished
greige fabric 312 relative to for making conventional sheets.
TABLE-US-00001 TABLE 1 Example SOP followed during rewinding and
warping 1) machine properly cleaned before rewinding cones and
ensured not to mix the normal yarn fluff before starting the
rewinding process. 2) Warping machine properly cleaned at creel,
Headstock and ensured not to mix the normal yarn fluff before
starting the set. 3) Identified board fixed during the warping. 4)
Machine run at 650 RPM 5) The prepared warping beam with proper
check of beam qulity being stored with proper identification.
Machine parameter during process 1) Drum pressure 180 dan 2)
Machine speed 650 mpm
TABLE-US-00002 TABLE 2 Example SOP followed during sizing 1)
Machine properly cleaned at creel, headstock and ensured not to mix
the normal yarn fluff before starting the set. 2) Previous set
chemical being drained out and ensured the proper cleaning of
cooker, storage tank and saw box. 3) Adequate moisture (6-6.5%) in
beam managed with the synchronizing of cylinder temperature and
machine speed. 4) Managed the warp stretch between 0.6 to 0.7%
throughout the set. 5) Managed the size pick up 9-10%. 6) Managed
with 3-4 lappers in a beam by proper creel tension, saw box roll
pressure. Machine parameter during process 1) Machine speed 55 mpm
2) Creel tension 600-650N 3) Zone 4 2300-2500N 4) Zone 5 3100-3300N
5) Press roll value 2950-3100N 6) Cyl. Temp. (Zones 1 & 2)
120-125 deg. C. 7) Cyl. Temp. (Zone 3) 105-110 deg. C. 8) Squeezing
pressure @ 5 mpm 5-6 kN 9) Squeezing pressure @ 100 mpm 10-12 kN
10) Saw box temp. 88 deg. C. 11) Cooking temp. 130 deg. C. 12)
Chemical holding time 25 min. 13) RF 9% 14) Viscosity 8 sec. 15)
The sized beam being drawn with identified board and loaded on
loom.
TABLE-US-00003 TABLE 3 Example SOP followed in loom shed 1)
Properly cleaning being followed before loading the set. 2) Before
starting the production, ensure the standard setting of the loom.
3) Ensure the quality of fabric before starting the loom for bulk
production. 4) 70 meter of roll being doffed and ensured for the
quality of woven fabric. 5) The doffed roll being covered with
proper polythene to free from dust. 6) The doffed roll being
inspected at 4 point system. Machine setting during process 1) Loom
speed 505 RPM 2) Head frame height in mm 70.70.68.67.70.72 3)
Backrest position 15/3 4) Shed crossing 290 deg (angular) 5) Weft
insertion-start 80 deg (angular) 6) Weft insertion-arrival 240 deg
(angular) 7) Loom efficiency 80%
TABLE-US-00004 TABLE 4 Comparison of Sizing and Loom Settings
Present Invention Prior Art During warping, the creel tension on
yarn maintained with 3 Gms/meter as against 3 Gms/meter 5 Gms/meter
5 Gms/meter for normal yarn. During sizing, managed the warp
stretch below 0.6% as against 0.9% for normal yarn, warp stretch
below warp stretch @ for better loom performance with minimum warp
breaks. 0.6% 0.9% During weaving, loom shed setting maintained for
minimum stress on warp by 15 mm 30 mm setting the back rest height
@ 15 as against 30 for normal yarn; and Setting the shed crossing
290 deg. as against 310 deg. for normal yarn. 290 deg 310 deg
[0087] As shown in Table 4, several machine settings in the warping
at 306, sizing at 308 and the weaving at 310 for making the
unfinished greige fabric 312 are shown in comparison to the machine
settings used for making conventional sheets. In example
embodiments, at warping 306 the creel tension on the yarn is
maintained at 3 GMs/meter as compared to conventional warping at 5
Gms/meter. During sizing at 308, the warp stretch is managed below
about 0.6% for better loom performance and minimum warp breaks, for
example compared to a warp stretch of about 0.9% for conventional
sizing settings. During weaving at 310, the loom shed setting is
maintained for minimum stress on the warp yarn by setting the back
rest height to 15 mm compared to 30 mm for conventional weaving.
And the shed crossing is set to 290 degrees compared to 310 degrees
for conventional machine settings.
[0088] According to example embodiments, testing was done to
confirm the improved thermal properties of the finished fabric 420,
including the following thermal resistance test. According to one
example embodiment, a test plate is set to 35 C (roughly equivalent
to skin temperature) while the ambient conditions are set to 20 C
to 25 C (23 C according to one example embodiment) and 65% relative
humidity. Due to the temperature difference, heat leaves the plate
and travels through the test fabric 420 into the ambient air. This
heat loss causes the test plate temperature to drop whereby the
instrument supplies more power to the plate to bring the
temperature back up to and maintain it at 35 C. This power input
(in W/m.sup.2) is then used to calculate the thermal resistance.
This test is driven by the temperature differential between the
plate and ambient air. The results of the thermal resistance test
conducted on a dry hot plate are detailed in Table 5. In example
embodiments, the total thermal resistance (R.sub.ct) can be
calculated using the following formula:
R.sub.ct=(T.sub.plate-T.sub.air).times.A.sub.plate/H.sub.input. In
example embodiments, R.sub.ct is the total thermal resistance,
A.sub.plate is the area of the plate test section (mm.sup.2),
T.sub.plate is the surface temperature of the plate (.degree. C.),
T.sub.air is the ambient air temperature, and H.sub.input is the
power input (W).
TABLE-US-00005 TABLE 5 Wool Research Association Thermal Insulation
Test by Hot Plate Value Test Method: ASTM D 1518-11a (Ambient
temp-23 degree celsius) Test Result (Thermal Dry Insulation Value)
Heat Flux S. No TC Product Construction Weave Blend Shade Article
.degree. C.m.sup.2/W Clo (W/M2) 1 400 Aero-1 80 s .times. 60 s/205
.times. 66 * 3 Sateen 100% Cotton Clay Brick Fabric 0.0242 0.156
120.76 2 400 Aero-2 80 s .times. 60 s/205 .times. 66 * 3 Sateen
100% Cotton Aqua Ocean Fabric 0.0274 0.1768 116.23 3 400
Conventional 60 s .times. 80 s/185 .times. 72 * 3 Sateen 100%
Cotton Bright White Fabric 0.016 0.105 122.8 Sheet
[0089] The thermal testing was conducted based on ASTM D 1518-11A
(Standard Test Method for Thermal Resistance of Batting Systems
Using a Hot Plate) at the Wool Research Association in India. Three
specimens were used, with Specimen 1 labeled "Aero-1," Specimen 2
labeled "Aero-2," and Specimen 3 labeled "Conventional Sheet" in
Table 5. Specimens 1 and 2 were the samples of the finished fabric
420, and their test results demonstrate the improved thermal
properties of the finished fabric 420. As can be seen from Table 5,
the two tested Specimens 1 and 2 of the finished fabric 420 have a
better thermal insulation index than the tested conventional sheet
(Specimen 3). The clo value for the Specimen 1 and 2 fabric sheets
are in fact far superior to the Specimen 3 conventional sheet.
[0090] The dry heat flux, which is the heat loss to keep the human
body at 35 degrees Celsius, was calculated based on the thermal
insulation index (R.sub.ct) and clo value, with the heat loss
parameter calculated from the thermal transport measurements. The
clo value is a unit of thermal resistance that indicates the
insulating ability of the test material, with materials having
higher clo values providing more thermal insulation. Total dry heat
flux (Qdry)(W/m.sup.2), gives the measured heat loss at the thermal
hot plate from which the fabric insulation values are calculated.
The test was conducted at 23 degrees Celsius ambient temperature to
calculate total heat loss. In example embodiments, A.sub.plate is
the area of the plate test section (mm.sup.2), for example, which
is sized to be at least about 254 mm.sup.2 according to example
embodiments.
[0091] According to another example embodiment, the present
invention relates to a method of forming a twice-blended
ultra-homogenous specialized yarn. According to example
embodiments, the method comprises mixing a plurality of base
material staple fibers, cleaning the base material staple fiber,
carding the base material staple fiber and forming a cleaned base
material staple sliver; mixing a plurality of dissolvable fibers,
cleaning the dissolvable fiber, carding the dissolvable fiber and
forming a cleaned dissolvable sliver; combining the cleaned base
material staple sliver and the cleaned dissolvable sliver for
mixing in a blow room to produce a homogenous blend of base
material staple fibers and dissolvable fibers; cleaning the
homogenous blend of base material staple fibers and dissolvable
fibers; carding the homogenous blend of base material staple fibers
and dissolvable fibers; forming a homogenously-blended sliver
comprising a homogenous blend of base material staple fibers and
dissolvable fibers; drawing the homogenously-blended sliver on a
draw frame; and spinning the homogenously-blended sliver to produce
the twice-blended ultra-homogenous specialized yarn, the
twice-blended ultra-homogenous specialized yarn having an
ultra-homogenous blend of base material staple fibers and
dissolvable fibers that are evenly and uniformly distributed
throughout the cross section thereof.
[0092] According to another example embodiment, the present
invention relates to a method of forming a twice-blended
ultra-homogenous specialized yarn. The method comprises mixing a
plurality of base material staple fibers, cleaning the base
material staple fiber, carding the base material staple fiber and
forming a cleaned base material staple web; providing a plurality
of dissolvable fibers; combining the cleaned base material staple
web and the plurality of dissolvable fibers for mixing in a blow
room to produce a homogenous blend of base material staple fibers
and dissolvable fibers; cleaning the homogenous blend of base
material staple fibers and dissolvable fibers; carding the
homogenous blend of base material staple fibers and dissolvable
fibers; forming a homogenously-blended sliver comprising a
homogenous blend of base material staple fibers and dissolvable
fibers; drawing the homogenously-blended sliver on a draw frame to
produce a twice-blended ultra-homogenous sliver; and spinning the
twice-blended ultra-homogenous sliver to produce the twice-blended
ultra-homogenous specialized yarn, the twice-blended
ultra-homogenous specialized yarn comprising an ultra-homogenous
blend of base material staple fibers and dissolvable fibers that
are evenly and uniformly distributed throughout the cross section
thereof.
[0093] According to another example embodiment, the present
invention comprises woven fabrics 700, 720, 740, 760, 800, 820,
900, 920 comprising higher thread counts of between about 450 to
about 1200. In example embodiments, the higher thread count fabrics
(e.g., luxury fabrics) preferably comprise attributes or
characteristics (e.g., performance features) such as being
thermally insulating, moisture-wicking, and breathable. According
to example embodiments, the specialized yarn 228 (as described
above) is incorporated with the one or more woven fabrics as
described below so as to provide superior thermal insulation,
superior breathability, and superior moisture wicking at thread
counts of 450 to about 1200.
[0094] To achieve attributes or characteristics in the woven fabric
such as superior thermal insulation, superior breathability, and
superior moisture wicking, the structure of the woven fabric is
preferably modified so as to maximize the above-mentioned
attributes or characteristics. In example embodiments, rather than
the woven structure of the fabric being a 5-end sateen weave (as
described above), a 7-end, 8-end, or 10-end sateen weave is
preferably provided, for example, so as to utilize their unique
diagonal structures for permitting a more open and more spacious
weave structure with a greater porous surface so as to allow the
maximum amount of air to become contained therein and therebetween.
Furthermore, at least the warp yarns of the woven fabrics
preferably comprise the specialized yarn 228, for example, so that
the porosity and breathability of the resulting woven fabrics are
further improved. Preferably, the specialized yarn 228 is spun with
a low twist multiplier so that the resulting processed specialized
yarn 228' is lofty (e.g., bulky and airy) and comprises improved
ventilation and porosity.
[0095] FIG. 10A shows a woven fabric 700 defining a 5-move, 7-end
sateen weave comprising a plurality of warp and weft yarns 702,
704. According to one example embodiment, the warp yarns 702 and
the weft yarns 704 comprise the specialized yarn 228. According to
another example embodiment, at least one of the warp and/or weft
yarns 702, 704 comprise the specialized yarn 228. And according to
preferred example embodiments, at least the warp yarns 702 comprise
the specialized yarn 228. In example embodiments, the woven fabric
700 comprises a thread count of between about 450-1200, an EPI
(ends per inch) value of between about 100-260, a PPI (picks per
inch) value of between about 1100-940, and a yarn count ranging
from between about 60 s-120 s for warp and between about 60 s-160 s
for weft. According to one example embodiment, for example, for a
600 thread count woven fabric, the warp crimp is about 2.80%, the
weft crimp is about 3.84%, and the fabric thickness ranges from
between about 0.11 millimeters to about 0.35 millimeters, for
example 0.23 millimeters according to one example embodiment. In
alternate example embodiments, the woven fabric 700 defining the
5-move, 7-end sateen weave can be configured to comprise other move
numbers. For example, FIG. 10B shows a woven fabric 720 comprising
a 2-move, 7-end sateen weave comprising a plurality of warp and
weft yarns 722, 724, FIG. 10C shows a woven fabric 740 comprising a
3-move, 7-end sateen weave comprising a plurality of warp and weft
yarns 742, 744, and FIG. 10D shows a woven fabric 760 comprising a
4-move, 7-end sateen weave comprising a plurality of warp and weft
yarns 762, 764. According to example embodiments, at least one of
the warp and/or weft yarns 722, 724, 742, 744, 762, 764 comprises
the specialized yarn 228. And according to preferred example
embodiments, at least the warp yarns 722, 742, 762 comprise the
specialized yarn 228.
[0096] According to another example embodiment, the specialized
yarn 228 can be used for constructing other desired woven fabrics
such as an 8-end or 10-end sateen weave. For example, FIGS. 11A-B
show woven fabrics 800, 820 comprising an 8-end sateen weave. The
woven fabric 800 comprises a 3-move, 8-end sateen weave and the
woven fabric 820 comprises a 5-move, 8-end sateen weave. According
to preferred example embodiments, at least the warp yarns 802, 822
can comprise the specialized fiber 228. According to other example
embodiments, both the warp yarns 802, 822 and the weft yarns 804,
824 can comprise the specialized fiber 228. Optionally, at least
one of the warp yarns 802, 822 or the weft yarns 804, 824 comprises
the specialized fibers 228. And FIGS. 12A-B show woven fabrics 900,
920 comprising a 10-end sateen weave. The woven fabric 900
comprises a 3-move, 10-end sateen weave and the woven fabric 920
comprises a 7-move, 10-end sateen weave. As similarly described
above, preferably at least the warp yarns 902, 922 can comprise the
specialized fiber 228. According to other example embodiments, both
the warp yarns 902, 922 and the weft yarns 904, 924 can comprise
the specialized fiber 228. Optionally, at least one of the warp
yarns 902, 922 or the weft yarns 904, 924 comprise the specialized
fibers 228.
[0097] According to example embodiments and as described above, the
woven fabrics 700, 720, 740, 760, 800, 820, 900, 920 can comprise
one or more specialized yarns 228 in either of the warp and/or weft
directions. According to example embodiments, the specialized yarns
228 can be manufactured as described above, for example, such that
the resulting processed specialized yarn 228' comprises a
homogenous distribution (between 97%-99%) of cotton fibers 102 and
pores P (e.g., formed form the PVA fibers 112) provided throughout
the length of the yarn 228'. According to example embodiments, the
specialized yarns 228 can comprise various other mixtures beyond
cotton fibers 102 and PVA fibers 112 (e.g., dissolvable fibers),
for example, wherein the cotton fibers 102 can further comprise
various other fibers and/or mixtures such as a cotton/poly blend,
or other blends including a higher thread count luxury cotton or
cotton and TENCEL blend, bamboo, modal, sea shell, cupro, silk,
wool, milk, poly (trimethylene terephthalate), acrylics, Lyocell,
sea weed, silver, charcoal, viscose or other cellulosic fibers,
and/or other conventional fibers or blends. According to example
embodiments, the various fibers as described above preferably
provide for improved thermal insulation, higher breathability and
moisture wicking and quick drying properties.
[0098] According to example embodiments, as similarly described
above, the specialized yarn 228 is a single ply yarn, and for
example, can be woven together with another specialized yarn 228,
or for example, can be woven with another conventional yarn
comprising cotton, a cotton/poly blend, or for example, a desired
material and/or composition. According to some example embodiments,
the specialized yarn can comprise a 2-ply yarn, or for example, a
3-ply yarn. In such a case, preferably two or three single ply
specialized yarns can be twisted together, for example, using an S
or Z twist such that additional bulk, strength and/or absorbency
can be provided in the finished fabric. According to some example
embodiments, the warp and/or weft yarn can comprise a 2-ply or
3-ply yarn comprising a combination of one or more specialized
yarns 228 and one or more conventional yarns. Accordingly,
according to some example embodiments, a fabric can comprise at
least one of a warp or weft yarn that is at least 2-ply or 3-ply,
for example, wherein at least one of the yarns of the 2-ply or
3-ply yarns comprises the specialized yarn 228.
[0099] According to another example embodiment, the warp and/or
weft yarns of the fabrics can comprise a 3-ply parallel specialized
yarn 228 configuration, for example, wherein three specialized
yarns 228 run parallel with respect to each other in either of the
warp and/or weft directions. According to example embodiments, by
providing three specialized yarns 228 (e.g., 3-ply parallel warp
and/or weft), a greater amount of surface area of the specialized
yarns 228 (and thus pores P) are exposed to the skin of the user,
and thus, a greater amount of heat and moisture absorbency is
attainable. In alternate example embodiments, a 4-ply, 5-ply or
6-ply parallel yarn configuration can be provided, for example, for
providing even greater breathability, and heat and moisture
absorbency.
[0100] In example embodiments, the woven fabrics 700, 720, 740,
760, 800, 820, 900, 920 can comprise a thread count of between
about 450-1200, an EPI (ends per inch) value of between about
100-260, a PPI (picks per inch) value of between about 1100-940,
and a yarn count ranging from between about 60 s-120 s for warp and
between about 60 s-160 s for weft. The warp crimp and weft crimp
can preferably be within a range from between about 1.40% to about
5.97%, and the fabric thickness can range from between about 0.09
millimeters to about 0.45 millimeters, for example between about
0.18 millimeters to about 0.27 millimeters according to one example
embodiment. Furthermore, the warp float size for each of the woven
fabrics 700, 720, 740, 760, 800, 820, 900, 920 is preferably
between about 1 millimeter to about 2 millimeters, for example,
above 1 millimeter to about 2 millimeters according to one example
embodiment. According to another example embodiment, the warp float
size is at least about 1.01 millimeters. According to some example
embodiments, the warp float size is 2 millimeters or less.
[0101] Furthermore, in addition to the attained performance
features of the woven fabrics described herein, for example,
comprising superior thermal insulation, superior breathability, and
superior moisture wicking, the woven fabrics preferably also
comprise additional performance features such as being resistant to
shrinking and pilling. With respect to the prevention of the woven
fabric shrinking, the woven fabric is crosslinked during the
finishing process so as to set or fix up the porosity of the pores
(of the processed specialized fiber 228') to remain therein
throughout the life of the fabric. Furthermore, in addition to
fixing up the porosity of the pores of the processed specialized
fibers 228', the other fibers of the woven fabric in addition to
the weave construction (e.g., 7-end, 8-end or 10-end) is preferably
set or fixed up so as to prevent shrinking over the life of the
fabric. As such, the woven fabrics 700, 720, 740, 760, 800, 820,
900, 920 comprising the specialized yarn 228 is preferably
configured so as to not be affected by one or more washes or other
process or actions that the fabric may go through during its
lifetime, for example, such that the pores of the specialized yarn
(and the other yarns and fabric construction) are prevented from
shrinking or degrading over time. Similarly, one or more processes
provided during the finishing of the woven fabrics 700, 720, 740,
760, 800, 820, 900, 920 so as to be pill-proof or resistant to
pilling.
[0102] With reference to Table 6 below, three separate performance
tests are summarized, for example, a thermal insulation test, a
breathability test and a moisture wicking test. According to
example embodiments, fabrics according to the present invention
(see Aireolux.TM.) perform substantially better and have far
superior performance properties compared to conventional sheets
(see Sateen) undergoing the same performance tests. In example
embodiments, the fabric of the present invention was tested against
a conventional fabric of the same thread count, for example thread
count of 500, 600 and 700 according to example embodiments of the
present invention. In other example embodiments, performance tests
were performed on fabrics of higher thread counts, for example
thread counts up to about 1200. In example embodiments, the
performance tests as described herein were tested after undergoing
one wash and tumble dry. According to example embodiments, the
thermal resistance test was conducted according to ASTM D 1518-11A
(Option #2), the breathability test was conducted according to ASTM
D737, and the moisture wicking test was conducted according to
AATCC 197.
[0103] In example embodiments, the thermal resistance is expressed
in square meters Celsius per watt (C.degree. m.sup.2/W), which can
be used to determine the dry heat flux (W/m.sup.2) across a given
area in response to a steady applied temperature gradient. As
described above, the total thermal resistance (R.sub.ct) can be
calculated using the following formula:
R.sub.ct=(T.sub.plate-T.sub.air).times.A.sub.plate/H.sub.input. In
example embodiments, R.sub.ct is the total thermal resistance
(C.degree. M.sup.2/W), A.sub.plate is the area of the plate test
section (mm.sup.2), T.sub.plate is the surface temperature of the
plate (.degree. C.), T.sub.air is the ambient air temperature
(.degree. C.), and H.sub.input is the power input (W). Other values
obtained that are related to the thermal resistance include a clo
value and tog value (described in greater detail below). In example
embodiments, the breathability test (e.g., air
permeability--measured in cubic feet per minute (CFM)) is conducted
at a pressure of 125 pa and a test area of 38 cm.sup.2. In example
embodiments, the moisture absorbency test defines the distance
(measured in millimeters) that a liquid is able to be transported
along vertically aligned fabric specimens over a given time.
[0104] In example embodiments, a tog is a measure of thermal
insulance of a unit area, also known as thermal resistance. As
described above, total thermal resistance (R.sub.ct) can be
expressed as:
R.sub.ct=(T.sub.plate-T.sub.air).times.A.sub.plate/H.sub.input. In
example embodiments, 1 tog is equivalent to 0.1 R.sub.ct. And a
clo, another thermal insulation measurement, can be expressed as 1
clo=0.155 R.sub.ct or 1.55 tog.
TABLE-US-00006 TABLE 6 Performance Tests Composition Thermal
Resistance - Hot Plate (ASTM D Moisture 1518-11a Dry Breathability
Wicking Option 2) Heat Flux (ASTM D737) (AATCC 197) S. no Tech TC
Construction Pretreatment (C.degree. m{circumflex over ( )}2/W)
(W/m.sup.2) (CFM) (mm) Remarks 1 Sateen 500 80 s .times. 100 s/216
.times. 71 * 4 1 Wash 0.0333 150.91 16.80 Warp-123, Weft 120 2
Aireoflux 500 80 s .times. 100 s .times. 216 .times. 71 * 4 1 Wash
0.0427 138.70 32.25 Warp-145, Available thead Weft 132 count-450 to
1200 3 Sateen 600 80 s .times. 120 s .times. 216 .times. 76 * 5 1
Wash 0.0248 217.50 16.53 Warp-137, Weft 137 4 Aireoflux 600 80 s
.times. 120 s/216 .times. 76 * 5 1 Wash 0.3490 148.55 17.40
Warp-159, Available thead Weft 151 count-450 to 1200 5 Sateen 700
80 s .times. 120 s .times. 216 .times. 80/6 1 Wash 0.0268 222.20
4.80 Warp-116, Weft 110 6 Aireoflux 700 80 s .times. 120 s .times.
216 .times. 80/6 1 Wash 0.0266 161.00 12.10 Warp-141, Available
thead Weft 143 count-450 to 1200
[0105] According to example embodiments and for comparison
purposes, a 500, 600 and 700 thread count conventional fabric (see
samples 1, 3 and 5) were tested against a 500, 600 and 700 thread
count fabric according to an example embodiment of the present
invention (see samples 2, 4 and 6). In example embodiments, each of
the samples (1-6) were first pretreated by undergoing a single cold
wash per AATCC 135 (40.degree. C.) followed by tumble drying. Each
of the samples then underwent several tests as shown in Table
6.
[0106] Starting with the conventional samples, the conventional 500
thread count fabric (sample 1) yielded a thermal resistance value
of 0.0333 C.degree. m.sup.2/W (clo=0.215, tog=0.333), a heat flux
of 150.91 W/m.sup.2, a breathability value of 16.80 CFM, and
moisture wicking values of 123 mm in the warp direction and 120 mm
in the weft direction. The conventional 600 thread count fabric
(sample 3) yielded a thermal resistance value of 0.0248 C.degree.
m.sup.2/W (clo=0.160, tog=0.248), a heat flux of 217.50 W/m.sup.2,
a breathability value of 16.53 CFM, and moisture wicking values of
137 mm in the warp direction and 137 mm in the weft direction. The
conventional 700 thread count fabric (sample 5) yielded a thermal
resistance value of 0.0268 C.degree. m.sup.2/W (clo=0.1729,
tog=0.268), a heat flux of 222.20 W/m.sup.2, a breathability value
of 4.80 CFM, and moisture wicking values of 116 mm in the warp
direction and 110 mm in the weft direction.
[0107] The 500 thread count fabric of the present invention (sample
2) yielded a thermal resistance value of 0.0427 C.degree. m.sup.2/W
(clo=0.275, tog=0.427), a heat flux of 138.70 W/m.sup.2, a
breathability value of 32.25 CFM, and moisture wicking values of
145 mm in the warp direction and 132 mm in the weft direction. The
600 thread count fabric (sample 4) of the present invention yielded
a thermal resistance value of 0.3490 C.degree. m.sup.2/W
(clo=0.226, tog=0.349), a heat flux of 148.55 W/m.sup.2, a
breathability value of 17.40 CFM, and moisture wicking values of
159 mm in the warp direction and 151 mm in the weft direction. The
700 thread count fabric (sample 6) of the present invention yielded
a thermal resistance value of 0.0266 C.degree. m.sup.2/W
(clo=0.172, tog=0.266), a heat flux of 161.00 W/m.sup.2, a
breathability value of 12.10 CFM, and moisture wicking values of
141 mm in the warp direction and 143 mm in the weft direction.
[0108] Table 7 shown below highlights the specific performance
tests in detail and provides conclusions based on the test results.
As such, the fabric of the present invention comprises supreme
breathability, moisture absorbency and thermal insulation compared
to conventional fabrics of the same thread count. Furthermore, as
depicted in Table 8 below, the fabrics of the present invention
(samples 2, 4, 6) comprise far superior characteristics than the
conventional fabric (samples 1, 3, 5). For example, according to
example embodiments, sample 2 is superior to sample 1 in each of
the performance tests, sample 4 is superior to sample 3 in each of
the performance tests, and sample 6 is superior to sample 5 in each
of the performance tests. For example, as detailed in Table 8, the
thermal resistance (e.g., temperature regulation) of sample 2 is
about 8% better than sample 2, the thermal resistance of sample 4
is about 31% better than sample 3, and the thermal resistance of
sample 6 is about 28% better than sample 5. The breathability of
sample 2 is about 192% better than sample 1, the breathability of
sample 4 is about 105% better than sample 3, and the breathability
of sample 6 is about 252% better than sample 5. And the moisture
absorption of sample 2 is about 14% better than sample 1, the
moisture absorption of sample 4 is about 16% better than sample 3,
and the moisture absorption of sample 6 is about 25.67 better than
sample 5.
TABLE-US-00007 TABLE 7 Test Description Which is best? Standard
Conclusion from above table Sweat guarded Hot It measures the heat
transfer from a warm, dry, Higher the value, no extablished std
Thermal resistance of AireoLux is Plate constant-temperature,
horizontal flat-plate up better is the better than conventional
sheets through a layer of the test material to a cool thermal
resistance therefore AireoLux is the best atmosphere and calculates
the resistance of the performer in Luxury segment. material.
Breathability Air permeability is defined as the rate of Higher the
value, 30 AireoLux In luxury segment is the airflow passing
perpendicularly through a known better the best performer area
under a prescribed air pressure differential Breathability between
the two surfaces of a material. Moisture Wicking This test method
is used to evaluate the ability Higher the value 5 Cm @ 30 Min.
AireoLux in Luxury segment is the of vertically alligned fabric
specimens to shows better best performer transport liquid along
and/or through them capability of the fabric to wick away the
moisture & keep you cool
TABLE-US-00008 TABLE 8 Temperature Moisture Samples Regulation
Breathability Absorption 1 Sateen 500 Aireolux Aireolux Aireolux 2
Aireolux 500 8% better 192% better 14% better than Sateen than
Sateen than Sateen 3 Sateen 600 Aireolux Aireolux Aireolux 4
Aireolux 600 31% better 105% better 16% better than Sateen than
Sateen than Sateen 5 Sateen 700 Aireolux Aireolux Aireolux 6
Aireolux 700 28% better 252% better 25.67% better than Sateen than
Sateen than Sateen
[0109] Thus, according to example embodiments, example embodiments
of the present invention comprise luxury fabrics of higher thread
counts (e.g., 450-1200), which comprise unique and superior
attributes and characteristics (e.g., superior thermal insulation,
superior breathability, and superior moisture wicking) compared to
known higher thread count fabrics. Preferably, by utilizing the
unique diagonal weave structures of the 7-end, 8-end and 10-end
sateen weaves in combination with the specialized, low twist
multiplier yarns 228 and a warp float size of 1 millimeter or
greater, higher thread count fabrics, or for example, luxury
fabrics, can achieve attributes and characteristics that were
previously unattainable. According to example embodiments, the
luxury, high-thread-count fabrics as described herein are provided
for bedding, for example, for bed sheets including a fitted sheet,
a top sheet, one or more pillow cases, etc. In example embodiments,
the bed sheets preferably continuously adjust to the body
temperature of a user that is lying on or between the bed sheets,
for example, such that when the user becomes hotter or heats up
moisture is wicked away to keep the user cool. And in a similar
manner, when the user cools down, the bed sheets wick away moisture
to keep the user warm. Preferably, moisture is wicked away from the
user's skin to keep them cool and comfortable throughout their rest
or sleep. Preferably, the specialized yarn and ultra-homogenous
porosity thereof causes the sheets to be exceptionally breathable
to provide a comfortable and restful sleep or rest. Furthermore,
the bed sheets preferably comprise a soft hand and feel to deliver
a superior degree of comfort.
[0110] While the invention has been described with reference to
example embodiments, it will be understood by those skilled in the
art that a variety of modifications, additions and deletions are
within the scope of the invention, as defined by the following
claims.
* * * * *