U.S. patent number RE41,574 [Application Number 12/032,321] was granted by the patent office on 2010-08-24 for velour fabric articles having flame retardance and improved dynamic insulation performance.
This patent grant is currently assigned to MMI-IPCO, LLC. Invention is credited to Edward P. Dionne, Charles Haryslak, Jane Hunter, William K. Lie, Douglas Lumb, Moshe Rock.
United States Patent |
RE41,574 |
Rock , et al. |
August 24, 2010 |
Velour fabric articles having flame retardance and improved dynamic
insulation performance
Abstract
A velour fabric article consists of a fabric body having a
technical face formed by a filament stitch yarn and a technical
back formed by a loop yarn. The filament stitch yarn includes a
heat sensitive material, e.g. a hot melt material or a heat
shrinkable material, and/or an elastomeric material, such as
spandex. The loop yarn includes flame retardant material, such as
M-Aramide fiber. The fabric body has a velour surface formed at one
or both of the technical back and the technical face. Raised fibers
of at least one of the technical face and the technical back may be
entangled, including in and/or through interstices of the fabric
body, toward the other of the technical face and the technical
back, e.g., by a hydroentanglement process applied after finishing.
The fabric body has permeability of about 90 ft.sup.3/ft.sup.2/min,
or less, under a pressure difference of 1/2 inch of water across
the fabric body.
Inventors: |
Rock; Moshe (Brookline, MA),
Dionne; Edward P. (Oxford, ME), Haryslak; Charles
(Marlborough, MA), Lie; William K. (Methuen, MA), Lumb;
Douglas (Methuen, MA), Hunter; Jane (Manassas, VA) |
Assignee: |
MMI-IPCO, LLC (Lawrence,
MA)
|
Family
ID: |
28674654 |
Appl.
No.: |
12/032,321 |
Filed: |
February 15, 2008 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
11635820 |
Dec 7, 2006 |
Re. 40314 |
|
|
|
09982720 |
Oct 18, 2001 |
|
|
|
|
09883643 |
Jun 18, 2001 |
|
|
|
|
09347825 |
Jul 2, 1999 |
|
|
|
Reissue of: |
10122024 |
Apr 12, 2002 |
06828003 |
Dec 7, 2004 |
|
|
Current U.S.
Class: |
428/97; 428/93;
428/91; 442/306; 428/920; 442/136; 428/921; 442/312; 428/95 |
Current CPC
Class: |
D04B
1/04 (20130101); A41D 31/102 (20190201); D10B
2331/021 (20130101); Y10T 428/23957 (20150401); A41D
2500/10 (20130101); D10B 2501/04 (20130101); Y10T
442/45 (20150401); Y10T 428/23979 (20150401); Y10S
428/92 (20130101); Y10S 428/921 (20130101); Y10T
442/2631 (20150401); Y10T 442/413 (20150401); A41D
31/08 (20190201); Y10T 428/23993 (20150401); D10B
2403/0111 (20130101); Y10T 428/23964 (20150401); Y10T
428/2395 (20150401); D10B 2403/0121 (20130101) |
Current International
Class: |
B32B
33/00 (20060101); D04B 1/14 (20060101); D04B
1/16 (20060101); B27N 9/00 (20060101) |
Field of
Search: |
;428/91,93,95-97,920,921
;442/136,306,308,311,312 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
0 111 409 |
|
Jun 1984 |
|
EP |
|
0111409 |
|
Jun 1984 |
|
EP |
|
0313261 |
|
Apr 1989 |
|
EP |
|
0445395 |
|
Sep 1991 |
|
EP |
|
0541206 |
|
May 1993 |
|
EP |
|
1067226 |
|
Jan 2001 |
|
EP |
|
2313486 |
|
Feb 1977 |
|
FR |
|
2 313 486 |
|
Feb 1977 |
|
FR |
|
2512081 |
|
Mar 1982 |
|
FR |
|
2 512 081 |
|
Mar 1983 |
|
FR |
|
2747133 |
|
Oct 1997 |
|
FR |
|
2 747 133 |
|
Oct 1997 |
|
FR |
|
2106153 |
|
Apr 1983 |
|
GB |
|
2 106 153 |
|
Jul 1983 |
|
GB |
|
WO 200044969 |
|
Aug 2000 |
|
WO |
|
Other References
Adanur, Sabit Ph.D., Wellington Handbook of Industrial Textiles,
Technomic Publishing Co., Inc. 1995. pp. 176-177, 597-599. cited by
examiner .
FR 2747133 A1, English Abstract Oct. 10, 1997. cited by examiner
.
European Search Report, EP 02257260, Jan. 15, 2003. cited by
examiner .
European Search Report, EP 05257418, 2 pages, dated Mar. 22, 2006.
cited by examiner .
Patent Abstracts of Japan; vol. 015, No. 173 (C-0828), May 2, 1991
& JP 03 040845 A; Feb. 1991. cited by examiner .
Patent Abstracts of Japan; vol. 1995, No. 11, Dec. 26, 1995 &
JP 07 197354 A; Aug. 1, 1995. cited by examiner .
International Search Report, EP 03 25 2366; Sep. 2003; P. Van
Gelder. cited by examiner .
Patent Abstracts of Japan; vol. 1998. No. 3, Feb. 27, 1998; JP 09
302560; Nov. 25, 1997. cited by examiner .
Canadian Journal of research; OL. 25, Sec. A; Jul., 1974; No. 4;
"The Effect of Wing on the Thermal Resistance of Clothing . . .
Various Permeabilities", P. Larose; pp. 169-190. cited by examiner
.
"Standard Test Method for Air Permeability of Textile Fabrics";
ASTM Designation: D737-96; pp. 230-234. cited by examiner.
|
Primary Examiner: Johnson; Jenna-Leigh
Attorney, Agent or Firm: Fish & Richardson P.C.
Parent Case Text
.Iadd.More than one reissue application has been filed for the
reissue of U.S. Pat. No. 6,828,003. This application is a
continuation of reissue application Ser. No. 11/635,820, filed,
Dec. 7, 2006, now U.S. Pat. No. RE 40,314, which is a broadening
reissue of U.S. Pat. No. 6,828,003, issued Dec. 7,
2004..Iaddend.
This application is a continuation-in-part of U.S. application Ser.
No. 09/982,720, filed Oct. 18, 2001, .Iadd.now abandoned
.Iaddend.which is a continuation-in-part of U.S. application Ser.
No. 09/883,643, filed Jun. 18, 2001, now abandoned, which is a
division of U.S. application Ser. No. 09/347,825, filed Jul. 2,
1999, now abandoned, the entire disclosures of all of which are
incorporated herein by reference.
Claims
What is claimed is:
.[.1. A velour fabric article comprises a fabric body having a
technical face formed by a filament stitch yarn and a technical
back formed by a loop yarn, said filament stitch yarn comprising
heat sensitive material and said loop yarn comprising flame
retardant material selected from the group consisting of: m-Aramide
fibers, m-Aramide fiber and p-Aramide fiber blends, and fibers and
fiber blends of inherent flame retardant materials, said fabric
body having a velour surface formed at one or both of said
technical back and said technical face, and said heat sensitive
material responding to application of heat during processing to
increase tortuosity with a result of said fabric body having
permeability of about 90 ft.sup.3/ft.sup.2min or less under a
pressure difference of 1/2 inch of water across the fabric
body..].
.[.2. The velour fabric article of claim 1, wherein said heat
sensitive material comprises hot melt material..].
.[.3. The velour fabric article of claim 1, wherein said heat
sensitive material comprises heat shrinkable material..].
.[.4. The velour fabric article of claim 1, wherein said heat
sensitive material is selected from the group consisting of
polypropylene, nylon, and polyester..].
.[.5. The velour fabric article of claim 1, claim 2, claim 3, or
claim 4, wherein said heat sensitive material responds to
application of dry heat..].
.[.6. The velour fabric article of claim 1, claim 2, claim 3, or
claim 4, wherein said heat sensitive material responds to
application of wet heat..].
.[.7. The velour fabric article of claim 6, wherein said heat
sensitive material responds to application of wet heat applied by
steam..].
.[.8. The velour fabric article of claim 6, wherein said heat
sensitive material responds to application of wet heat applied by
hot water..].
.[.9. The velour fabric article of claim 1, claim 2, claim 3, or
claim 4, wherein said heat sensitive material responds to
application of heat of about 212.degree. F. to about 450.degree. F.
applied for about 2 minutes to about 60 minutes..].
.[.10. The velour fabric article of claim 1, claim 2, claim 3, or
claim 4, wherein said filament stitch yarn comprises elastomeric
material..].
.[.11. The velour fabric article of claim 10, wherein said
elastomeric material comprises spandex..].
.[.12. The velour fabric article of claim 10, wherein filaments of
said heat sensitive material and filaments of said elastomeric
material are commingled together..].
.[.13. The velour fabric article of claim 10, wherein filaments o
said heat sensitive material and filaments of said elastomeric
material are plaited together..].
.[.14. The velour fabric article of claim 10, wherein raised fibers
of the velour surface of at least one of the technical face and the
technical back is entangled, including in and/or through
interstices of the fabric body toward the other of the technical
face and the technical back..].
.[.15. The velour fabric article of claim 14, wherein raised fiber
of the technical back are entangled, including in and/or through
interstices of the fabric body, toward the technical face..].
.[.16. The velour fabric article of claim 1, claim 2, claim 3, or
claim 4, wherein said filament stitch yarn is a cored yarn
comprising a core and a sheath, said sheath comprising hot melt
material..].
.[.17. The velour fabric article of claim 16, wherein said hot melt
material is selected from the group consisting of polypropylene,
polyester and polyamide..].
.[.18. The velour fabric article of claim 16, wherein said core
comprises a material selected from the group consisting of
polyester and nylon..].
.[.19. The velour fabric article of claim 1, wherein said loop yarn
splits to release multiple small diameter filaments..].
.[.20. The velour fabric article of claim 19, wherein said loop
yarn splits by application of heat to release said multiple small
diameter filaments..].
.[.21. The velour fabric article of claim 20, wherein said loop
yarn comprises an "islands-in-sea" construction..].
.[.22. The velour fabric article of claim 19, wherein said loop
yarn splits by application of a chemical treatment to release said
multiple small diameter filaments..].
.[.23. The velour fabric article of claim 19, wherein said loop
yarn splits by application of a mechanical action to release said
multiple small diameter filaments..].
.[.24. The velour fabric article of claim 1, wherein said loop yarn
is textured..].
.[.25. The velour fabric article of claim 1, wherein said stitch
yarn is textured..].
.[.26. The velour fabric article of claim 1, claim 2, claim 3, or
claim 4, wherein raised fibers of the velour surface of at least
one of the technical face and the technical back is entangled,
including in and/or through interstices of the fabric body toward
the other of the technical face and the technical back..].
.[.27. The velour fabric article of claim 26, wherein raised fiber
of the technical back are entangled, including in and/or through
interstices of the fabric body, toward the technical face..].
.[.28. The velour fabric article of claim 1, wherein said fabric
body has a velour surface region formed at said technical
back..].
.[.29. The velour fabric article of claim 1, wherein said fabric
body has a velour surface region formed at each of said technical
back and said technical face..].
.[.30. A velour fabric article comprises a fabric body having a
technical face formed by a filament stitch yarn and a technical
back formed by a loop yarn, said filament stitch yarn comprising
elastomeric material and said loop yarn comprises flame retardant
material selected from the group consisting of: m-Aramide fiber and
p-Aramide fiber blends, and fibers and fiber blends of inherent
flame retardant materials, said fabric body having a velour surface
formed at one or both of said technical back and said technical
face, and said fabric body having permeability of about 90
ft.sup.3/ft.sup.2/min or less under a pressure difference of 1/2
inch of water across the fabric body..].
.[.31. The velour fabric article of claim 30, wherein said
elastomeric material comprises spandex..].
.[.32. The velour fabric article of claim 1 or claim 30, wherein
said fabric body has permeability of about 70 ft.sup.3/ft.sup.2/min
or less..].
.[.33. The velour fabric article of claim 30, wherein raised fibers
of the velour surface of at least one of the technical face and the
technical back is entangled, including in and/or through
interstices of the fabric body toward the other of the technical
face and the technical back..].
.[.34. The velour fabric of claim 32, wherein raised fibers of the
technical back are entangled, including in and/or through
interstices of the fabric body, toward the technical face..].
.Iadd.35. A velour fabric article comprises a fabric body having a
technical face formed by a filament stitch yarn and a technical
back formed by a loop yarn, said filament stitch yarn comprising
heat sensitive material and said loop yarn comprising a spun yarn
including flame retardant material selected from the group
consisting of: m-Aramide fibers, m-Aramide fiber and p-Aramide
fiber blends, and fibers and fiber blends of inherent flame
retardant materials, said fabric body having a velour surface
formed at one or both of said technical back and said technical
face, and said heat sensitive material responding to application of
heat during processing to increase tortuosity and decrease
permeability, thereby to improve dynamic insulation performance of
the fabric article..Iaddend.
.Iadd.36. A velour fabric article comprises a fabric body having a
technical face formed by a filament stitch yarn and a technical
back formed by a loop yarn, said filament stitch yarn comprising
elastomeric material and said loop yarn comprising a spun yarn
including flame retardant material selected from the group
consisting of: m-Aramide fibers, m-Aramide fiber and p-Aramide
fiber blends, and fibers and fiber blends of inherent flame
retardant materials, said fabric body having a velour surface
formed at one or both of said technical back and said technical
face..Iaddend.
.Iadd.37. The velour fabric article of claim 35 or claim 36,
wherein the loop yarn forming the technical back comprises natural
materials..Iaddend.
.Iadd.38. The velour fabric article of claim 37, wherein the loop
yarn forming the technical back comprises synthetic
materials..Iaddend.
.Iadd.39. The velour fabric article of any one of claims 35 or
claim 36, wherein the loop yarn forming the technical back
comprises synthetic materials..Iaddend.
.Iadd.40. The velour fabric article of claim 35, wherein said heat
sensitive material responds to application of heat during
processing to increase tortuosity with a result of said fabric body
having permeability of about 90 ft.sup.3/ft.sup.2/min or less under
a pressure difference of 1/2 inch of water across the fabric
body..Iaddend.
.Iadd.41. The velour fabric article of claim 35, wherein said heat
sensitive material responds to application of heat during
processing to increase tortuosity with a result of said fabric body
having permeability of less than about 193 ft.sup.3/ft.sup.2/min
under a pressure difference of 1/2 inch of water across the fabric
body..Iaddend.
.Iadd.42. The velour fabric article of claim 35, wherein said
filament stitch yarn comprises elastomeric material..Iaddend.
.Iadd.43. The velour fabric article of claim 36 or claim 42,
wherein said elastomeric material comprises spandex..Iaddend.
.Iadd.44. The velour fabric article of claim 35 or claim 36,
wherein raised fibers of the velour surface of at least one of the
technical face and the technical back is entangled, including in
and/or through interstices of the fabric body toward the other of
the technical face and the technical back..Iaddend.
Description
This invention relates to velour fabric articles, and, more
particularly, to velour fabric articles having improved dynamic
insulation performance due to relatively greater densification and
tortuosity, and improved flame retardance.
BACKGROUND
Velour fabric articles having one or more fleece or raised surface
regions at one surface or at both surfaces, e.g., achieved by
processes of sanding, brushing and/or napping of exposed fibers,
are known to have good insulation performance under static
conditions, i.e., in calm or still air with no wind blowing through
the fabric. However, the insulating performance of these fabric
articles drops rapidly under dynamic conditions, i.e., in a
chilling wind. As a result, a consumer wearing a velour fabric
article will often find it necessary to also wear a shell, e.g., of
woven nylon or other low permeability material, when conditions are
likely to be windy.
It is also known to increase the thermal insulation performance of
velour fabric articles by incorporating a relatively coarser stitch
yarn and/or by tightening the stitch. However, these approaches
result in fabric articles with very poor stretch, increased
stiffness and increased weight.
SUMMARY
According to one aspect of the invention, a double-face velour
fabric article comprises a fabric body having a technical face
formed by a filament stitch yarn and a technical back formed by a
loop yarn, the filament stitch yarn comprising heat sensitive
material and the loop yarn comprising flame retardant material, the
fabric body having a velour surface formed at one or both of the
technical back and the technical face, and the heat sensitive
material responding to application of heat during processing to
increase tortuosity with a result of the fabric body having
permeability of about 90 ft.sup.3/ft.sup.2/min or less under a
pressure difference of 1/2 inch of water across the fabric body
(according to the testing method of ASTM Designation: D 737-96,
"Standard Test Method for Air Permeability of Textile Fabrics," the
entire disclosure of which is incorporated herein by
reference).
Preferred embodiments of this aspect of the invention may include
one or more of the following additional features. The flame
retardant material comprises m-Aramide fibers. The heat sensitive
material is preferably selected from the group consisting of
polypropylene, polyester, and polyamide. The heat sensitive
material comprises heat shrinkable material, preferably selected
from the group consisting of polypropylene, nylon, and polyester.
The heat sensitive material responds to application of dry heat
and/or to application of wet heat, e.g. steam or hot water, e.g. at
about 212.degree. F. to about 450.degree. F. applied for about 2
minutes to about 60 minutes. The filament stitch yarn comprises
elastomeric material, e.g. spandex. Filaments of the heat sensitive
material and filaments of the elastomeric material are commingled
or plaited together. The filament stitch yarn is a cored yarn
comprising a core and a sheath, the sheath comprising hot melt
material. The core material is preferably selected from the group
consisting of polyester and nylon, and the hot melt material is
preferably selected from the group consisting of polypropylene,
polyester and polyamide. The loop yarn is split, e.g. by
application of heat, e.g. the loop yarn of fine denier fibers or
filaments comprises an "islands-in-sea" construction, or by
application of a chemical, e.g. caustic soda, or by mechanical
action, e.g. napping, to release multiple small diameter filaments.
The loop yarn and/or the filament stitch yarn are textured. Raised
fibers of the velour surface, of at least one of the technical face
and the technical back, are entangled, including in and/or through
interstices of the fabric body toward the other of the technical
face and the technical back. Raised fibers of the technical back
are entangled, including in and/or through interstices of the
fabric body, toward the technical face. The fabric body has a
velour surface region formed at the technical back or the fabric
body has a velour surface region formed at each of the technical
back and the technical face.
According to another aspect of the invention, a double-face velour
fabric article comprises a fabric body having a technical face
formed by a filament stitch yarn and a technical back formed by a
filament loop yarn or spun loop yarn, the filament stitch yarn
comprising elastomeric material and the loop yarn comprising flame
retardant material, the fabric body having a velour surface formed
at one or both of the technical back and the technical face, and
the fabric body having permeability of about 90
ft.sup.3/ft.sup.2/min or less under a pressure difference of 1/2
inch of water across the fabric body.
Preferred embodiments of both of these aspects of the invention may
include one or more of the following additional features. The flame
retardant material comprises m-Aramide fibers. The elastomeric
material comprises spandex. The fabric body has permeability of
about 70 ft.sup.3/ft.sup.2/min or less. Raised fibers of the velour
surface of at least one of the technical face and the technical
back is entangled, including in and/or through interstices of the
fabric body toward the other of the technical face and the
technical back. Preferably, raised fibers of the technical back are
entangled, including in and/or through interstices of the fabric
body, toward the technical face.
According to yet another aspect of the invention, a method of
forming a velour fabric body comprises the steps of: joining a
filament or spun loop yarn and a filament stitch yarn to form a
fabric prebody, the filament stitch yarn forming a technical face
of the fabric prebody and the loop yarn forming a technical back of
the fabric prebody, the filament stitch yarn comprising heat
sensitive material and the loop yarn comprising flame retardant
material, finishing at least one of the technical face and the
technical back of the fabric prebody, thereby to form a velour
fabric body having at least one velour surface region, entangling
raised fibers of at least one of the technical face and the
technical back, including in and/or through interstices of the
fabric body, thereby to increase density and tortuosity of the
fiber body, the fabric body having permeability of about 90
ft.sup.3/ft.sup.2/min or less under a pressure difference of 1/2
inch of water across the fabric body.
Preferred embodiments of this aspect of the invention may include
one or more of the following additional features. The method
comprises the further step of entangling the raised fibers in a
process of hydroentanglement, by directing fine, high-pressure jets
upon at least one of the technical face and the technical back. The
method comprises the further step of directing fine, high-pressure
jets upon the technical back, to cause raised fibers of the velour
surface of the technical back to entangle, including in and/or
through interstices of the fabric body, toward the technical face.
The filament stitch yarn comprises heat sensitive material, and the
method comprises the further step of exposing said fabric body to
heating sufficient to cause a response by the heat sensitive
material, thereby to increase tortuosity. The method comprises the
further step of entangling the raised fibers in a process of
hydroentanglement, by directing fine, high-pressure water jets upon
at least one of the technical face and the technical back. The
method comprises the further step of directing fine, high pressure
jets (e.g., water jets or air jets) upon the technical back, to
cause raised fibers of the velour surface of the technical back to
entangle, including in and/or through interstices of the fabric
body, toward the technical face. The method comprises the step of
finishing the technical face and the technical back of the fabric
prebody, thereby to form a velour fabric body having velour regions
at opposite surfaces. The method comprises exposing the fabric body
to the heating sufficient to cause a response by the heat sensitive
material during dyeing and/or during finishing. The method
comprises exposing the fabric body to dry heat and/or to wet heat,
e.g. steam or hot water. The method comprises exposing the fabric
body to heating sufficient to cause a response by the heat
sensitive material for about 2 minutes to about 60 minutes at about
212.degree. F. to about 450.degree. F. The method comprises
exposing the fabric body to heating sufficient to cause a response
by the heat sensitive material, thereby to increase tortuosity with
a result of the fabric body having permeability of about 70
ft.sup.3/ft.sup.2/min or less. The method comprises joining a loop
yarn and a filament stitch yarn, the filament stitch yarn
comprising elastomeric material, e.g., spandex.
An objective of the invention is to provide velour fabric articles
having flame retardance and improved dynamic insulation performance
while avoiding increased weight and/or loss of stretch and/or loss
of flexibility. A further objective is to provide velour fabric
articles that may be worn in chilling, windy conditions without
markedly diminished insulation performance. Generally, tortuosity,
and therefore density, is increased by using heat-sensitive and/or
elastomeric materials in the stitch yarns and entangling the loop
yarn fibers. The improved dynamic insulation performance achieved
in conditions of relative wind speed (i.e., wind blowing and/or
movement of the wearer in relation to ambient atmosphere) enhances
flame retardance properties by allowing less air to penetrate
through the fabric construction. Thus flame retardance is enhanced,
e.g. in accordance with very stringent flame retardance
requirements of the protective cloth and military markets, e.g., as
set forth in NFPA 1975-94 (the complete disclosure of which is
incorporated herein by reference), by including fibers of inherent
flame retardant material, e.g., m-Aramide fibers (NOMEX.RTM., as
available from E. I. du Pont de Nemours and Company, of Wilmington,
Del.) in the loop yarn of fleece or raised surface regions of the
resulting velour fabric articles.
The details of one or more embodiments of the invention are set
forth in the accompanying drawings and the description below. Other
features, objects, and advantages of the invention will be apparent
from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a somewhat diagrammatic end section view of a double-face
fabric prebody, e.g., as formed in a reverse plaiting circular
knitting process.
FIG. 2 is a somewhat diagrammatic end section view of a double-face
velour fabric article of the invention formed by finishing the
double-face fabric prebody of FIG. 1; and
FIG. 3 is a somewhat diagrammatic end section view of a prior art
double-face velour fabric article that is comparable to the
double-face velour fabric article of FIG. 2.
FIG. 4 is a perspective view of a segment of a circular knitting
machine, and
FIGS. 5-11 are sequential views of a cylinder latch needle in a
reverse plaiting circular knitting process, e.g., for use in
forming the double-face fabric prebody of FIG. 1.
FIG. 12 is a somewhat diagrammatic end section view of a
double-face velour fabric article being subjected to a process of
hydroentanglement; and
FIG. 13 is a similar, somewhat diagrammatic end section view of a
resulting double-face velour fabric article of the invention,
having improved dynamic insulation performance.
FIG. 14 is a plot of curves showing the relationship between change
in effective thermal insulation and wind velocity for covers or
fabrics of different permeability (P. Larose, "The Effect of Wind
on the Thermal Resistance of Clothing with Special Reference to the
Protection Given by Coverall Fabrics of Various Permeabilities,"
Canadian Journal of Research, Vol. 25, Sec. A, No. 4, (July 1947),
pp. 169-190.).
FIGS. 15-20 are somewhat diagrammatic end section views of other
embodiments of double-face velour fabric articles of the invention
formed of filament stitch yarns and/or loop yarns including or
consisting largely of materials with characteristics selected for
improving dynamic insulation performance of the fabric article,
namely heat sensitive materials, elastic materials and/or
combinations thereof;
FIG. 21 is a somewhat diagrammatic end section view of an
alternative embodiment of a double-face velour fabric article of
the invention formed of loop yarns including, or consisting largely
of, materials with characteristics selected for improving flame
retardance; and
FIG. 22 is a somewhat diagrammatic end section view of another
alternative embodiment of a velour fabric article of the invention
having raised or fleece surface region(s) formed at a single
surface by finishing fibers of loop yarns including, or consisting
largely of, materials with characteristics selected for improving
flame retardance.
Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
Referring to FIG. 1, a double-face fabric prebody 12, e.g., for use
in forming a double-face velour fabric article 10 of the invention
(FIG. 2), is formed by joining a stitch yarn 14 and a loop yarn 16
in a standard reverse plaiting circular knitting (terry knitting)
process (see FIGS. 4-11, including a depiction of the position of
the latch needle at seven different ti e points 1-7, shown together
in FIG. 4. and individually in FIGS. 5-11), e.g., as described in
Knitting Technology, by David J. Spencer (Woodhead Publishing
Limited, 2nd edition, 1996), the entire disclosure of which is
incorporated herein by reference. In the terry knitting process,
the stitch yarn 14 forms the technical face 18 of the resulting
fabric prebody 12 and the loop yarn 16 forms the opposite technical
back 20, where it is formed into loops 22. In the fabric prebody 12
formed by reverse plaiting circular knitting, the loop yarn 16
extends outwardly to overlie and cover the stitch yarn 14 at the
technical face 18.
The loop yarn 16 forming the technical back 20 of the knit fabric
body 12 can be made of any synthetic or natural material. The cross
section and luster of the fibers or filaments may be varied, e.g.,
as dictated by requirements of the intended end use. The loop yarn
16 can be a textured or flat filament or, preferably, a yarn of
fine denier filaments or fibers (e.g., 1.5 dpf or lower), with a
textured yarn being preferred for relatively greater dynamic
insulating effect, as discussed below. The loop yarn overall denier
is typically in the range of about 70 denier to 300 denier, with a
preferred count of about 150 denier. At the preferred count, the
filament count range is from about 100 filaments to 300 filaments,
therefore providing a denier per filament (dpf) of from 1.5 to 0.5,
respectively. A relatively smaller dpf, e.g. 1 dpf, is preferred
for relatively greater dynamic insulating effect, as will be
discussed below. A preferred commercial loop yarn is a 150/132
denier textured polyester yarn of fine denier filaments or fibers
with a dpf of 1.14, e.g. as available from UNIFI, Inc., of
Greensboro, N.C.
The stitch yarn 14 forming the technical face 16 of the knit fabric
body 12 can be also made of any type of synthetic or natural
material in a textured or flat filament yarn, with a textured yarn
being preferred for relatively greater dynamic insulating effect.
The range of stitch yarn count denier is typically between about 50
denier to 150 denier. Where the loop yarn is 150/132 textured, the
preferred stitch yarn count is about 100 denier, and the filament
count ranges from about 34 filaments to 200 filaments, i.e. 100/34
to 100/200, resulting in dpf from about 3 dpf to 0.5 dpf, with
relatively finer filaments being preferred, again, for relatively
greater dynamic insulating performance. A preferred stitch yarn is
100/136 denier textured polyester with about 0.7 dpf, e.g. as
available commercially from UNIFI, Inc. Another preferred yarn is
130/408 denier textured polyester with about 0.3 dpf, e.g. as
available from Hyosung, Inc., of Seoul, Korea.
From these examples, it can be seen that, for achieving markedly
improved dynamic insulating performance, use of a textured 150/132
loop yarn and a textured 100/136 stitch yarn is preferred.
In comparison, in a prior art double-face velour fabric article
(100, FIG. 3) without the improved dynamic insulation performance
of the present invention, a typical stitch yarn 102 is 70/34 denier
filament textured polyester, with individual fiber fineness of
greater than 2.0 dpf, e.g. as available commercially from UNIFI,
Inc.
In a preferred method of the invention, the fabric prebody 12 is
formed by reverse plaiting on a fine cut circular knitting machine
(e.g., 28 cut). This is principally a terry knit construction,
where segments 22 of the loop yarn 16 cover the stitch yarn 14 o
the technical back 20 and loops 23 of the loop yarn 16 form loops
23 at the technical face 18 of the fabric prebody 12 (see FIG.
1).
The fabric prebody 12 is next subjected to finishing. During the
finishing process, the technical face and technical back surfaces
18, 20, respectively, of the fabric prebody 12, with the segments
22 of loop yarn 16 overlying the stitch yarn 14 at the technical
face surface 18 and the loops 23 formed at the technical back
surface 20, go through a finishing process such as sanding,
brushing and/or napping, to generate a velour 24, 26. The yarn
fibers are raised at both faces of the fabric prebody 12 (FIG. 1),
including the technical face 18 and the technical back 20, to form
the velour 24, 26 at each face of the fabric body 30 of the
double-face velour fabric article 10 (FIG. 2) of the invention. The
fabric prebody 12 and/or fabric body 10 may also be treated, e.g.,
chemically, to make it hydrophobic.
Referring to FIG. 12, after finishing, the fabric article 10 is
next subjected to a process of hydroentanglement, such as employed
in fabrication of spun staples yarn and in the fabrication of
non-woven fabrics. During this process, fine, high-pressure water
jets 32 (or air jets) are directed onto, e.g., the technical back
20 of the fabric article 10. In this manner, raised fibers 34 of
the velour surface of the technical back 20 are entangled,
including in and/or through interstices of the fabric body 30,
toward the technical face 18. The hydroentanglement process thus
serves to densify the velour surface, resulting in the double-face
fabric article 40 (FIG. 13), advantageously, without substantial
increase in bulk or thickness, for improved dynamic insulation,
i.e. against through-flow of air, e.g., in a chilling wind. By way
of example only, after finishing, the technical back 20 of a
double-face velour fabric article 10 may be treated by
hydroentanglement using fine, high-pressure water jets 32, e.g.,
with water applied at 100 m/sec to 350 m/sec through jets having
apertures of 0.01 mm to 1.0 mm diameter. Alternatively, raised
fibers of the technical face may be entangled in and/or through
interstices of the fabric body, toward the technical back.
Entangling raised fibers of the technical back, i.e., of the loop
yarn, including in and/or through interstices of the fabric body,
toward the technical face, results in relatively greater
densification and therefore greater tortuosity, e.g., as compared
to entanglement of raised fibers of the technical face, including
in and/or through interstices of the fabric body, toward the
technical back. Entangling from back to face, in addition to
resulting in a relatively greater increase in tortuosity, also
increases smoothness of the fabric/garment outer surface, while
entangling from face to back increases tortuosity and increases
smoothness of the fabric/garment inner surface.
Fabric performance and aesthetics of the fabric article 40 can also
be adjusted by selection of knitting gauge (e.g., in the range of
about 18 to about 36, and preferably about 28), yarn type (e.g.,
preferably textured, or flat filament), yarn denier (e.g., about 70
to about 300, and preferably about 100), fiber denier (e.g., about
0.3 to about 1.5, and preferably about 1.0), etc. Adjustment of jet
speed and/or aperture size, e.g., within the ranges mentioned
above, can further or instead be employed to adjust fabric
performance and/or aesthetics.
The fabric article 40 is thereafter heat set to stabilize the
fabric article width.
In this and other embodiments of the invention described below,
heat may be applied to the fabric body, e.g. dry heat and/or wet
heat, such as hot water or steam, e.g. during finishing or dyeing.
As mentioned elsewhere, the stitch yarn (and/or the loop yarn) may
include heat sensitive and/or elastomeric materials.
In a resulting double-face velour fabric article 10 of this
embodiment of the invention, the overall density, i.e., weight per
length, of the filament stitch yarn 14 is closely comparable to
stitch yarn 102 used in a comparable prior art fabric article 100
having velour 104, 106 at the opposite faces. The diameter of the
filament stitch yarn 14 may be slightly greater than that of the
prior art stitch yarn 102 (likely due to increased
filament-to-filament engagement of the filaments of the filament
stitch yarn 14). The yarn count and gauge of the double-face velour
fabric article 10 of the invention are also substantially the same
as those for the comparable prior art fabric article 100. As a
result, the weight and stretch performance of the double-face
velour fabric article 10 of the invention is closely comparable to
the weight and stretch of the prior art double-face velour fabric
article 100 of the same gauge and yarn count.
The fact that the weight density of the filament stitch yarn 14 and
the stitch yarn 102 are the same indicates that the ratio of yarn
material to open volume for each of the respective articles is also
approximately the same. However, in the filament stitch yarn 14,
and in the resulting double-face velour fabric article 10 of the
invention, the average cross sectional area of the individual
filaments is considerably less that the average cross sectional
area of filaments in the stitch yarn 102 employed in the comparable
prior art fabric article 100, e.g. the denier per filament (dpf) of
the preferred filament stitch yarn 14 is about 0.7 dpf, as compared
to 3.0 dpf for the stitch yarn 102 of comparable prior art fabric
article 100. As a result, the paths for passage of air, e.g., a
chilling wind, through double-face velour fabric article 10 of the
invention, while relatively more numerous, are also considerably
smaller and relatively more tortuous, as compared to a comparable
prior art double-face velour fabric article 100. The enhanced
performance of the fabric article of the invention is achieved by
increasing the yarn count and the filament count to make the paths
through the fabric more tortuous, thus making it more difficult for
air, i.e., a chilling wind, to penetrate quickly through the
double-face velour fabric article 10 of the invention. As a result,
the dynamic insulation performance of the double-face velour fabric
of the invention is dramatically increased over the prior art.
In FIG. 14, there is reproduced a plot of curves showing the
relationship between change in effective thermal insulation and
wind velocity for covers or fabrics of different permeabilities, as
appeared in an article by P. Larose, entitled "The Effect of Wind
on the Thermal Resistance of Clothing with Special Reference to the
Protection Given by Coverall Fabrics of Various Permeabilities,"
which appeared in Canadian Journal of Research (Vol. 25, Sec. A,
No. 4, (July 1947), pp. 169-190), the entire disclosure of which is
incorporated herein by reference. The permeabilities of the
materials tested varied between 0 and 193 ft.sup.3/ft.sup.2/min
under a pressure difference of 1/2 inch of water across the
fabric.
In particular, it can be seen in the plot that at zero wind
velocity there is relatively little difference in insulating
performance among the materials tested. The dynamic insulating
performance for each of the materials tested also decreased with
increasing wind velocity. However, as may be seen in the plot, the
rate of decrease in dynamic insulating performance was much more
precipitous in fabrics of relatively greater permeability, i.e. as
permeability increased, the rate of loss of dynamic insulating
performance with increasing wind velocity was relatively smaller
for fabrics of low permeability, as compared to fabrics having
relatively greater permeability.
In Table A (below), the improvement in dynamic insulation
performance of double-face velour fabric articles 10 (FIG. 2) of
the invention in a chilling wind can easily be seen when compared
to the performance of a comparable prior art double-face velour
fabric article 100 (FIG. 3). In particular, the double-face velour
fabric article 10 of the invention has considerably better dynamic
insulating performance, and good static (no wind) and dynamic
(windy) insulation performance, due to the increased tortuosity of
air paths through the fabric, with good stretch properties and
light weight.
The word "tortuosity" is used to describe the fabric property
enhanced according to this invention by increasing yarn count and
filament count. The paths through the fabric are made more
"tortuous" than those of prior art fabrics, and greater
"tortuosity" results in greater dynamic insulating effect. In
addition, if a given fabric body is subjected to less than normal
stretching, resulting in reduced final width of the fabric (i.e.,
the width resulting after heat setting of the fabric during the
finishing process), the higher, still, the dynamic insulating
performance of the resulting fabric article of the invention.
TABLE-US-00001 TABLE A A1 A2 B1 B2 Loop Yarn 150/100 150/132
150/100 150/132 textured textured textured textured Stitch Yarn
100/34 100/34 100/34 100/34 textured textured textured textured
Width 58-inch 58-inch 54-inch 54-inch cuttable cuttable cuttable
cuttable "Dynamic 100-110 cfm 60-70 cfm 70-80 cfm 50-60 cfm
Insulating Performance" Compare: A1 to A2 A2 has finer loop yarn,
and therefore relatively better dynamic insulating performance.
Compare: A1 to B1 B1 has narrower width, and therefore better
dynamic insulating performance. Compare: A1 to B2 B2 has finer loop
yarn, and therefore better dynamic insulating performance. Compare:
A1 to B2 B2 has finer loop yarn and narrower width, and therefore
better dynamic insulating performance.
In other preferred embodiments, fabric articles of the invention
having relatively greater densification and tortuosity, and
therefore increased dynamic insulation performance for enhanced
protection from wind penetration, are achieved by incorporation of
stitch yarns and/or loop yarns of predetermined selected
characteristics. For example, stitch yarns and/or loop yarns
including, or formed largely of, heat sensitive materials, e.g. hot
melt or heat shrinkable materials, and/or elastomeric materials,
such as spandex, may be employed.
For example, referring now to FIG. 15, in a preferred embodiment, a
fabric article 30 of the invention formed by reverse plaiting on a
fine cut circular knitting machine includes a stitch yarn 32 and a
loop yarn 35 finished into a velour 36, 38 at the opposite
surfaces. The stitch yarn 32 includes, or consists largely of, yarn
or filaments of heat sensitive material 33, e.g. heat shrinkable
material, or hot melt material (typically commingled (e.g.,
blended) with other fiber that will maintain yarn integrity after
heat treatment). The loop yarn 35, which, in this embodiment, may
be a filament yarn but is more typically a spun yarn, include, or
consists largely of, fibers of suitable flame retardant material,
e.g., such as m-Aramide, 1.5 denier, e.g. as manufactured by E. I.
du Pont de Nemours and Company, of Wilmington, Del., under the
trademark NOMEX.RTM.. The m-aramide fibers may be used alone, or in
a blend, e.g. with fibers of p-aramide, e.g. as manufactured by E.
I. du Pont de Nemours and Company, o Wilmington, Del., under the
trademark KEVLAR.RTM., and/or with fibers of other suitable
material having good electrostatic dissipation characteristics.
Suitable heat sensitive materials include polypropylene, nylon,
polyester, polyamide, and the like, preferably with high shrinkage,
e.g., about 5% to about 50% after about 2 minutes to about 60
minutes at about 212.degree. F. to about 450.degree. F. Heat is
thereafter applied to the fabric article, e.g., dry heat and/or wet
heat, such as hot water or steam, e.g. during dyeing and/or
finishing. Upon exposure to heat, the hot melt material fuses to
narrow or fill interstices between the yarns filaments, and the
heat shrinkable material shortens and thickens, and/or reduces in
effective length, thus to reduce the paths for passage of chilling
wind through the fabric and thereby increase the tortuosity and the
dynamic insulation performance of the fabric article 30 of the
invention.
Referring next to FIG. 16, in another embodiment, in a fabric
article 40 of the invention, the stitch yarn 42 comprises a cored
yarn 43 having a core formed, e.g., of polyester or nylon, with a
sheath formed of a heat sensitive material, e.g., a hot melt
material, such as polypropylene, polyester or nylon, e.g. as
available commercially from Engineered Yarn Company, of Fall River,
Mass. The loop yarn 44 includes, or consists largely of, fibers of
flame retardant material 46. During heating of the fabric article
of this embodiment, e.g. during dyeing and/or finishing, the hot
melt material of the sheath fuses, thus increasing the tortuosity
and further reducing the paths for passage of chilling wind through
the fabric and improving the dynamic insulation performance of the
fabric article 40 of the invention.
Referring now to FIG. 17, in a fabric article 50 of the invention,
the stitch yarn 52 includes elastomeric material 53, e.g. such as
spandex. The loop yarn 54 includes, or consists largely of, fibers
of flame retardant material 56. The elastomeric material 53 in the
stitch yarn 52 also provides for relatively greater densification
and tortuosity, and therefore increased dynamic insulation
performance for enhanced protection from wind penetration, as well
as providing for fabric stretch and enhanced wearer comfort.
Referring now to FIG. 18, a fabric article 60 of the invention may
also be formed of stitch yarns 62 including or consisting largely
of combinations of heat sensitive materials 63 and elastomeric
materials 65. For example, stitch yarns employed in the fabric
article 60 may include fibers or filaments of different
characteristics that have been commingled or plaited together. The
loop yarn 64 includes, or consists largely of, fibers of flame
retardant materials 66.
Referring to FIG. 19, in another embodiment, a fabric article 70 of
the invention is formed of loop yarns 72 of standard denier that,
upon application of heat, e.g. during dyeing and/or finishing,
split axially into multiple, elongated fibers or filaments. The
result is a reduction or narrowing of paths for passage of chilling
wind through the fabric, to increase tortuosity and dynamic
insulation performance of the fabric article 70. The loop yarns may
be caused to split also by application, e.g., of a chemical
treatment, e.g. caustic soda, or by application of a mechanical
action, e.g. napping.
Referring finally to FIG. 20, in yet another embodiment, a fabric
article 80 of the invention is formed of loop yarns 82 having an
"islands-in-sea" construction. Namely, the loop yarns 82 are formed
of a hot melt polymeric body ("sea") containing multiple filaments
("islands") of small diameter, e.g. 0.01 to 0.03 denier. Upon
application of heat to the fabric article 80, e.g., during dyeing
and/or finishing, the hot melt material melts to release the
individual, small diameter filaments. Again, the release of the
small filaments results in increased tortuosity and dynamic
insulation performance of the fabric article 80.
Alternatively, referring to FIG. 21, in a different embodiment, a
double face velour fabric article 90 of the invention is formed of
very bulky filament stitch yarn 92 with relatively low shrinkage.
The resulting fabric article 90 will be significantly heavier, less
drapeable, and will have relatively poor stretch/recovery, e.g. as
compared to the embodiments described above. However, the high
bulk, high thickness of the raised surface regions 94, 96 formed by
finishing fibers of the loop yarn 93 of flame retardant material 98
will provide enhanced protection or shielding of the stitch yarn 92
from excessive heat and thermal shrinkage, as well as from burning
and melting.
Finally, referring to FIG. 22, in yet another embodiment of the
invention, a velour fabric article 101, in this case having one or
more raised or fleece surface regions 103 at only one surface, is
formed with a plaiting circular knit construction from a loop yarn
105, e.g. including, or consisting largely of, flame retardant
material 107, such as m-Aramide fibers (NOMEX.RTM.) of 1.5 denier,
and a filament stitch yarn 108, e.g. including, or consisting
largely of, thermoplastic filament yarn 110, formed of materials
such as polyester, nylon, or polypropylene, commingled or plaited
with spandex material 112, such as LYCRA.RTM. (also available from
E. I. du Pont). The fibers of the loop yarn 104 are finished at the
technical back 114 to create a velour or fleece region 103 at one
surface. The fabric article 101 of this embodiment has good
stretch, when tested according to ASTM 2594, in both length and
width dimensions. The single face velour fabric 101 can be formed
into articles for tight fit, which enhances the comfort and
insulation performance in dynamic (windy) conditions. Positioning
the fleece surface 103 of flame retardant material 107 against the
wearer's skin also shields against potential drip of the
thermoplastic stitch yarn material 110 onto the skin, e.g. in a
fire condition. Positioning of the flame retardant surface region
103 against the skin also improves thermal insulation (in cold
weather), as well as providing enhanced thermal insulation, as
measured on a Frazier air permeability unit in accordance with ASTM
D-737. It also shields against penetration of material from melting
fibers of the stitch yarn 108 through to burn the wearer's
skin.
Due to the increased tortuosity, including after heat treatment, a
fabric article of the invention formed with stitch yarns including
or consisting largely of heat sensitive materials and/or
elastomeric materials, such as spandex, and/or loop yarns formed of
heat sensitive materials and/or elastomeric materials such as
spandex, and/or cored yarns having a sheath of hot melt material,
have enhanced dynamic insulation performance, e.g. as compared to a
prior art fabric article 100 (FIG. 3) having the same weight. As a
result, the fabric articles of the invention are particularly
suited for use, e.g., in lightweight clothing and the like for use
in extreme conditions of chilling wind and cold temperature.
Examples of fabric articles of the invention formed with heat
sensitive materials and/or elastomeric materials will now be
described. The air permeability was tested according to ASTM D-737
(the complete disclosure of which is incorporated herein by
reference) on a Frazier machine with 1/2 of water pressure
drop.
EXAMPLE 1
A fabric article of the invention, designated S/7380, was formed of
a stitch yarn consisting of 150/34 POWERSTRETCH.TM. heat shrinkable
textured polyester, available from UNIFI, Inc., and a loop yarn
consisting of 150/132 textured polyester. After exposure to heat,
the air permeability of the finished fabric article was 70
ft.sup.3/ft.sup.2/min.
EXAMPLE 2
Another fabric article of the invention, designated E555P, was
formed of a stitch yarn consisting of 50/36 textured polyester with
20 denier spandex on every other end plaited with the 50/36
textured polyester and a loop yarn consisting of 150/132 textured
polyester. After exposure to heat, the air permeability of the
finished fabric article was 59 ft.sup.3/ft.sup.2/min.
EXAMPLE 3
Yet another fabric article of the invention, designated E657Y, was
formed of a stitch yarn consisting of 50/36 textured polyester
commingled with 40/20 textured polypropylene and a loop yarn
consisting of 100/96 textured polyester. After exposure to heat,
the air permeability of the finished fabric article was 38-40
ft.sup.3/ft.sup.2/min.
EXAMPLE 4
Another fabric article of the invention, designated E667Q, was
formed of a stitch yarn consisting of 100/34 POWERSTRETCH.TM. heat
shrinkable textured polyester and a loop yarn consisting of 100/96
textured polyester. After exposure to heat, the air permeability of
the finished fabric article was 60-70 ft.sup.3/ft.sup.2/min.
A number of embodiments of the invention have been described.
Nevertheless, it will be understood that various modifications may
be made without departing from the spirit and scope of the
invention. For example, any suitable type of yarn may be employed.
Also, other suitable methods of constructing a velour fabric
article of the invention may be employed. For example, in the
preferred embodiment described above, the construction provided by
reverse plaiting is employed in order to expose the loop yarn 16
for finishing at both surfaces of the fabric body, with segments 22
of the loop yarn 16 overlaying the stitch yarn 14 at the technical
face 18 and formed into loops 23 at the technical back 20. This is
preferred, for reasons of dynamic insulation performance, over a
construction in which only the loop yarn is finished. However,
where improvement of dynamic insulation performance is not the
primary or an overwhelming consideration, a construction exposing
the stitch yarn and the loop yarn side by side for finishing at one
or both surfaces of a fabric body may be preferred. In embodiments
of fabric articles of the invention formed with heat sensitive
materials, heat may be applied other than or in addition to during
dyeing and/or finishing, e.g., before, after, or between these
stages of manufacture. Also, referring again to FIG. 13, a
double-face velour fabric article 40 of the invention may be formed
by applying the hydroentanglement process to the technical face 18
and/or the technical back 20, e.g., using fine, high-pressure water
jets 32 and/or 32', respectively.
As mentioned above, a fabric article with stitch yarn and/or loop
yarn comprising heat sensitive and/or elastomeric material may also
be entangled or hydroentangled according to the invention.
Accordingly, other embodiments are within the scope of the
following claims.
* * * * *