CA2929724A1 - Color-fast and high-crocking combination fabric and method for making the same - Google Patents

Color-fast and high-crocking combination fabric and method for making the same Download PDF

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Publication number
CA2929724A1
CA2929724A1 CA2929724A CA2929724A CA2929724A1 CA 2929724 A1 CA2929724 A1 CA 2929724A1 CA 2929724 A CA2929724 A CA 2929724A CA 2929724 A CA2929724 A CA 2929724A CA 2929724 A1 CA2929724 A1 CA 2929724A1
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Canada
Prior art keywords
fiber
natural
yarn
fabric
polyester
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA2929724A
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French (fr)
Inventor
Dominic Kin-Ming Poon
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Individual
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Individual
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Filing date
Publication date
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Publication of CA2929724A1 publication Critical patent/CA2929724A1/en
Abandoned legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/04—Blended or other yarns or threads containing components made from different materials
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/208—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based
    • D03D15/217—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads cellulose-based natural from plants, e.g. cotton
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/54—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads coloured
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/01—Natural vegetable fibres
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]

Abstract

A colour-fast and high-crocking combination fabric and methods for making the same. The colour-fast and high-crocking fabric consists of dyed natural fibres and dyed polyester fibres. The natural and polyester fibres are dyed and/or coloured before being combined into yarns and fabrics. The colour-fast and high-crocking combination fabric has very high colour-fastness as measured by crocking standard, while maintaining a quality hand feel. The colour-fastness can withstand at least thirty regular cold-temperature home-wash laundries.

Description

2 PCT/US2014/064135 COLOR-FAST AND HIGH-CROCKING COMBINATION FABRIC AND METHOD
FOR MAKING THE SAME
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Serial Number 61/900,307, filed on November 5, 2013, the entire contents of which are herein incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to textiles and fabrics, and, more particularly, to environmentally friendly fabrics having a high crocking standard, long-lasting color fastness, and quality hand feel.
[0003] In the textile industry, two considerations for manufacturers when producing fabrics are color-fastness, crocking standard, and quality of feel, i.e., hand feel. These three considerations often act at odds with one another, with those fabrics having a great hand feel lacking in color-fastness and/or high crocking, and vice versa. Regarding color-fastness, there is particularly a lot of discussion and demand in the clothing industry for high-quality apparel that maintains color fastness, in particular for black apparel that resists fading.
Recent surveys indicate that, on average, about 30-40% of a woman's closet is black.
[0004] A common concern for casualwear and sportswear is how to keep or maintain the color of the clothing without fading, crocking, and bleeding after washing.
Certain textile producers use chemical treatments to increase color-fastness and crocking, but this comes at the expense of hand feel. Those fabrics that yield a high-quality hand feel often have the problems of crocking, color fastness, and shedding.
[0005] It can readily be appreciated that there is a need for a fabric having a high crocking standard while still maintaining color fastness and a high-quality hand feel. The present invention fulfills this need and provides further related advantages.

SUMMARY OF THE INVENTION
[0006] The present invention may be embodied in a method comprising coloring and/or dyeing natural fibers and polyester fibers; placing the colored/dyed natural fibers and the colored polyester fibers in a picking line; creating a plurality of combined ropes consisting essentially of the colored/dyed natural fibers and the colored/dyed polyester fibers; and spinning the plurality of combined ropes into a yarns. The polyester fibers may be a recycled polyester fiber, and the natural fibers may be a natural wood fiber. In one aspect of this embodiment, the yarn may have a crocking standard of at least 4Ø
[0007] In another aspect of this embodiment, spinning the plurality of combined ropes into a yarn comprises spinning the plurality of combined ropes into a plurality of warp yarns and a plurality of weft yams. The method may further comprise joining the plurality of warp yarns and the plurality of weft yarns into a fabric. In a further aspect, the plurality of the warp yams may comprise at least 50% to at least 70% colored/dyed natural fibers, and the plurality of the weft yarns may comprise at least 30% to at least 50% colored/dyed polyester fiber. In yet a further aspect, the warp yarns may comprise approximately 65% colored/dyed natural fibers and approximately 35% colored/dyed polyester fibers, and the weft yams may comprise approximately 65% colored/dyed polyester fibers and approximately 35%
colored/dyed natural wood fibers.
[0008] The present invention may also be embodied in a yarn consisting essentially of a polyester fiber and a natural fiber, wherein the polyester fiber and the natural fiber are colored/dyed as fibers before being joined into a yarn. The polyester fiber may be a recycled polyester fiber, and the natural fiber may be a natural wood fiber. In one aspect of this embodiment, the yam may have a crocking standard of at least 4Ø
[0009] The present invention may also be embodied in a fabric consisting essentially of a warp yam consisting essentially of polyester fiber and natural fiber; and a weft yarn consisting essentially of polyester fiber and natural fiber, wherein the warp yarn has at least 50% natural fibers, and the weft yarn has at least 50% polyester fibers. In a further aspect, the warp yarns may comprise at least 65% natural fibers, and the weft yarns may comprise at least 65%
polyester fibers. The polyester fiber may be a recycled polyester fiber, and the natural fiber may be a natural wood fiber. The yam itself may already have a color-fast characteristic due to the coloring/dyeing of the natural and polyester fibers prescribed in the paragraphs above in this section. The yarn may then be further developed into fabric for consumer apparel or industrial use. The resulting fabric/garment can maintain color fastness without bleeding for at least thirty regular cold-temperature home-wash laundries.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following drawings.
[0011] FIG. 1 provides an image of warp and weft yams woven into a color-fast combination fabric, in accordance with an aspect of an embodiment of the present invention.
[0012] FIG. 2 provides a flowchart for a color-fast combination fabric method in accordance with an embodiment of the present invention.
DESCRIPTION OF THE INVENTION
[0013] The present invention may reside in combination yams and a combination fabric comprising natural and polyester fibers. Both the natural and polyester fibers are dyed as fibers, before they are combined into yarns which then can be knit or woven into fabrics. This process of dying the fibers rather than the yarns or fabrics provides increased color-fastness and higher crocking standard to the end product. The natural fiber is used to create a high-quality hand feel that is not available with a polyester fiber, while the polyester fiber provides the added advantage of increased color-fastness that is presently not available with natural fibers. Although the present disclosure will discuss the invention with respect to black fabrics composed of black natural fibers and black polyester fibers, it will be understood that the present invention may be applied to encompass fabrics of any color, such as Forever White, Red, Grey, Blue, etc.
[0014] The natural fiber component of the combination fabric may comprise a dyed wood fiber. An example of a current such product is the Lenzing Modal (R) COLOR fiber in black. Crocking standard is a standard of measure that may be used to measure the color-fastness of a fabric or fiber, with 5.0 being the highest color-fastness. The black Lenzing Modal fiber offers a fine hand-feel similar to silk. However, the black Modal fiber offers a dry crocking standard between 3.5 and 4.0 and a wet crocking standard between 2.5 and 3.0, which are only average in terms of crocking performance. The wood fiber fabric, made from wood pulp material, offers the added advantage of being an environmentally friendly product.
[0015] The polyester fiber component of the combination fabric may comprise a recycled polyester fiber. One such product is the Repreve polyester fiber made by Unifi, Inc. This fiber has a high crocking standard between 4.0 and 5Ø This recycled polyester fiber also offers the added advantage of being an environmentally friendly product.
[0016] The natural fibers and polyester fibers are combined into a combination yarn. The combination yam is made of a combination of the natural wood fiber and the polyester fiber. In one embodiment, the fibers may be combined such that the composition ratio of natural fiber to polyester fiber comprises greater than 50% polyester. In a presently preferred embodiment, the preferred warp-yarn ratio is approximately 65% natural wood (Modal) and approximately 35%
polyester fiber. The weft-yam ratio is approximately 65% polyester fiber and 35% natural wood (Modal) fiber. The combination of the black Lenzing Modal COLOR fiber with the black Repreve polyester fiber in the presently preferred 65/35 warp ratio and 35/65 weft ratio results in a crocking standard between 4.0-5.0, which is difficult to achieve in the apparel industry, while maintaining the silk-like hand feel of the Lenzing Modal fiber. This combination yam may be used on its own to create a fabric, or combined with other yarns to create a fabric, as will be described in greater detail below.
[0017] The present invention may also be embodied in a color-fast fabric comprising the color-fast combination yarn discussed above. Yams are generally woven or knit into fabrics. An example of yarns woven into a color-fast fabric 10 is demonstrated in FIG. 1.
The color-fast combination fabric 10 may consist of a single type of yam, such as the combination yam described above, or multiple different types of yarns. In one embodiment, as depicted in FIG. 1, the color-fast fabric may 10 consist of warp yarns 12 and weft yarns 14, the warp yarns 12 and the weft yarns 14 each consisting essentially of natural and polyester fibers, as described above.
The warp yarns 12 and the weft yarns 14 may have different polyester fiber/natural fiber content ratios. In one embodiment, the warp yarns 12 may have a high natural-wood fiber content of greater than 50%, as described in the color-fast combination yarn described above, while the weft yarns 14 have a higher polyester fiber content. In a presently preferred embodiment, the warp yarns 12 have a natural-wood fiber content of at least 50%, while the weft yarns 14 have a polyester fiber content of at least 50%. In yet a further preferred embodiment, the warp yarns 12 have a natural fiber content of approximately 65% modal (natural wood fiber) and approximately 35% polyester, while the weft yarns 14 have a polyester fiber content of at least 65%. As discussed above with respect to the color-fast combination yarn, the color-fast fabric 10 maintains quality hand-feel while providing superior color-fastness. The combination fabric 10 also increases the life of the fabric, as it sheds less than natural fibers and has better tear and tensile strength.
[0018] The present invention may also be embodied in a method for creating a combination fabric. FIG. 2 provides a flow-chart representation of a color-fast combination method 100. The disclosed method 100 may be implemented in most current mills without increasing operational costs. The method comprises dying natural fiber (e.g., black Modal fiber) and polyester fiber (e.g., Repreve) as fibers, rather than the yarn or the fabric being dyed and/or colored at a later step (101). These colored fibers are then placed in a picking line, and delivered into a blower to clean the fibers and to mix them together (102). The mixed fibers then go through a carding process to remove any extraneous materials, such as cotton seeds, unwanted fibers, or any other waste (103). The fibers are then sent to a drawing room or draw frame to create a single rope comprising both types of fibers (104). The combined fiber ropes then go through a spinning process to form yarns (105). Manufacturers may use any suitable spinning process, including open end or ring spinning. Determination of which spinning method to use will depend on the desired look and weight of the final fabric. Finally, the yarns are knit or woven into a fabric (106).
[0019] As previously described, the yams used to make a fabric may be identical such that a single yam is used to make a fabric, or the yarns may have different polyester fiber to natural fiber ratios. It is preferable that a certain portion of the yams used to make the fabric (e.g., warp yarns discussed above) have greater than 50% natural-wood fiber, and, preferably, a warp-yam ratio of approximately 65%/35% natural fiber to polyester fiber and a weft-yarn ratio of at least 65% polyester fiber.
[0020] Although the invention has been disclosed with reference only to presently preferred embodiments, those of ordinary skill in the art will appreciate that various modifications can be made without departing from the invention. The specification and figures are, accordingly, to be regarded in an illustrative rather than a restrictive sense. As such, the present invention is defined only by the following claims and recited limitations.

Claims (20)

1. A method comprising:
placing colored or dyed natural fibers and colored or dyed polyester fibers in a picking line;
creating a plurality of combined ropes consisting essentially of the colored or dyed natural fibers and the colored or dyed polyester fibers; and spinning the plurality of combined ropes into yarns.
2. The method of claim 1, wherein the polyester fiber comprises recycled polyester fiber.
3. The method of claim 1, wherein the natural fiber comprises natural wood fiber.
4. The method of claim 1, wherein the yarn has a crocking standard of at least 4Ø
5. The method of claim 1, wherein spinning the plurality of combined ropes into a yarn comprises spinning the plurality of combined ropes into a plurality of warp yarns and a plurality of weft yarns;
and the method further comprises joining the plurality of warp yarns and the plurality of weft yarns into a fabric.
6. The method of claim 5, wherein the plurality of warp yarns have at least 50% natural fiber.
7. The method of claim 6, wherein the plurality of warp yarns have at least 65% natural fiber.
8. The method of claim 5, wherein the plurality of weft yarns have at least 30% polyester fiber.
9. The method of claim 8, wherein the plurality of weft yarns have at least 35% polyester fiber.
10. A yarn consisting essentially of:
polyester fiber; and natural fiber, wherein the polyester fiber and the natural fiber are dyed as fibers before being joined into a yarn.
11. The yarn of claim 10, wherein the polyester fiber comprises recycled polyester fiber.
12. The yarn of claim 10, wherein the natural fiber comprises natural wood fiber.
13. The yarn of claim 10, wherein the yarn has a crocking standard of at least 4Ø
14. The yarn of claim 10, wherein the yarn consists of at least 50% natural fiber.
15. The yarn of claim 14, wherein the yarn consists of at least 65% natural fiber.
16. A fabric consisting essentially of:
a warp yarn consisting essentially of natural fiber and polyester fiber; and a weft yarn consisting essentially of polyester fiber and natural fiber;
wherein the warp yarn has at least 50% natural fiber; and wherein the weft yarn has at least 60% polyester fiber.
17. The fabric of claim 16, wherein the polyester fiber comprises recycled polyester fiber.
18. The fabric of claim 16, wherein the natural fiber comprises natural wood fiber.
19. The fabric of claim 16, wherein the warp yarn has at least 35%
polyester fiber.
20. The fabric of claim 16, wherein the weft yarn has at least 65%
polyester fiber.
CA2929724A 2013-11-05 2014-11-05 Color-fast and high-crocking combination fabric and method for making the same Abandoned CA2929724A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201361900307P 2013-11-05 2013-11-05
US61/900,307 2013-11-05
PCT/US2014/064135 WO2015069772A1 (en) 2013-11-05 2014-11-05 Color-fast and high-crocking combination fabric and method for making the same

Publications (1)

Publication Number Publication Date
CA2929724A1 true CA2929724A1 (en) 2015-05-14

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CA2929724A Abandoned CA2929724A1 (en) 2013-11-05 2014-11-05 Color-fast and high-crocking combination fabric and method for making the same

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US (1) US20150122368A1 (en)
CN (1) CN105960485A (en)
CA (1) CA2929724A1 (en)
WO (1) WO2015069772A1 (en)

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CN105297219A (en) * 2015-09-22 2016-02-03 太仓市特灵化纤有限公司 Bacteria-resistant and odor-removing blending fiber
CN105544048A (en) * 2015-12-03 2016-05-04 太仓圣丹绒服装有限公司 Metal wire fabrics
US10138581B2 (en) * 2016-01-27 2018-11-27 Twin Dragon Marketing, Inc. Woven fabric and method of making same
US20180179673A1 (en) * 2016-12-23 2018-06-28 Taylor Home & Fashions Limited Spinning process of waterless colored heather yarns
US20180179672A1 (en) * 2016-12-23 2018-06-28 Taylor Home & Fashions Limited Spinning Process of Waterless Colored Heather Yarns
US20180179674A1 (en) * 2016-12-23 2018-06-28 Taylor Home & Fashions Limited Spinning process of waterless colored heather yarns

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US20030190853A1 (en) * 1999-12-21 2003-10-09 Scott A. Lovingood Chambray fabric having unique characteristics and method of manufacturing same
US6477826B2 (en) * 2001-01-11 2002-11-12 Sara Lee Corporation Open end spun, cotton/rayon blended yarn
JP2006307379A (en) * 2005-04-28 2006-11-09 Toray Ind Inc Woven or knitted fabric
CN101117740B (en) * 2007-08-30 2010-05-26 浙江云山纺织印染有限公司 Method for making blended stain color yarn
CN101487158B (en) * 2009-02-12 2011-05-11 浙江富润纺织有限公司 Anti-ultraviolet cool wool spinning fabric and method of manufacturing the same
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Publication number Publication date
US20150122368A1 (en) 2015-05-07
WO2015069772A1 (en) 2015-05-14
CN105960485A (en) 2016-09-21

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Effective date: 20191105