Classifications

• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D1/00—Woven fabrics designed to make specified articles
  • D03D1/0011—Woven fabrics for labels

Definitions

• the invention relates generally to woven fabrics and methods, and more particularly to woven labels .
• Fabric labels or tags are typically affixed to merchandise to indicate the source. Labels may also provide information, such as instructions for care and maintenance of the product. Clothing labels, in particular, often bear trademarks and logos with a high level of detail and color. The need to provide such detail must be balanced by the need for softness as such tags are affixed to clothing items, for example, which are meant to be worn.
• Printed labels have two main drawbacks. First, the ink will eventually wear off as a result of being rubbed or washed, thereby rendering the label useless. When a graphic or logo on a printed label wears off, it gives the impression that the product to which the label is affixed is cheap and lacking in quality. Second, the printed cloth may lack softness and thus end up stiff, which presents a discomfort to the one wearing the item of clothing. Partially peeled ink can scratch the skin of the wearer of the article of clothing.
• Woven labels have colored yarn that is woven into a pattern in order to bear a specific logo or graphic. Very thin yarn is generally referred to as thread. Yarn is manufactured by either a spinning or air texturizing process. Though woven labels do not suffer from the drawback of having ink wearing off, woven labels tend to be limited in density. The limitations in density derive at least in part from the thickness of the yarn which is measured in denier. The limitations in density in turn limit the depth, or clarity, of the graphic on the label. Just as a high resolution monitor can provide more detail and clarity than a low resolution monitor, a lesser dense label would be limited in the amount of detail it can provide in bearing a graphic, logo, trademark or any other image. Accordingly, manufacturers are limited in what types of logos and/or trademarks are available for incorporating into a label. Furthermore, conventional woven labels also lack softness which can present discomfort to the wearer.
• FIGs 1-5 illustrate woven labels according to the prior art.
• the density of a commonly known fabric called "Taffeta” is illustrated.
• the density of Taffeta labels generally range from 29 to 32 picks per centimeter.
• Figure 2 is a close-up photographic view of an actual Taffeta label according to the prior art bearing the image of a moose head.
• FIG. 3 illustrates the density of a prior art Damask yarn which generally ranges from 48 to 54 picks per centimeter.
• Figure 4 is a close-up photographic view of a Damask label according to the prior art bearing the same moose head graphic as shown in the Taffeta label of Figure 2.
• Figure 5 is a magnified photographic view of the twist of an actual Damask thread according to the prior art.
• a woven label comprises a first yarn having a first color and a first thickness less than 75 denier, a second yarn having a second color and a second thickness less than 75 denier, and a density of at least 80 picks per centimeter.
• the thicknesses of the first and second yarns are preferably between 50 denier and 75 denier.
• the density preferably comprises a range between 90 to 100 picks per centimeter.
• a high density microdenier woven label is provided using a slower weaving process.
• the label comprises at least one yarn having a thickness less than 75 denier and a density of at least 80 picks per centimeter.
• the density is provided by a weaving machine weaving at a rate between 560 to 640 picks per minute.
• the thickness of the yarn is preferably between 50 denier and 75 denier.
• the density preferably comprises a range between 90 to 100 picks per centimeter.
• a method of manufacturing a woven label comprises the steps of providing a yarn with a thickness of 75 denier or less, weaving the yarn at a speed less than 700 picks per minute, and forming the label with a density of at least 80 picks per centimeter.
• the step of weaving the yarn at the speed less than 700 picks per minute comprises the step of weaving the yarn at the speed between 560 to 640 picks per minute.
• the step of forming the label with the density of at least 80 picks per centimeter comprises the step of forming the label with the density of 90 to 100 picks per centimeter.
• the method further comprises the step of programming a weaving machine to weave at the density between 90 to 100 picks per centimeter.
• the method also comprises programming the weaving machine to weave at the rate of 560 to 640 picks per minute.
• the invention also includes a label obtained by this preferred method of manufacturing.
• a high density woven label includes a finer grade yarn spun from specially selected polyester fabrics.
• the yarn has a thickness of less than 75 denier.
• the label comprises differently colored yarn that is woven together to form a graphic, logo or trademark.
• the woven label is particularly useful as a clothing tag.
• the woven label has a density of more than 80 picks per centimeter.
• a preferred method of manufacturing is also provided which includes weaving the yarn at a slower than normal weaving rate.
• FIG. 1 is a magnified photographic view of the density of a prior art Taffeta woven label:
• FIG. 2 is a close-up photographic view of an actual woven label composed of prior art Taffeta yarn
• FIG. 3 is a magnified photographic view of the density of a prior art Damask woven label:
• FIG. 4 close-up photographic view of an actual woven label composed of prior art Damask yarn
• FIG. 5 is a magnified photographic view of a prior art Damask yarn
• FIG. 6 is a magnified photographic view of a preferred yarn according to the invention.
• FIG. 7 is a magnified photographic view of the density of a preferred woven label according to the invention.
• FIG. 8 is a close-up photographic view of an actual woven label according to the invention.
• FIG. 9 is a block diagram of a preferred method of manufacturing a woven label according to the invention.
• a first preferred embodiment of a woven label is illustrated in Figures 7 and 8 and designated generally by the reference numeral 10.
• the label 10 preferably comprises a clothing label adapted to be affixed to articles of clothing and thus worn. Nonetheless, the label 10 according to the invention may be used on a variety of articles where woven labels are utilized, such as linens, pillows, furniture, bedding, and other such products.
• the label 10 comprises differently colored yarns, or threads, 20 woven according to a preferred method of manufacturing discussed herein.
• Each yarn 20 is preferably composed of one or more selected polyester fabrics.
• the label 10 comprises finer grade yarns known as microdenier yarns that have a thickness of 80 denier or less.
• the microdenier yarn 20 preferably has a thickness in the range of 50 to 75 denier. Whereas conventional "damask" thread has a thickness of 75 to 100 denier, the yams according to the invention each have a thickness of 50 to 75 denier without compromising strength.
• Figure 6 is a magnified photographic view showing the tighter twist of the preferred yarn 20 according to the invention. Compared with the twist of a prior art damask yarn as shown in Figure 5, the tighter twist of the yarn 20 according to the invention is noticeably greater in Figure 6. This tighter twist of the preferred yarn provides the yarn with greater tensile strength.
• the finer grade yarn 20 not only provides greater strength, but also enables a more densely woven label to be produced.
• a standard weaving machine is programmed to weave the label 10 at a greater density than that of the conventional label.
• the weaving machine is programmed to provide a density of at least 80 picks per centimeter, and preferably in the range of 90 to 100 picks per centimeter.
• the weaving machine is programmed such that the weaving process is reduced from the normal rate of 700 to 750 picks per minute to approximately 630 picks per minute, with the preferred range being between 560 picks per minute on the slower end to 640 picks per minute on the relatively quicker end. It will be appreciated that such a step of slowing down the weaving rate would not be obvious to one of ordinary skill in the art since the general trend in art of weaving is to quicken the weaving rate in order to produce more product in a set period of time. To provide the unique, higher quality label 10 according to the invention, output per amount of time might need to be reduced due to the reduced weaving speed.
• a higher density label 10 is accomplished.
• the label 10 according to the invention has a density of at least 80 picks per centimeter, with a preferred range between 90 to 100 picks per centimeter.
• Figure 7 illustrates the density of the label 10 which is preferably in the range between 90 to 100 picks per centimeter.
• the label 10 according to the invention in Figure 8 provides a remarkably greater depth and clarity in the image of the moose head.
• the woven label according to the invention now enables manufacturers, particularly clothiers, to incorporate more detailed logos and trademarks into the labels. And, since the label is woven and not printed, the graphic will not wear off despite repeated wearing and washing. It will further be appreciated that a more detailed graphic on a label that does not wear off will ultimately provide consumers with the impression of a higher quality product.
• woven labels 10 according to the invention have been tested in accordance with commonly known procedures in the industry.
• an extension test was performed with a STM 468 repeated extension machine, using the SATRA PM 103 test method.
• a STM 117 flex and stretch machine was utilized with a test method of SATRA PM 147.
• an STM 466 tensile testing center was used to measure tensile breakage strength, using the test method of SATRA PM35.
• a preferred method 100 of manufacturing a woven label is illustrated in Figure 9.
• the method 1 0O comprises the step 110 of providing finer grade microdenier yam having a thickness of 75 denier or less, and preferably in the range of 50 to 75 denier. This step involves selecting and mixing polyester fibers to produce the yarn.
• a standard weaving machine is programmed to provide a label with a density greater than that of conventional labels, namely, a density greater than 80 picks per centimeter, and preferably in the range of 80 to 100 picks per centimeter.
• the weaving machine is programmed to weave labels at a slower rate than the known conventional rate of 700 picks or more per minute.
• the weaving machine is programmed to weave in the range of 560 to 640 picks per minute, and preferably at or about 630 picks per minute.
• step 140 yam is woven by the weaving machine at the slower rate, namely, between 560 to 640 picks per minute, in order to achieve the unique density as described above.
• the yarn woven at a slower rate it is also woven at a greater density in step 150.
• Step 150 comprises weaving the yarn to provide a label with a density of at least 80 picks per centimeter, and preferably in the range of 90 to 100 picks per centimeter. It will be appreciated that the thinness of the yarn, higher density weaving and slower rate of weaving enables the label to reach the desired density without compromising strength or softness.
• fitness tests are performed on the sample woven label in step 160. These fitness tests may include the extension, flexibility and tensile tests discussed above.
• step 170 also comprises analyzing the fitness test on the label to determine if the label is of sufficient quality to sold.
• step 170 may also include the step of discarding any labels which do not pass the fitness tests.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Woven Fabrics (AREA)
• Treatment Of Fiber Materials (AREA)

Applications Claiming Priority (2)

Publications (1)

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• 2005
  • 2005-09-26 EP EP05800093A patent/EP1791995A2/de not_active Withdrawn
  • 2005-09-26 WO PCT/US2005/034265 patent/WO2006036832A2/en not_active Ceased
  • 2005-09-26 AU AU2005289683A patent/AU2005289683A1/en not_active Abandoned
  • 2005-09-26 JP JP2007533679A patent/JP2008514828A/ja not_active Withdrawn
  • 2005-09-26 BR BRPI0515879-6A patent/BRPI0515879A/pt not_active Application Discontinuation
  • 2005-09-26 CN CNA2005800323026A patent/CN101142351A/zh active Pending
  • 2005-09-26 US US11/236,114 patent/US20060070681A1/en not_active Abandoned

Non-Patent Citations (1)

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