KR20150105996A - Stretch yarns and fabrics with multiple elastic yarns - Google Patents

Abstract

Articles and methods involving core spun yarns are included herein. The core spun yarn comprises a sheath of hard fibers and two sets of elastic fibers, wherein the set of elastic fibers has different properties. The properties can be different in one or more ways and can have different denier, composition or draft, for example. Either or both of the sets of elastic fibers may be pre-covered.

Description

[0001] STRETCH YARNS AND FABRICS WITH MULTIPLE ELASTIC YARNS [0002]

The present invention relates to the production of stretchable composite yarns and fabrics. The present invention specifically relates to fabrics and methods comprising two sets of elastic core fibers in one yarn.

Elastic fabric with elastic composite yarns has long been commercially available. Textile and garment manufacturers generally know how to make fabrics that have the right quality parameters to achieve a consumer acceptable fabric. At present in commercially available fabrics, there is only one elastic fiber system inside the yarn and fabric. One elastic fiber provides a dual function of stretchability and resilience. Fabrics having easy stretchability, high recoverability and low shrinkage performance are difficult to obtain.

Easy stretch is one important feature for comfortable garments. A more pleasant garment can easily be stretched when the garment is worn on the human body and moved. This fabric has a low pressure applied to the body by the garment. The garment can be cut to achieve a more streamlined appearance and can be better fitted to the body while still maintaining comfort in the wearer in motion. This performance can be achieved by minimizing the resistance of the garment to the demands of the moving body through low fabric tensile modulus.

For fabrics with low tensile modulus, however, a typical quality problem is that after the fabric has been overstretched in some areas of the body, such as knees, buttocks and waist, especially in the case of fabrics having a high level of elasticity, And shape can not be quickly recovered. Typically, the fabric has a low resilience when the tensile modulus is low. Consumers suffer from loosening and stretching after a long period of wear.

Conversely, in order to have a fabric with good recoverability, additional retractive force is needed within the fabric. Larger or more elastic fibers can be added to the fabric. However, such fabrics have high stretch modulus and greater disruptive forces. Consumers complain about increased garment pressure and uncomfortable constraints while wearing and moving. At the same time, the fabric has poor dimensional stability. Heat setting is a process required to control fabric shrinkage. The comfort of the garment and the freedom of movement are impaired by the fabric shape formation and recovery function. Fabrics with easy stretchability, high resilience and low shrinkage performance are still desired.

For many years, composite elastic yarns have been widely known. For example, U.S. Patent Nos. 4,470,250, 4,998,403, 713,465, and 6,848,151 disclose that elastomeric fibers, such as spandex, can be made from an elastomeric composite yarn that facilitates acceptable knitted or woven processing and also has acceptable characteristics for various end use fabrics Lt; RTI ID = 0.0 > inelastic < / RTI > In US patent applications US 2008 / 0268734A1 and USA 2008 / 0318485A1, a rigid filament is used with the elastic filament as the core inside the core spun yarn.

Thus, there is a need for the production of flexible woven fabrics with easy stretchability, easy processability, low shrinkage, fabrication of friendly garments, and excellent resilience and low elongation.

One aspect includes a method of making a composite yarn having two sets of different elastic core fibers, also referred to as double-elastic composite yarns. Double elastic composite yarns and stretch fabrics and garments made from such composite yarns are also included.

According to a first embodiment of the method, two sets of elastic fibers and hard fibers having different properties are covered together to form a composite yarn, wherein the two sets of elastic fibers have different drafts for their original length during the yarn covering process (draft). The elastic fibers can be 11 to 560 dtex bare spandex yarns and the hard fibers have a yarn count of 10 to 900 dtex. One suitable hard yarn is cotton yarn. The elastic core fibers I and the elastic core fibers II are independently selected from elastomeric or non-elastomeric fibers.

According to a second embodiment of the method, two sets of elastic fibers (elastic core fibers I and elastic core fibers II) and hard fibers having different properties are covered together to form a composite yarn, wherein the two sets of elastic fibers Different polymer compositions and different stress-strain behavior. The elastic fibers can be 11 to 560 dtex of untreated spandex, and the hard fibers have a yarn count of 10 to 900 dtex. One suitable hard yarn is cotton yarn.

According to a third embodiment of the method, two sets of different elastic core fibers (elastic core fibers I and elastic core fibers II) and hard fibers are covered together to form a composite yarn, wherein at least one set of elastic core fibers Is a pre-covering elastic yarn. Another set of elastic core yarns may be a spandex or pre-covering elastic yarn. The untreated spandex yarn denier has 11 to 560 dtex and the hard fiber has a yarn count of 10 to 900 dtex. One suitable hard yarn is cotton yarn.

According to a fourth embodiment of the method, the two sets of different elastic core fibers and hard fibers are covered together to form a composite yarn, wherein the at least one elastic core fiber is a non-elastomeric stretchable fiber. Another set of elastic core yarns may be untreated elastomers such as spandex. The untreated spandex yarn denier has 11 to 560 dtex and the hard fiber has a yarn count of 10 to 900 dtex. One suitable hard yarn is cotton yarn.

Fabrics are made using double elastic yarns made by one of these alternatives. The double elastic yarns are used in one or more directions of the fabric. Any type of fabric may be used, including woven, circular, lightly knitted and woven fabrics. Additional processing may include refining, bleaching, dyeing, drying, sanforizing, singeing, de-sizing, polishing, and any combination of these steps. The fabric produced may be formed of a garment.

The detailed description will refer to the following drawings, wherein like numerals denote like elements.
1 shows a core spun yarn having two kinds of elastic cores.
Fig. 2 is a schematic view of a core spinning device having two drafting mechanisms for two kinds of untreated elastic fibers. Fig.
3 is a schematic view of a core spinning device with two drafting mechanisms in combination with a weighting roll;
Figure 4 is a schematic view of a core spinning device with two drafting mechanisms for one kind of elastomeric nonwoven fabric and one kind of pre-covering elastic yarn.

Elastomeric fibers are commonly used to provide stretch and elastic recovery in woven fabrics and garments. "Elastomeric fibers" are continuous filaments (optionally multifilaments) or multiple filaments that have no diluent, with a breaking elongation of greater than 100%, regardless of crimp. The elastomeric fibers are (1) stretched to twice their length; (2) then held for 1 minute; (3) When relaxed, it contracts to less than 1.5 times its original length within one minute of being relaxed. As used herein, the term "elastomeric fiber" means one or more elastomeric fibers or filaments. Such elastomeric fibers include, but are not limited to, rubber filaments, blends of component filaments and elastosteos, rastol, and spandex.

"Spandex" is a manufactured filament in which the filament-forming material is a long chain synthetic polymer composed of at least 85% by weight of segmented polyurethane.

An "elastosteester" is a manufactured filament in which the fiber forming material is a long chain synthetic polymer composed of at least 50 wt% aliphatic polyether and at least 35 wt% polyester.

"Mixed constituent filaments" are continuous filaments or fibers comprising two or more polymers attached together along the length of the filaments, wherein each polymer comprises a different general class, such as an elastomeric polyether amide core and a lobe, Or a polyamide sheath having a wing.

Is a fiber of a crosslinked synthetic polymer having a low but significant crystallinity consisting of at least 95% by weight of ethylene and at least one other olefinic unit. The fibers exhibit elasticity and exhibit substantially heat resistance.

"Polyester bicomponent filaments" refer to fibers that have a pair of closely attached fibers along the length of the fiber, such that the fiber cross-section is, for example, a parallel, eccentric sheath-core or other suitable cross- Quot; means a continuous filament comprising a polyester. Fabrics made from such filaments, such as Elasterell-p, PTT / PET bicomponent fibers, have excellent recovery properties.

"Non-elastomeric elastic fiber" means a stretchable filament that does not contain elastomeric fibers. However, the recoverable stretchability of such yarns, such as textured PPT stretch filaments, textured PET stretch filaments, bicomponent stretch filament fibers, or PBT stretch filaments, should exceed 20% in test with the ASTM D6720 method .

The "pre-covering elastic yarn" is surrounded by hard yarn prior to the core spinning process, twisted with hard yarn, or mixed with hard yarn. The pre-covering elastic yarns comprising elastomeric fibers and hard yarns are also referred to herein as "pre-covering yarns ". Hard yarn covering serves to protect the elastomeric fibers from wear during the fabrics manufacturing process. Such abrasion can result in the fracture of the elastomeric fibers, which results in a discontinued process and undesirable fabric non-uniformity. Additionally, the covering facilitates stabilization of elastomeric fiber elastomeric behavior, so that the elongation of the pre-covering elastic yarn during the fabric manufacturing process can be more uniformly controlled than is possible with the non-fabricated elastomeric fibers. The pre-covering yarn can also increase the tensile modulus of yarns and fabrics, which facilitates improvement of fabric recovery and dimensional stability.

The pre-covering yarn comprises (a) a single-coated elastomeric fiber with hard yarn; (b) elastomeric fibers doubly coated with hard yarn; (c) elastomeric fibers that are continuously covered with staple fibers (i.e., core spun or core-spinning) and then twisted during winding; (d) elastomeric and hard yarns mixed and entangled by air jet; And (e) co-twisted elastomeric fibers and hard yarns.

A "dual elastic composite yarn" is a composite yarn comprising two sets of elastic core fibers with a single yarn covered by a rigid staple fiber sheath. The term " double elastic yarn "is used interchangeably throughout this specification.

The stretch fabric of some embodiments includes a double elastic core spun yarn in a weft direction. In some embodiments, especially in the case of high stretch fabrics, fabrics having high recovery properties that are unexpectedly achieved are achieved. This is achieved by the use of a core spun yarn containing two different elastic fibers with different stretch properties. Those of ordinary skill in the relevant art will appreciate that in the case where weft stretchability is desired, the fabric may include such core spun yarns with double elastic fibers in the weft direction.

1, the double elastic yarn 8 according to the present invention will necessarily include two types of elastic filament cores: the elastic core I (4 in FIG. 1) and the elastic core II (6 in FIG. 1) . The elastic core filament is preferably surrounded by a fibrous sheath 2 made up of spinnable staple fibers along its entire length.

One embodiment of representative core spinning apparatus 40 is shown in FIG. Two separate fiber drafting instruments 46 and 64 are installed in the machine. During core spinning, the elastic core filament I 48 and the elastic core filament II 60 are placed on transfer rolls 46 and 64 separately and combined with the hard yarn to form a composite core spun yarn. The elastic core filaments from the tube 48 and the tube 60 are unwound in the direction of the arrows 50 and 62 by the action of the forward-drive feed rollers 46 and 64. Feed rollers 46 and 64 function as a cradle for tube 48 and tube 60 and deliver elastic fiber yarns 52 and 66 at a predetermined rate.

The hard fibers or yarns 44 are unwound from the tube 54 and are brought into contact with the elastic core filaments 52 and 66 at the location of the front roller 42. The joined elastic core filaments 52 and 66 and the hard fibers 44 are core-spun together in the spinning mechanism 56.

The elastic core filament I (52) and the elastic core filament (II) 66 are stretched (drafted) before entering the front roller (42). The elastic filament is expanded and contracted through the speed difference between the feed roller 46 or 64 and the front roller 42. [ The transfer speed of the front roller 42 is faster than the speed of the supply rollers 46 and 64. And adjusts the speed of feed rollers 46 and 64 to provide the desired draft or stretchability.

The stretchability is generally 1.01X to 5.0X times (1.01X to 5.0X) of non-stretchable fibers. Too low stretch will result in low quality yarns with green-through and decentralized elastic filaments. Too high stretch will result in breakage of the elastic filaments and core voids.

Another embodiment of representative core spinning device 40 is shown in Fig. The elastic core I is a non-processed elastic filament 48 while the elastic core II 12 is a pre-covering elastic yarn. From the tube 12, the elastic core II is unwound in the direction of the arrow 62 by the action of the forward-drive supply roller 64. The weighting roll 66 functions to maintain stable contact between the elastic core II and the feed roller 64 to deliver the yarn 68 of the elastic core II at a predetermined speed. The other elements of Fig. 3 are as described for Fig.

Another embodiment of representative core spinning device 40 is shown in FIG. The elastic core I is a non-processed elastic filament 48 while the elastic core II 12 is a pre-covering elastic yarn. The elastic core II from the tube 12 is drawn out from the end and then passes through a tension regulator and a guide bar. The tension regulator functions to stably maintain the tension of the yarn at a predetermined level. The stretchability of the non-stretchable fibers is generally 1.01X to 5.0X times (1.01X to 5.0X) of the non-stretchable fibers. The other elements of Fig. 4 are as described with respect to Fig.

According to some embodiments of the method, the two types of elastic fibers and the hard fibers having different properties are covered together to form the composite yarn, wherein the two types of elastic fibers have different drafts for their original length during the yarn covering process It is newly built. The draft of the two types of elastic fibers can be selected from a 1.01X to 5.0X times draft. In the two types of elastic core fibers having different denier or different filament counts, the elasticity of the elastic core I and the elastic core II may differ from each other depending on the elastic fiber performance and the requirements of the fabric quality. In many cases, one core is more drafted to provide high stretch performance, while another core is less stretched to provide a fabric with low shrinkage and high resilience.

In conventional fabrics, if the thermal setting is not used for "fixing" the spandex, the fabric may have high shrinkage, excessive fabric weight, and excessive elongation, which may cause the consumer to experience a negative experience. Excessive shrinkage during the fabric finishing process can result in wrinkles on the fabric surface during processing and washing at home. Wrinkles that occur in this manner are usually difficult to remove by ironing .

By using one of the elastic core fibers in a low draft, a high temperature heat setting step in the process can be avoided. This novel process can reduce thermal damage to certain fibers (i. E., Cotton) and thereby improve the feel of the finished fabric. The fabrics of some embodiments can be made without a thermal fixation step, wherein the fabric can be made from a garment. As an added benefit, thermosensitive hard yarns can be used in novel processes for making shirts < RTI ID = 0.0 > elastic fabrics, < / RTI > In addition, the abbreviated process provides the fabricator with an advantage of productivity.

It has been unexpectedly found that core spun yarns having two different elastic core fibers have higher elasticity and resilience than core spun yarns made of single elastic core filaments having the same denier. For example, core spun yarns having two types of cores, 30d / 3 filament spandex and 40D / 4 filament spandex, have greater resilience than core spun yarns made from a single core of 70D / 5 filament yarns under the same draft. Therefore, a core spun yarn having a higher elasticity and a higher restoring force can be produced using the same amount of spandex.

Two types of elastic fibers having different properties can be used and are covered with the sheath of the hard fibers to form a composite yarn wherein the two types of elastic fibers can have different polymer compositions and different stress-strain behavior. One example is the use of two spandex fibers with different heat setting efficiencies in one core spun yarn, such as the generic LYCRA® spandex fiber T162C and the easy set Lycra® fiber T562B. The fabric is heat set above the Ijsety Lycra® fiber heat setting temperature, but below the typical LYCRA® fiber heat setting temperature. Therefore, the fabric achieves partial heat setting that provides acceptable fabric shrinkage with good stretchability and stretchability.

Another example is a core spun yarn containing an elastic core I having a high tensile modulus and an elastic core II having a low tensile modulus. The elastic core I provides a fabric with high resilience and low fabric elongation while the elastic core II with a low elastic modulus provides a fabric with easy stretchability and low shrinkage to enable easy stretchability, Resulting in a fabric having stability. Elastic fibers having different chemical compositions may also be combined with one type of core spun yarn, such as polyolefin elastic fiber rastol and spandex. Spandex fibers provide high resilience, while Rastol fibers contribute to good heat resistance and reduced shrinkage performance.

The combination of the elastic core I and the elastic core II includes elastic and non-elastic fibers; Or elastically-worked fibers and pre-covering elastic yarns; Or pre-covering elastic yarns and pre-covering elastic yarns. The elastomeric nonwoven may be from about 11 dtex to about 444 dtex (denier - about 10 D to about 400 D), such as from about 11 dtex to about 180 dtex (denier - 10 D to about 162 D).

The pre-covering elastic yarn may be a single-coated elastomeric fiber of various types, such as hard yarn; Elastomeric fibers doubly coated with hard yarn; Elastomeric fibers that are continuously covered with staple fibers (i.e., core-spinning) and then twisted during winding; Elastomeric and hard yarns mixed and entangled by air injection; And elastomeric fibers and hard yarns twisted together. Preferred pre-covering elastic yarns are spandex air jet covering yarns having textured polyester and nylon filaments, such as 40D or 70D spandex air covered yarns with 50D to 150D polyester. The pre-covering elastic yarn is produced in a separate machine before the core spun yarn process.

The pre-covering elastic yarn may be present in any desired amount, for example, in an amount of from about 5 to about 35 weight percent, based on the total weight of the double elastic yarn. The linear density of the pre-covering yarn ranges from about 15 denier (16.5 dtex) to about 900 denier (990 dtex), for example, from about 30 denier to 300 denier (33 dtex to 330 dtex). When the ratio of yarn denier between the pre-covering yarn and the entire double yarn is less than 35%, the fabric does not exhibit substantial green-through. After the finishing process, the two types of elastic core fibers including the pre-covering yarn are invisible and non-contactable.

The denier of the elastomeric nonwoven fabric (before covering forming the pre-covering yarn) is from about 11 dtex to about 444 dtex (denier - about 10 D to about 400 D), such as from about 11 dtex to about 180 dtex 162D). During the pre-covering process, the elastic fibers are drafted to 1.1X to 6X of their original length. In pre-covering, the elastic fibers are pre-covered with one or more hard yarns having a hard yarn denier of 10 to 600 denier.

Another combination of elastic core fibers I and elastic core fibers II may be one set of elastomeric nonwoven fibers and another set of non-elastomeric elastic fibers. The non-elastomeric elastic fibers can be textured PET stretchable filaments, textured PPT stretchable filaments, bicomponent fibers, or PBT stretchable fibers. Surprisingly, it has been found that when the non-elastomeric elastic fibers having recoverable stretchability in excess of 20% are used as one of the elastic core fibers, the performance of the core spun yarns and fabric significantly changes. The fabric has high elasticity and high resilience. The linear density of the non-elastomeric elastic fibers may range from about 15 dtex to about 450 dtex, such as from about 30 dtex to about 165 dtex, for example, from about 30 dtex to about 165 dtex. If the denier is too high, the fabric may exhibit substantial green-through.

The elastomeric fiber content in the double-elastic core spun yarn is from about 0.1% to about 20%, for example from about 0.5% to about 15%, and from about 5% to about 10%, based on the weight of the yarn. The elastomeric fiber content in the fabric may be from about 0.01% to about 10%, such as from about 0.5% to about 5%, based on the total weight of the fabric.

The staple fibers of the double elastic yarn may be natural fibers such as cotton, wool or linen. They may also be used as single component staple artificial or synthetic fibers, poly (ethylene terephthalate) and poly (trimethylene terephthalate) fibers, polycaprolactam fibers, poly (hexamethylene adipamide) , Rayon fibers, nylon, and combinations thereof.

These double elastic yarns can be used in the manufacture of stretch fabrics, where they are made up of plain weave, poplin, twill, oxford, dobby, sateen, satin, Various weave patterns can be applied including. The fabric of some embodiments may have an elongation of about 10% to about 45% in the warp and / or weft direction. The fabric may have a shrinkage of less than about 15% after washing. The stretch woven fabric may have excellent surface feel. Garments may be made from the fabrics described herein.

The slope may be the same as or different from the weft. The fabric may exhibit only weft-stretchability, or it may exhibit stretchability in both directions, where useful stretchability and recovery properties appear in both warp and weft directions.

Air jet looms, rapier looms, projectile looms, water jet looms and shuttle looms can be used. Dyeing and finishing processes are important in the production of satisfactory fabrics. The fabric may be finished in a continuous range process and a post-spray process. Conventional equipment found in continuous finishing plants and backfill plants is usually adequate for processing. Typical finishing process sequences include preparation, dyeing and finishing. In the preparation and dyeing processes, including embossing, scouring, refining, bleaching, polishing and dyeing, the usual processing methods of elastic woven fabrics are usually satisfactory.

Analysis method:

Yarn's recoverable elasticity

The recoverable stretchability of the elastic fibers used in the examples was measured as follows. Each yarn sample was formed with a total of 5000 +/- 5 denier (5550 dtex) using a tare reel with a tension of about 0.1 gpd (0.09 dN / tex). The tufts were conditioned for at least 16 hours at 70 ° F (+/- 2 ° F) (21 ° +/- 1 ° C) and 65% (+/- 2%) relative humidity. The tufts were suspended from the stand substantially vertically and suspended at a weight of 6 mg / denier (5.4 mg / dtex) (for example, 30 grams in the case of 5550 dtex tufts) , And the length of the tufts was measured to within 1 mm and recorded as "C _{b &} quot ;. A weight of 5.4 mg / dtex was left in the trough during the test period. Thereafter, a weight of 1030 grams (206 mg / d; 185.4 mg / dtex) was hung under the tufts and the length of the tufts was measured to within 1 mm and recorded as "L _b ".

After removing 1030 g of weight, the tufts were soaked in boiling water at 100 ° C for 10 minutes, after which the tufts were removed from the water and conditioned as above for 16 hours. This step simulates a commercial fabric relief process, which is one way of creating the stretch of fabric. The length of the tuft was measured as above and its length was recorded as "C _{a &} quot ;. A weight of 1030 grams was hanged again on the tufts and the length of the tufts was measured as above and recorded as "L _{a &} quot ;. Recoverable Elasticity (%) of Yar after Relaxation "CC _a " to CC _a = 100 x (L _a - C _a ) / L _a . The shrinkage of the yarn Cs (%) = 100 X - was calculated based on the formula of _{(L b L a) / L} b.

The elongation of the woven fabric (stretchability)

The fabric was evaluated for elongation (%) under a specified load (i.e., force) in the direction of stretch of the fabric (s) in the direction of the composite yarn (i.e., weft, warp or weft and warp). Three samples of 60 cm x 6.5 cm dimensions were cut from the fabric. The length dimension (60 cm) corresponds to the stretching direction. The sample was partially unwound to reduce the sample width to 5.0 cm. The samples were then conditioned for at least 16 hours at 20 DEG C +/- 2 DEG C and 65% +/- 2% relative humidity.

A first benchmark was set at 6.5 cm from the end of the sample across the width of each sample. The second benchmark was set at 50.0 cm from the first benchmark across the width of the sample. Using the extra fabric from the second benchmark to the other end of the sample, the metal pin was stitched to form an insertable loop. Thereafter, the notch was cut into the loop so that the weight could be attached to the metal pin.

The non-loop end of the sample was clamped to suspend the fabric sample vertically. 17.8 The weight of the Newton (N) (4 LB) was attached to the metal pin through a hanging fabric loop, and the fabric sample was stretched by weight. The sample was "stretched" by stretching for 3 seconds by weight, and then the weight was lifted to manually remove the force. This cycle was performed three times. Thereafter, the weights were allowed to hang freely, and a fabric sample was stretched. When the fabric was subjected to a load, the distance between the two benchmarks was measured in millimeters, and this distance was designated as ML. The original distance between the benchmarks (i.e., the non-stretch distance) is designated as GL. The fabric elongation (%) for each individual sample was calculated as follows:

% Elongation (E%) = ((ML-GL) / GL) x 100

Three elongation results were averaged for final results.

Woven fabric elongation (unrecoverable elasticity)

After stretching, the unstretched fabric will correctly recover its original length before stretching. Typically, however, the stretch fabric will not be completely restored and will be slightly longer after extended stretching. This slight increase in length is called "kidney ".

The above fabric elongation test shall be completed before the extension test. Only the stretching direction of the fabric was tested. In the case of two-direction stretch fabrics, both directions were tested. Three samples, each 55.0 cm x 6.0 cm, were cut from the fabric. These were samples that were different from those used in the elongation test. The direction of 55.0 cm should correspond to the stretching direction. The sample was partially unwound to reduce the sample width to 5.0 cm. Samples were conditioned at the temperature and humidity of the elongation test. Two benchmarks were set, exactly 50 cm apart, across the width of the sample.

The elongation percentage (E%) found from the elongation test was used to calculate the length of the sample at 80% of this known elongation. This was calculated as follows:

E (length) at 80% = (E% / 100) x 0.80 x L

Where L was the original length between the benchmarks (i.e., 50.0 cm). Both ends of the sample were clamped and the sample was stretched until the length between the benchmarks was the calculated L + E (length). This stretch was maintained for 30 minutes, after which time the stretch was released and the sample was freely suspended and relaxed. After 60 minutes% elongation was measured as follows:

% Elongation = (L2 x 100) / L

Where L2 is the increase in length between sample benchmarks after relaxation and L is the original length between benchmarks. The% elongation was measured for each sample and the results were averaged to determine the elongation.

Shrinkage ratio of woven fabric

The shrinkage of the fabric after washing was measured. The fabric was first conditioned at the temperature and humidity of the elongation and elongation tests. Thereafter, two samples (60 cm x 60 cm) were cut from the fabric. Samples were taken at least 15 cm away from the edge. A square with four sides of 40 cm x 40 cm was indicated on the fabric sample.

The samples were washed in a washing machine with a load fabric. The total load of the washer was 2 kg as air-dried material, and less than half of the laundry was made of the test sample. The laundry was washed softly and dehydrated at a water temperature of 40 ° C. An amount of detergent of from 1 g / l to 3 g / l was used, depending on the hardness of the water. The samples were placed on a flat surface until dry and then conditioned at 20 ° C +/- 2 ° C and 65% relative humidity +/- 2% rh for 16 hours.

Thereafter, the distance between the marks was measured to measure the shrinkage of the fabric sample in the warp and weft directions. The contraction ratio C% after washing was calculated as follows:

C% = ((L1 - L2) / L1) x 100

Where L1 is the original distance between the marks (40 cm) and L2 is the distance after drying. The results for the samples were averaged and recorded for both weft and slant directions. The negative shrinkage value reflects expansion, which in some cases is possible due to the behavior of the hard yarn.

Weight of fabric

The woven fabric sample was die-perforated with a 10 cm diameter die. Each cut weave fabric sample was weighed in grams. Thereafter, the "fabric weight" was calculated in units of grams / m < ^{2 &} gt ;.

Example :

The following examples demonstrate the ability to be used in the preparation of the present invention and its various fabrics. The present invention is capable of other and different embodiments and its various details are capable of variation in various obvious aspects without departing from the scope and spirit of the invention. Accordingly, the embodiments are to be considered as illustrative and not restrictive in character.

In each of the following denim fabric embodiments, 100% pure open end spun yarns or ring spun yarns were used as warp yarns. For denim fabrics, two types of yarns were included: 7.0 Ne OE yarns and 8.5 Ne OE yarns with irregular array patterns. Prior to making the yarn, the yarn was indigo-dyed in the form of a rope. After that, they were sized and weaved. The bottom weight fabric was a 20 Ne 100% smooth-surfaced ring spun yarn. They were sized and weaved.

Table 1 lists four examples of core spun yarns of the present invention containing a conventional one type of elastic core filament and two sets of elastic cores.

A plurality of core spun yarns having double elastic core fibers were used as weft yarns. Various elastic core fibers were used in the core, including a spandex, pre-covering polyester / lycra spandex fiber or pre-covering nylon / spandex yarn. Table 2 lists the materials and process methods used to make the core spun yarns of each example. Table 3 summarizes the detailed fabric structure and performance of each fabric. Lycra® spandex is manufactured by INVISTA, Inc., Wichita, KY. a. egg. Is available from Invista, S. a. For example, in the column titled spandex, 40D means 40 denier; 3.5X means the draft of LYCRA® (machine draft) granted by the core spinning machine. In the column entitled 'Kangseong Sisyan', 20's is the line density of spun yarn measured by the English Cotton Count System. The remainder of Table 1 and Table 2 are clearly labeled.

Using the core spun yarns of each of the examples in Table 2, a stretch woven fabric was subsequently prepared. Table 3 summarizes the quality characteristics of the yarns, weave patterns, and fabrics used in the fabrics. Some additional explanations for each embodiment are provided below. Unless otherwise stated, the fabric was woven in a Donier air-jet or rapier loom. The loom speed was 500 picks / min. The fabric width was about 76 inches and about 72 inches in loom and greige, respectively. The loom had a dual weave beam capability.

In the examples, each raw fabric was finished by a jiggle dyeing machine. Each woven fabric was pre-refined at 49 占 폚 for 10 minutes with 3.0 wt% Lubit 占 64 (Sybron Inc.). Thereafter, 6.0 wt% of Synthazyme® (Dooley Chemicals LLC Inc) and 2.0 wt% Merpol® LFH (manufactured by DuPont) (EI DuPont Co.) at 71 ° C for 30 minutes and then treated with 3.0 wt% Lubit® 64, 0.5 wt% Merfol® LFH, and 0.5 wt% trisodium phosphate at 82 ° C for 30 Min. After fabric finishing, it was dried at 160 DEG C for 1 minute in a tente frame.

<Table 1>

<Table 2>

<Table 3>

Example  Yarn A: A typical core spun yarn with one elastic core fiber

This is not the yarn of the present invention. This core spun yarn is one 40d Lycra® spandex fiber with 16 Nes covered with cotton sheath. The draft of LYCRA ® fiber is 3.5X during the covering process. The face twist level TM is 18 twists per inch. The yarn has recoverable stretchability of 17.71% after boiling.

Example  Yarn B: Core spun yarn having two kinds of elastic core fibers

Core spun yarns are two sets of Lycra® spandex fibers with 16 Nes covered with cotton sheath. The elastic core I fiber is 20D T162B, and the elastic core II fiber is also 20D T162B. The total denier of the elastic fibers is 40 denier. The draft of LYCRA ® fiber is 3.5X during the covering process. The face twist level TM is 18 twisters per inch. Thus, this core spun yarn has the same structure as Example Yar A, including yarn count, Lycra fiber denier and yarn twist level, except that it has two sets of elastic core filaments instead of one set of core spun yarns . The recoverable stretchability of the yarn is 20.63%, which is higher than the yarn of Sample A by 2.92 percent. This means that yarns having two sets of filament cores have higher recoverable stretchability than yarns having the same set of filament cores under the same spandex content. In this manner, the yarns of the present invention can provide high stretchability and high resilience using the same amount of elastic fibers for the fabric.

Example  Yarn C: A typical core spun yarn having one kind of elastic core fibers

This is not the yarn of the present invention. The core spun yarn is one 70d Lycra® spandex fiber with 16 Nes covered with cotton sheath. The draft of LYCRA ® fiber is 3.8X during the covering process. The face twist level TM is 18 twisters per inch. The yarn has a recoverable stretchability of 38.71% after boiling and has a shrinkage rate of 2.28%.

Example  Yarn D: core spun yarn having two kinds of elastic core fibers

Core spun yarns are two sets of Lycra® spandex fibers with 16 Nes covered with cotton sheath. The elastic core I fiber is 30D T162B and the elastic core II fiber is 40D T162B. The total denier of elastic fibers is 70 denier. The draft of Du Lycra ® fiber is 3.8X during the covering process. The face twist level TM is 18 twisters per inch. Thus, this core spun yarn has the same structure as Example yarn C, except that it has two sets of elastic core filaments instead of one set of core spun yarns. The recoverable stretchability of this yarn is 40.88%, which is higher than yarn sample C by 2.17 percentage units. This shows that yarns having two sets of filament cores have higher recoverable stretchability than yarns having a set of filament cores under the same spandex content. In this manner, the yarns of the present invention can provide high stretchability and high resilience using the same amount of elastic fibers for the fabric.

Example  1: Typical stretch woven bottom wait  textile

This example is a comparative example that does not follow the present invention. The slope is ring spun yarn of 40/2 Ne number. The company is 20 Ne cotton yarn with 40D Lycra® core spun yarn. The Lycra® draft is 3.5X. This yarn is a typical stretch yarn used in typical stretch weave khaki fabrics. The loom speed was 500 picks per minute at a pick level of 56 picks / inch. Table 3 summarizes the test results. The test results show that after finishing the fabric has a weight (8.95 g / m ² ), elasticity (37.6%), width (50.5 inches), weft shrinkage (0.91%) and fabric elongation (8.7%). The data suggest that this combination of stretch yarns and fabric construction result in high fabric elongation.

Example  2: Elastic fabric with double elastic fibers

This sample has the same fabric structure as in Example 1. The only difference is the use of 20s wefts with dual elastic core fibers: 40D Lycra® fibers in 3.5X draft and 40d Lycra® fibers in 1.8X draft. The slope is a ring spinning cotton yarn of 40/2 Ne. The loom speed was 500 picks per minute at 56 picks / inch. Table 3 summarizes the test results. This clearly shows that this sample has similar stretch but has a lower fabric elongation level (6.4%). Thus, by using two different draft elastic core fibers in the same yarn, the covering yarns and fabric can achieve different characteristics. For example, high drafts of elastic core I fibers provide fabrics with high stretchability, while low drafts of elastic core II fibers have a low elongation, high recoverability, but do not exhibit an increase in fabric shrinkage Respectively. In this way, fabrics having high stretchability, high recoverability and low shrinkability can be produced.

Example  3: stretch fabric containing double elastic fibers

This sample has the same fabric structure as in Example 1. The only difference is the use of core spun yarns in wefts: 40D T162B Lycra® fiber with 3.5X draft and 40d IZsety Lycra® fiber with 3.5X draft. The slope is 20 Ne 100% cotton ring spun yarn. A 3/1 twill weave pattern was applied. The finished fabric had weight (9.19 g / m ² ), 38.4% elongation in the machine direction and 7.9% elongation. This clearly shows that the Ejiseti Lycra® fibers of Elastic Core II reduce the fabric elongation from 8.7% to 7.9% of Example 1 while maintaining the fabric stretch level.

Ijetsit Lycra® fibers can be heat set at about 170 ° C, which is about 20 ° C lower than the heat setting temperature of T162B Lycra® fibers. Thus, when the fabric was heat set at a temperature of 170 캜 to 190 캜, the fabric was partially heat set. Only Ijsety Lycra® fiber was fixed and T162B was not fixed. In this way, the fabric retained excellent stretchability and resilience, while maintaining shrinkage below a certain level.

Example  4: spandex  And stretchable fabric having elastic polyolefin fibers

The slope is open end yarn mixed with 7.0 Ne number and 8.4 Ne number. The slope was indigo dyed before being made into beams. The company is a 16 Ne core spun yarn with 40D T162B Lycra® spandex and 40D elastic polyolefin fibers. Lycra® fibers and elastic polyester fibers were 3.5X drafted during the covering process. Table 3 lists the fabric properties. The fabrics made from these yarns exhibited good surface feel, good stretchability (47.8%) and good resilience (6.5% elongation). All test results suggest that the combination of spandex and elastic polyolefin filaments may result in good fabric stretchability and extensibility. The fabric did not show green-through. Elastic filaments were not visible on the fabric surface and on the back of the fabric.

Compared with spandex, elastic polyolefin fibers or rastol fibers have low resilience, but have excellent heat resistance, good chemical resistance, low fabric shrinkage and good surface feel. Fabrics containing both spandex and elastic polyolefins were able to provide good stretchability and good resilience with good heat resistance, low shrinkage and excellent chemical resistance, e.g. resistance to chlorine in pool and denim bleaching processes.

Example  5: spandex  And an elastic fabric containing pre-covering elastic yarn

This sample has the same fabric structure as in Example 1. The difference is a weft direction core spun yarn containing one type of unmodulated 40D Lycra® fiber and one type of pre-covering elastic yarn (40D / 34f nylon / 40D Lycra® aircoated yarn) on the core of the yarn. The draft of the unprocessed 40D Lycra® fiber is 1.8X and the draft of the Lycra® fiber in the pre-covering elastic yarn is 3.2X. This fabric had the same slope and structure as in Example 1. Also, the weaving and finishing process was the same as that of Example 1. Table 3 summarizes the test results. It can be seen that this sample has good stretchability (35.9%), good wool shrinkage (0.65%) and good fabric elongation (5.3%). Fabric appearance and touch were excellent. After addition of the pre-covering elastic yarn (40D / 34f nylon / 40D Lycra® fiber AJY yarn), the fabric elongation was significantly reduced.

Example  6: spandex  And an elastic fabric containing pre-covering elastic yarn

This sample has the same fabric structure as in Example 5. The only difference is the draft of 40D untreated Lycra® fibers during the covering process. The draft of the untreated Lycra® fiber was 3.5X, which was 1.8X in Example 5. The fabric weight was 8.96 OZ / yd ² and the weft elongation was 37.8%. The fabric had very low elongation (5.9%) in the warp direction. This sample again confirms that the addition of additional elastic composite yarns can produce fabrics with high stretch performance with low elongation. The double elastic yarn made the fabric elongation from 8.7% to 5.9% of the Example 1. Compared with Example 5, the increase in draft also resulted in increased weight and stretchability.

Example  7: spandex  And stretch denim containing pre-covering elastic yarn

This embodiment has the same warp and the same fabric structure as in the fourth embodiment. The slope is open end yarn mixed with 7.0 Ne number and 8.4 Ne number. The slope was indigo dyed before being made into beams. The company is a 16 Ne core spun yarn with 40D Lycra® spandex and 50D / 24f polyester 40D Lycra® fiber air-jet covering yarn. LYCRA® drafts are 3.5X and 1.8X on the unprocessed and composite cores. This sample is a fabric of the present invention. The loom speed was 500 picks per minute at a pick level of 44 picks / inch. Table 3 summarizes the test results. The test results show that after washing, the fabric has a weight (12.80 OZ / Y ² ), 35.3% weft stretch and 3.5% elongation of weft.

Example  8: spandex  And stretch denim containing pre-covering elastic yarn

This example shows the same warp and the same fabric structure as Example 7 except for the Lycra® fiber draft of the pre-covering elastic yarn (1.8X draft in Example 7, 2.6X draft in Example 8) . Table 3 summarizes the test results. It is clear that this sample has a good stretch (weft 40.4%) as compared to sample 7. [

Example  9: spandex  &Lt; RTI ID = 0.0 &gt; PBT &lt; / RTI &gt;

This example has the same warp and the same fabric structure as Examples 7 and 8, except that 50D / 26f PBT stretchable fibers are used as elastic core II fibers. This untreated 50D / 26f PBT fiber had a recoverable stretch of 40.23% and a shrinkage of 3.44% in the test according to the ASTM D6720 method. Elastic core I Lycra® fiber was 3.5X drafted during the covering process. Table 3 lists the fabric properties.

The fabrics made from these yarns exhibited good surface feel, good stretchability (40.7%) and good recoverability (6.0% elongation). All test results suggest that the combination of spandex and non-elastomeric stretch filaments can result in good fabric stretchability and extensibility. The fabric did not show green-through; Elastic filaments were not visible on both the fabric surface and the back of the fabric.

Claims (21)

a) cords of hard fibers;
b) one set of elastic fibers (elastic core fibers I); And
c) a second set of elastic fibers (elastic core fibers II)
, Wherein the elastic core fibers (I) and the elastic core fibers (II) have different elastic properties. The article of claim 1, wherein the elastic core fibers I and the elastic core fibers II have different denier or different filaments. The article of claim 1, wherein the elastic core fibers I and the elastic core fibers II have different drafts. The article of claim 1, wherein the elastic core fibers I and the elastic core fibers II have different polymer compositions. The article of claim 1, wherein the at least one resilient core fiber comprises elastomeric fibers having a denier of from about 10 denier to about 450 denier. 6. The article of claim 5, wherein the at least one elastic core fiber comprises spandex fibers. The article of claim 1, wherein the at least one resilient core fiber comprises an elastic polyolefin fiber having a denier of from about 10 denier to about 450 denier. The article according to claim 7, wherein the elastic polyolefin fiber is rastol fiber. The article of claim 1, wherein the at least one set of elastic core yarns is a pre-covering elastic yarn having a denier of from about 15 denier to about 300 denier. 10. The article of claim 9, wherein the pre-covering elastic yarn comprises a covering selected from the group of air-covered yarns, single-coated yarns, double-coated yarns, and combinations thereof. 10. The article of claim 9, wherein the pre-covering elastic yarn is polyester and spandex aircovered yarn. The article of claim 1, wherein the at least one resilient core fiber comprises non-elastomeric resilient fibers having a denier of from about 15 to about 450 denier. 13. The article of claim 12, wherein the non-elastomeric resilient yarn is selected from the group of filaments having a recoverable stretchability of the yarn of greater than 20% in test according to the ASTM D6720-07 method. 14. The article of claim 13, wherein the non-elastomeric elastic yarn comprises at least one fiber selected from the group consisting of polyester, nylon, PTT fibers, PBT fibers, bicomponent fibers, and combinations thereof. The article of claim 1, wherein the sheath of the hard fiber is selected from the group consisting of wool, linen, silk, polyester, nylon, olefin, cotton, and combinations thereof. At least one of warp and weft
a) cords of hard fibers;
b) one set of elastic fibers (elastic core fibers I); And
c) a second set of elastic fibers (elastic core fibers II)
, Wherein the elastic core fibers (I) and the elastic core fibers (II) have different elastic properties. 17. The article of claim 16, wherein the fabric has a stretch of from about 10 to about 45 percent in the machine direction. 17. The article of claim 16, wherein the fabric comprises a garment. Either slope or weft, or both slope and weft
a) cords of hard fibers;
b) one set of elastic fibers (elastic core fibers I); And
c) a second set of elastic fibers (elastic core fibers II)
Wherein the elastic core fibers I and the elastic core fibers II have different elastic properties. &Lt; RTI ID = 0.0 &gt; 11. &lt; / RTI &gt; a) cords of hard fibers;
b) one set of elastic fibers (elastic core fibers I); And
c) a second set of elastic fibers (elastic core fibers II)
, Wherein the elastic core fibers (I) and the elastic core fibers (II) have different elastic properties. 21. The article of claim 20, wherein the fabric is a woven or warp or a circular knitted fabric.

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