NZ767219A - Improved woven fabric - Google Patents

Abstract

A woven textile fabric including: 132 to 190 EPI cotton warp yarns; and multi-filament polyester weft yarns, wherein the cotton yarns have a cotton count of 30s to 80s, the multi-filament polyester yarns have a denier of 8D to 19D, the fabric has a high total thread count ranging from 500 to 3000, and proportion of the cotton in the fabric is 50% or above by weight of the fabric, and wherein the multi-filament polyester yarns are wound, substantially parallel to one another and substantially adjacent to one another, on a multi-pick yarn package at an angle between 15 to 25 degrees and at a type A shore hardness between 65 to 80 to enable simultaneous insertion of the multi-filament polyester yarns during a single pick insertion event of a pick insertion apparatus of a loom, further wherein said fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs. Fabric weaving using multi-ply polyester yarns can result significant in yarn breakage due to higher entanglement. The present invention provides for higher loom speeds and lower yarn breakage by weaving multi-filament polyester yarns such that they are substantially parallel and substantially adjacent to one another.

Description

ED WOVEN FABRIC FIELD OF THE INVENTION The present disclosure relates generally to the technical field of woven fabrics.

More specifically, the present disclosure pertains to a woven e fabric with higher thread count that exhibits low pilling tendency, while being economical.

BACKGROUND OF THE INVENTION Pilling is a condition that arises in fabrics due to the formation of little 'pills' of entangled fibers ng to the fabric surface giving it an tly appearance. They are formed by a rubbing action on loose fibers, which are present on the fabric surface. It was originally a fault found mainly in knitted n goods made from soft twisted yarns. However, introduction of man-made fibers into clothing has aggravated its seriousness e these fibers are stronger than wool so that the pills remain ed to the fabric surface rather than breaking away as would be the case with the wool. Pilling, in l, affects the appearance of fabrics and reduces the use performance of fabrics; however, it may not affect the durability or functionality of the fabric per se.

There are several ways to preclude pilling or decreasing pilling cy of a fabric.

One solution is singeing process and spinning the yarn with a high number of twists per inch.

Other methods include ally treatment of the fabric during the manufacturing process in order to reduce their propensity to pill. Sometimes polymeric coatings are also applied to bind fibers into the fabric surface and prevent initial fuzz from forming. However, all these method suffers from one or more limitations as would be apparent to persons skilled in the art.

Accordingly, there remains a long felt need in the art for a woven textile fabric with higher thread count that exhibits low pilling tendency. It is always desirable if such fabric would be economical.

OBJECTS OF THE INVENTION An object of the present disclosure is to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

Another object of the present disclosure is to provide a woven fabric that has an sed thread count.

Another object of the present disclosure is to provide a woven fabric that exhibits increased th and durability. id="p-8"

[0008] Another object of the present disclosure is to provide a new and improved woven fabric that can be manufactured in an easy, efficient and cost-effective manner.

Another object of the present disclosure is to provide a new and improved woven fabric that has enhanced aesthetic characteristics.

Another object of the present disclosure is to provide a new and improved woven fabric that can be used in a variety of applications.

Further object of the present disclosure is to e a woven fabric that exhibits low pilling tendency.

SUMMARY id="p-12"

[0012] The present disclosure relates generally to the technical field of woven fabrics.

More specifically, the present disclosure ns to a woven textile fabric with higher thread count that exhibits low pilling tendency, while being economical.

An aspect of the present disclosure provides a woven textile fabric, said fabric sing: 132 to 190 ends per square inch (EPI) cotton warp yarns; and multi-filament polyester weft yarns, wherein the cotton yarns have a cotton count of 30s to 80s, the multifilament ter yarns have a denier of 8D to 50D, and the fabric has a high total thread count ranging from 500 to 3000, and wherein the multi-filament polyester yarns are wound, substantially parallel to one another and substantially adjacent to one another, on a multi-pick yarn package at an angle between 15 and 30 degrees and at a type A shore hardness between 60 to 90 to enable simultaneous ion of the multi-filament polyester yarns during a single pick insertion event of a pick insertion apparatus of a loom. In an embodiment, the fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs.

In an embodiment, the cotton yarn comprises 100% cotton yarns or blend of cotton and any or a ation of a tic fiber and a l fiber such that the blend has a cotton content of at least 90%. In an embodiment, the multi-filament polyester yarns comprise 100% polyester multi-filament texturized yarns. In an embodiment, proportion of the cotton in the fabric is 50% or above by weight of the fabric. In an embodiment, the filament polyester yarns have a denier of 8D to 30D. In an embodiment, the fabric comprises 368 to 2868 picks per square inch (PPI) multi-filament polyester yarns. In an embodiment, the multi-filament polyester yarns comprise 7 to 28 filaments. In an embodiment, the fabric comprises any of a twill weave and a satin weave. In an embodiment, the cotton yarns have a cotton count of 40s to 60s. In an embodiment, the multi-filament polyester yarns are wound on the multi-pick yarn package at an angle between 15 and 25 degrees. In an embodiment, the filament polyester weft yarns are wound on the multi-pick yarn e at a type A shore hardness between 65 to 80. In an embodiment, the multi-filament polyester weft yarns are woven into the fabric in a group of at least two multi-filament polyester weft yarns, said at least two multi-filament polyester weft yarns being substantially parallel to one another and substantially adjacent to one another.

DETAILED DESCRIPTION The description that follows, and the embodiments described therein, is provided by way of ration of an example, or examples, of ular embodiments of the principles and aspects of the present disclosure. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the disclosure.

The present disclosure relates generally to the technical field of woven fabrics.

More specifically, the present disclosure pertains to a woven textile fabric with higher thread count that ts low pilling tendency while being economical.

As used herein, a person skilled in the nt art may generally understand the term "comprising" to lly mean the ce of the stated features, integers, steps, or components as referred to in the claims, but that it does not preclude the presence or addition of one or more other features, rs, steps, components or groups thereof. id="p-18"

[0018] All publications herein are incorporated by reference to the same extent as if each dual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. id="p-19"

[0019] The expression "rating of 3 or above" as used throughout the present disclosure, in the context of the fabric tested for pilling after 1000 rubs, generally s low g tendency of the fabric being . In other words, when the pilling tendency of the finished fabric is measured by any of the standard methods such as ASTM D4970 or ISO 12945-2:2014 and rated on a scale/grade/rating of 1 – 5, the scale/rating/grade 1 indicating very severe pilling and scale/rating/grade 5 indicating no pilling after the specified number of rubs, the fabric exhibits the rating of 3 or 4 or 5 after 1000 rubs or cycles, i.e. the finished fabric has low pilling tendency.

The term c" and "finished fabric", as used herein throughout the present disclosure synonymously and interchangeably, in the context of the fabric being tested for pilling tendency or g ance denotes the dyed, bleached or printed fabric, or otherwise a fabric that is substantially ready for use (e.g. consumer use) without need to be subjected to any further processing that can alter its pilling tendency or pilling resistance. For example, the raw woven fabric may be ted to dying and/or printing and/or bleaching s(es) to produce the finished fabric. Such finished fabric is then ted to the test for measurement of pilling resistance or pilling tendency.

In some embodiments, the numbers expressing quantities used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term "about." Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary ng techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain n errors arily resulting from the standard deviation found in their tive testing measurements.

The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise ted herein, each individual value is incorporated into the specification as if it were individually recited herein. id="p-23"

[0023] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. "such as") provided with respect to certain embodiments herein is intended merely to better illuminate the ion and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention. id="p-24"

[0024] As used in the description herein and throughout the claims that , the meaning of "a," "an," and "the" includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of "in" includes "in" and "on" unless the context clearly dictates otherwise.

Groupings of alternative elements or embodiments of the invention sed herein are not to be construed as limitations. Each group member can be ed to and claimed individually or in any combination with other s of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of ience and/or ability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written id="p-26"

[0026] An aspect of the present disclosure provides a woven textile fabric, said fabric comprising: 132 to 190 ends per square inch (EPI) cotton warp yarns; and multi-filament polyester weft yarns, wherein the cotton yarns have a cotton count of 30s to 80s, the multifilament polyester yarns have a denier of 8D to 50D, and the fabric has a high total thread count ranging from 500 to 3000, and wherein the multi-filament polyester yarns are wound, substantially el to one another and substantially adjacent to one another, on a multi-pick yarn package at an angle between 15 and 30 degrees and at a type A shore hardness between 60 to 90 to enable aneous insertion of the multi-filament polyester yarns during a single pick insertion event of a pick insertion apparatus of a loom.

In an embodiment, the fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs. Any of the methods as known to or appreciated by a person skilled in the art for g of pilling resistance, such as ASTM D4970 and ISO 12945-2. In an embodiment, the fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs in accordance with ASTM D4970. In an embodiment, the fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs in accordance with ISO 12945-2:2014.

ASTM D4970 and ISO 2 methods make use of a Martindale Tester, wherein the fabric (i.e. the finished ) being tested is rubbed face to face for a specified number of rubs/cycles, and the pill balls are evaluated using a photographic visual standard for comparison and given a 1 – 5 rating, n rating/grade 1 indicates very severe g and rating/grade 5 indicates no pilling.

In an embodiment, the cotton yarn comprises 100% cotton yarns. Alternatively, the cotton yarn may comprise blend of cotton and any or a combination of a synthetic fiber and a natural fiber such that the blend has a cotton content of at least 90%. In an ment, the multi-filament polyester yarns comprise 100% polyester multi-filament texturized yarns.

In an embodiment, the proportion of the cotton in the fabric is 50% or above by weight of the fabric. Simply put, the content/proportion of the cotton in the fabric is higher than that of the Polyester.

In an embodiment, the multi-filament polyester yarns have a denier of 8D to 30D.

In an embodiment, the fabric comprises 368 to 2868 picks per square inch (PPI) multi-filament polyester yarns. In an embodiment, the multi-filament polyester yarns comprise 7 to 28 filaments. id="p-31"

[0031] In an embodiment, the fabric comprises any of a twill weave and a satin weave. In an embodiment, the fabric comprises a twill weave.

In an embodiment, the cotton yarns have a cotton count of 40s to 60s. In an embodiment, the multi-filament polyester yarns are wound on the multi-pick yarn package at an angle (winding angle) between 15 and 25 degrees. In an ment, the multi-filament polyester weft yarns are wound on the multi-pick yarn package at a type A shore hardness between 65 to 80. In an embodiment, the multi-filament polyester weft yarns are woven into the fabric in a group of at least two multi-filament polyester weft yarns, said at least two multifilament polyester weft yarns being ntially parallel to one r and substantially nt to one another. id="p-33"

[0033] Table 1 below illustrates properties of the fabric, realized in accordance with ments of the present disclosure.

Table 1: Properties of the Fabric Sample Polyester Polyester Cotton Cotton Feel Pilling Tensile Total No. Weft filaments Yarn content Factor (1-5) Strength thread (Denier) Count (%) (1-5) (1-10) Count 1 12 14 50 54 3 4 7 1500 2 15 14 50 52 3 3 6 1500 3 14 7 60 58 5 4 7 800 4 17 7 60 52 4 3 6 800 10 14 60 60 5 3 8 2000 6 20 7 60 48 3 2 5 800 7 20 14 60 40 2 1 6 2000 8 21 14 50 48 1 1 4 1500 As can be seen from the Table 1 above, when the cotton content of the fabric falls below 50% (i.e. the proportion of cotton in the fabric is less than that of the Polyester), the fabric exhibits high pilling tendency (or low ance to pilling). id="p-35"

[0035] Table 2 and 3 below illustrates effects of Type A shore hardness and winding angle of the filament polyester weft yarns on the instances of yarn breakage and speed of the weaving, which eventually exerts profound effect on the cost of production of the .

Table 2: Effect of Type A Shore Hardness Sample Type A Winding Instances of ces of Average No. shore angle intermingling yarn approximate hardness (average, per ge weaving bobbin/spool) (average, per speed (looms) bobbin/spool) 1 35 19 200 100 50 2 50 19 125 66 100 3 60 19 30 15 350 4 65 19 5 3 500 70 19 2 2 600 6 80 19 7 4 450 7 90 19 15 10 300 8 100 19 200 100 50 Table 3: Effect of Winding Angle Sample Winding Type A Instances of Instances of Average No. angle shore intermingling yarn approximate hardness (average, per breakage weaving bobbin/spool) (average, per speed (loom) bobbin/spool) 1 10 70 150 90 50 2 15 70 25 12 300 3 20 70 2 2 600 4 25 70 10 6 500 30 70 35 20 275 6 35 70 90 50 125 As can be seen from the Table 2 and 3 above, winding angle and Type A shore hardness of the multi-filament polyester yarns exerts a pronounced effect on the instances of intermingling of yarns, and optimization of g angle and Type A shore hardness affords dramatic reduction in instances of intermingling and yarn breakage without compromising unwinding speed of the yarn.

The fabric of the present invention exhibits low tendency of pilling, while achieving the balance between feel, pilling resistance and the tensile strength. Further, the fabric of the present invention is icantly economical owing to, at least, reduced wastage during the production and/or increased speed of weaving due to lower instances of yarn breakage.

While some embodiments of the present sure have been illustrated and described, those are completely ary in nature. The disclosure is not limited to the embodiments as elaborated herein only and it would be apparent to those skilled in the art that numerous modifications besides those already described are possible without departing from the inventive concepts herein. All such cations, changes, ions, substitutions, and equivalents are completely within the scope of the present disclosure. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, y modify and/or adapt for various applications such specific embodiments without departing from the c concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. ore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the ed claims.

ADVANTAGES The present disclosure provides to overcome or ameliorate at least one of the antages of the prior art and/or provides a useful alternative.

The present disclosure provides a woven fabric that has an increased thread count. id="p-42"

[0042] The present disclosure provides a woven fabric that exhibits increased strength and durability.

The present disclosure provides a new and ed woven fabric that can be manufactured in an easy, efficient and cost-effective manner.

The present disclosure provides a new and improved woven fabric that has enhanced aesthetic characteristics.

The present disclosure provides a new and improved woven fabric that can be used in a variety of applications.

The t disclosure es a woven fabric that exhibits low pilling tendency.

Claims (6)

1. A woven textile fabric, said fabric comprising: 132 to 190 ends per square inch (EPI) cotton warp yarns; and multi-filament polyester weft yarns, wherein the cotton yarns have a cotton count of 50s to 60s, the filament polyester yarns have a denier of 8D to 19D, the fabric having a high total thread count ranging from 500 to 3000, and proportion of the cotton in the fabric being 50% or above by weight of the fabric, and wherein the multi-filament polyester yarns are wound, substantially parallel to one another and substantially nt to one another, on a multi-pick yarn package at an angle between 15 and 25 degrees and at a type A shore ss between 65 to 80 to enable simultaneous insertion of the multi-filament polyester yarns during a single pick insertion event of a pick insertion apparatus of a loom, further wherein said fabric exhibits rating of 3 or above when the fabric is tested for pilling after 1000 rubs.

2. The fabric as claimed in claim 1, wherein the cotton yarn comprises 100% cotton yarns or blend of cotton and any or a combination of a tic fiber and a natural fiber such that the blend has a cotton content of at least 90%.

3. The fabric as claimed in claim 1, wherein the filament polyester yarns comprise 100% polyester multi-filament texturized yarns.

4. The fabric as claimed in claim 1, wherein the fabric comprises 368 to 2868 picks per square inch (PPI) filament polyester yarns, and wherein the multi-filament polyester yarns comprise 7 to 28 filaments.

5. The fabric as claimed in claim 1, wherein the fabric is of a twill weave.

6. The fabric as claimed in claim 1, wherein the multi-filament polyester weft yarns are woven into the fabric in a group of at least two multi-filament polyester weft yarns, said at least two filament polyester weft yarn being substantially parallel to one another and substantially adjacent to one another