US20170159214A1 - Lyocell-Polyester Fabric and Methods of Manufacture - Google Patents
Lyocell-Polyester Fabric and Methods of Manufacture Download PDFInfo
- Publication number
- US20170159214A1 US20170159214A1 US14/995,648 US201614995648A US2017159214A1 US 20170159214 A1 US20170159214 A1 US 20170159214A1 US 201614995648 A US201614995648 A US 201614995648A US 2017159214 A1 US2017159214 A1 US 2017159214A1
- Authority
- US
- United States
- Prior art keywords
- fabric
- warp
- weft
- lyocell
- yarn
- 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
Links
Images
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
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/425—Cellulose series
- D04H1/4258—Regenerated cellulose series
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01H—SPINNING OR TWISTING
- D01H1/00—Spinning or twisting machines in which the product is wound-up continuously
- D01H1/14—Details
-
- 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
- D03D15/225—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 artificial, e.g. viscose
-
- 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
- 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
- D10B2201/20—Cellulose-derived artificial 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]
Definitions
- the present disclosure relates to textiles. More particularly, the present disclosure relates to textiles using a combination of materials, one in warp and another in weft.
- the yarns may be single or double yarns, although the disclosure is not limited thereto.
- Fabrics are typically classified by the materials utilized and by the thread count (i.e., the number of threads in one square inch of finished fabric).
- the thread count (TC) is commonly recognized as setting the quality standard for the textile. Finished products which are produced by using the fabrics are also labeled based on the thread count of fabric. For lower thread count, coarser count yarn may be used and for higher thread count, finer count yarn will be used to match the required grams per square meter of fabric.
- polyester and rayon may be blended together in the thread formation and the blend may be used in the warp and weft to make a fabric, or the blend may be used in the warp, and another material such as cotton may be used in the weft in the manufacture of the fabric.
- a fabric using lyocell in the warp and a multifilament polyester in the weft is disclosed.
- the lyocell is chosen to have a count of between Ne40 and Ne120, and the polyester yarn is chosen to have a count of between 15 denier and 100 denier.
- the fabric is woven from 100 to 250 ends per inch in warp and 100 to 1800 picks per inch in weft so that the thread count of the fabric is between 200 TC to 2000 TC or threads per square inch.
- the tensile strength of the lyocell-polyester fabric in the warp direction is between 4 and 15 pounds and between 4 and 20 pounds in the weft direction (ASTM D1424 method).
- the fill ratio of the fabric in warp to weft is between 1:1 and 1:10.
- the relative humidity is maintaining at between 40% and 50% in order to provide lyocell fibers that will provide desirable softness and moisture-wicking properties.
- the disclosed lyocell-multifilament polyester fabric has surprising advantageous characteristics including low shrinkage, good durability, a desirable softness, a cool feel due to its moisture-wicking properties, and an excellent uniformity in color when dyed.
- the disclosed lyocell-multifilament polyester fabric has particular application for use in bed linens, although it is not limited thereto.
- the FIGURE is a flow chart of a method of manufacture of a lyocell-multifilament polyester fabric.
- a fabric is made by weaving lyocell yarn and polyester yarn, with only lyocell fiber in the warp and only polyester in the weft.
- Lyocell is a regenerated cellulosic fiber made from dissolving pulp of e.g., eucalyptus trees, using a dry jet-wet spinning process.
- a known brand of lyocell is sold under the trade name TENCEL®, a trademark of Lenzing AG of Lenzing Austria.
- Polyester is a category of polymer that contains the ester functional group in its main chain and most commonly refers to polyethylene terephthalate (PET).
- PET polyethylene terephthalate
- Polyester is generally synthesized by utilizing a polycondensation reaction. More particularly, an alcohol and carboxylic acid are reacted to form a carboxylic ester. To assemble the polymer, water formed by the reaction is continually removed by azeotrope distillation.
- lyocell fibers are often classified in to two categories: standard fibers and micro fibers.
- standard TENCEL fiber is used for producing yarn from Ne40/1 to Ne70/1 (where Ne is the English count).
- the staple length and micronaire value of micro TENCEL is 34 mm and 0.9 dtex respectively.
- micro TENCEL is used for producing yarn from Ne70/1 to Ne120/1.
- standard and micro lyocell fibers may be mixed in a desired ratio during spinning of the yarn.
- the basic warp yarn count of the fabric is between Ne40/1 and Ne120/1.
- the polyester yarn count in the weft is between 15 D (denier) and 100 D.
- the fabric is woven from 100 to 250 ends per inch in the warp and 100 to 1800 picks per inch in the weft.
- the thread count of the fabric is between 200 TC and 2000 TC (where TC is thread count or threads per square inch).
- doubled yarn Ne40/2 to Ne120/2 is used in the warp.
- the polyester yarn count in the weft is between 15 D (denier) and 100 D.
- the fabric is woven from 100 to 250 ends per inch in the warp and 100 to 1800 picks per inch in the weft.
- the thread count of the fabric is between 200 TC and 2000 TC (where TC is thread count or threads per square inch).
- the lyocell fibers are chosen based on the desired count of the fabric.
- the fiber is opened and fed into the bale opener.
- the fibers are opened by beaters. Since the fiber length is uniform, beating is kept to a minimum.
- the fibers are converted into sliver form by carding. In carding, mild opening is given to the fiber, waste is removed and paralyzing of fibers takes place. In one aspect, because of standard length in fiber, waste will be a bare minimum and hence the resulting production in carding is large (40 kg/hour/carding). In one embodiment, carding is conducted at between 680 and 760 points/square inch.
- the output of draw frame sliver is taken to a spinning machine such as a Simplex machine, and the output from Simplex machine is a roving with a mild twist.
- the relative humidity is carefully maintained at between 40% and 50% during spinning.
- the relative humidity is carefully maintained at between 44% and 46% during spinning for best results.
- the result of spinning is a roving hank at typically between 1.4 to 2.75 hanks/pound.
- the lyocell is taken to a ring frame for twisting the yarn.
- the lyocell yarn is twisted at between 3.9 to 4.2 TM (twists multiplier).
- the ring cops are wound into a cone in an auto-coner after elimination of process faults in the yarn. If required, yarn is doubled in TFO for high end value added products.
- the polyester yarn used in the weft of the lyocell-polyester fabric is chosen.
- the weft count ranges from 15 Denier to 100 Denier.
- the number of filaments in the polyester yarn may vary based on the desired count and end product. It will be appreciated that the polyester yarn may be chosen at any point prior to weaving.
- the lyocell warp yarns are then prepared.
- the ends per inch in the warp are from 100 to 250.
- the number of ends in the warping machine and number of beams are decided.
- the warp beams are produced with zero unwinding tension to minimize the loss in elongation during the process.
- the pressure applied on the warping beam during winding is maintained from 150 daN to 200 daN to prevent or minimize a change in the shape of the yarn.
- the unwinding speed of the yarn from a full cone is started at approximately (plus or minus 10%) 250 meters per minute and after completing approximately 1500 meters length, the unwinding speed is increased to up to approximately 800 meters per minute.
- strength is added to the lyocell warp yarn by applying modified starch to the lyocell yarn so it can withstand the stress and strain of weaving.
- additional care is taken to minimize the slippage of the warp sheet in hot cylinders in sizing machine.
- the sizing add-on varies from 4% to 14% depending on the count, construction of the fabric and loom speed.
- the temperature is maintained between 115° C. to 145° C.
- the sized beams are taken to drawing-in where there is a sort change in the loom.
- the reed count used to produce the lyocell-polyester fabric is from 32 (dents per inch) to 74 (dents per inch) based on the thread count of the fabric.
- the warp yarn is drawn through droppers, healds (heddles) and reeds in the drawing-in process.
- the weaving process is conducted.
- the drawn beam is taken from the drawing-in department to loom in the weaving department in case of a sort change in loom.
- the beam is loaded and knotted with the previous warp in the loom.
- the lyocell-polyester fabric may be woven in plain, satin, twill, drill, stripes, herring bone and other dobby weaves, among other manners.
- the lyocell-polyester fabric is woven in an air jet weaving machine using a satin weave.
- the speed of the weaving machines may vary widely. By way of example only, the speed may vary from 300 to 700 picks per minutes based on the count and construction of the fabric.
- the air consumption of the air jet machines is from 30 to 60 CFM.
- the lyocell-polyester fabric may also be produced in rapier, projectile and magnetic levitation bullet looms.
- the lyocell warp yarn is passed through the let-off back rest roller, warp stop motion, heald and reed.
- the woven fabric is passed through take up pressure rollers to cloth roll in the loom.
- the polyester weft yarn is drawn from its package to the feeding point in the loom via stop motions, guides and a weft accumulator. The determined length of the weft is set in the accumulator and inserted in the weaving machines by means of air or projectile or rapiers or magnetic levitation bullets.
- the fabric warp tensile strength of the resulting fabric is between 4 lbs and 15 lbs (ASTM D1424 method), and the fabric weft tensile strength is between 4 lbs and 20 lbs. In one embodiment, the fabric fill ratio is between 1:1 and 1:10.
- the produced grey lyocell-polyester fabric may be taken from the loom to the warehouse for inspection and packing. Thereafter, the fabric may be sent to a processing department for subsequent processing and finishing. More particularly, the grey fabric received from weaving may be made into bigger batches in rolls as per the order length. Thereafter, it may be processed through a singeing process to remove protruding fibers in the fabric. Both the front and back sides of the fabric may be singed. Afterwards, the fabric may be desized, where the size applied on the yarn in preparation for weaving is removed. Then processed fabric may then be passed through scouring and washing processes. If desired, the fabric may be treated with caustic soda, or it may be processed through a mercerizing machine.
- the fabric is then ready for dyeing, such that the color is applied on the fabric.
- a jigger dyeing machine is used to dye the fabric.
- the fabric may be dyed using a cold pad batch (CPB) or continuous dyeing range (CDR) dyeing machine.
- CDR continuous dyeing range
- the dyed fabric may be subject to finishing where one or more of a softner, resin, antipilling agent and silicon softner may be added.
- the finished fabric has a good hand feel.
- the fabric produced with lyocell in warp and polyester in weft is used for producing the bed linens in various sizes.
- the bed linens are labeled according to the thread count of fabrics used; from 200 TC to 2000 TC. It will be appreciated that the lyocell-polyester fabric may be used to make other fabric products.
- the lyocell-polyester fabric having a lyocell warp yarn count between Ne40/1 and Ne120/1 or between Ne40/2 and Ne120/2 and a polyester weft yarn count between 15 denier and 100 denier, where the fabric is woven from 100 to 250 ends per inch in the warp and 100 to 1800 picks per inch in the weft and the thread count of the fabric is between 200 TC and 2000 TC, and where the lyocell yarn is spun in an environment where the relative humidity is carefully maintained at between 40% and 50% during spinning, has surprising advantageous characteristics including low shrinkage, good durability, a desirable softness, a cool feel due to its moisture-wicking properties, and an excellent uniformity in color when dyed.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Woven Fabrics (AREA)
Abstract
A fabric is disclosed and includes warp yarns of only lyocell fiber, and weft yarns of multifilament polyester only, where the fabric has a warp yarn count from Ne40 to Ne120, a weft yarn count from 15 D (denier) to 100 D, a thread count (TC) between 200 and 2000, with ends per inch in warp between 100 and 250, and picks per inch in weft being between 100 to 1800. In one embodiment, the lyocell fiber is lyocell fiber resulting from being spun in an environment where the relative humidity is maintained at between 40% and 50%, or between 44% and 46%. The resulting fabric has low shrinkage, good durability, a desirable softness, a cool feel due to its moisture-wicking properties, and an excellent uniformity in color when dyed.
Description
- This application claims priority to Indian application serial number 6472/CHE/2015, filed on Dec. 2, 2015, which is hereby incorporated herein by reference in its entirety.
- 1. Field
- The present disclosure relates to textiles. More particularly, the present disclosure relates to textiles using a combination of materials, one in warp and another in weft. The yarns may be single or double yarns, although the disclosure is not limited thereto.
- 2. State of the Art
- Fabrics are typically classified by the materials utilized and by the thread count (i.e., the number of threads in one square inch of finished fabric). The thread count (TC) is commonly recognized as setting the quality standard for the textile. Finished products which are produced by using the fabrics are also labeled based on the thread count of fabric. For lower thread count, coarser count yarn may be used and for higher thread count, finer count yarn will be used to match the required grams per square meter of fabric.
- In some cases it is known to blend materials together in making threads that are used in the fabric. For example, polyester and rayon may be blended together in the thread formation and the blend may be used in the warp and weft to make a fabric, or the blend may be used in the warp, and another material such as cotton may be used in the weft in the manufacture of the fabric.
- A fabric using lyocell in the warp and a multifilament polyester in the weft is disclosed. The lyocell is chosen to have a count of between Ne40 and Ne120, and the polyester yarn is chosen to have a count of between 15 denier and 100 denier. In one embodiment, the fabric is woven from 100 to 250 ends per inch in warp and 100 to 1800 picks per inch in weft so that the thread count of the fabric is between 200 TC to 2000 TC or threads per square inch. In one embodiment, the tensile strength of the lyocell-polyester fabric in the warp direction is between 4 and 15 pounds and between 4 and 20 pounds in the weft direction (ASTM D1424 method). In one embodiment the fill ratio of the fabric in warp to weft is between 1:1 and 1:10.
- In one embodiment, in spinning the lyocell fibers, the relative humidity is maintaining at between 40% and 50% in order to provide lyocell fibers that will provide desirable softness and moisture-wicking properties.
- The disclosed lyocell-multifilament polyester fabric has surprising advantageous characteristics including low shrinkage, good durability, a desirable softness, a cool feel due to its moisture-wicking properties, and an excellent uniformity in color when dyed. The disclosed lyocell-multifilament polyester fabric has particular application for use in bed linens, although it is not limited thereto.
- The FIGURE is a flow chart of a method of manufacture of a lyocell-multifilament polyester fabric.
- A fabric is made by weaving lyocell yarn and polyester yarn, with only lyocell fiber in the warp and only polyester in the weft. Lyocell is a regenerated cellulosic fiber made from dissolving pulp of e.g., eucalyptus trees, using a dry jet-wet spinning process. A known brand of lyocell is sold under the trade name TENCEL®, a trademark of Lenzing AG of Lenzing Austria. Polyester is a category of polymer that contains the ester functional group in its main chain and most commonly refers to polyethylene terephthalate (PET). Polyester is generally synthesized by utilizing a polycondensation reaction. More particularly, an alcohol and carboxylic acid are reacted to form a carboxylic ester. To assemble the polymer, water formed by the reaction is continually removed by azeotrope distillation.
- In one aspect, lyocell fibers are often classified in to two categories: standard fibers and micro fibers. The staple length and micronaire value of standard TENCEL fiber is 38 mm and 1.3 dtex respectively (where 1 dtex=1 gram/10,000 m). In one embodiment, standard TENCEL fiber is used for producing yarn from Ne40/1 to Ne70/1 (where Ne is the English count). The staple length and micronaire value of micro TENCEL is 34 mm and 0.9 dtex respectively. In one embodiment, micro TENCEL is used for producing yarn from Ne70/1 to Ne120/1. If desired, in one embodiment, standard and micro lyocell fibers may be mixed in a desired ratio during spinning of the yarn.
- In one embodiment, the basic warp yarn count of the fabric is between Ne40/1 and Ne120/1. The polyester yarn count in the weft is between 15 D (denier) and 100 D. The fabric is woven from 100 to 250 ends per inch in the warp and 100 to 1800 picks per inch in the weft. The thread count of the fabric is between 200 TC and 2000 TC (where TC is thread count or threads per square inch).
- In another embodiment, doubled yarn Ne40/2 to Ne120/2 is used in the warp. The polyester yarn count in the weft is between 15 D (denier) and 100 D. The fabric is woven from 100 to 250 ends per inch in the warp and 100 to 1800 picks per inch in the weft. The thread count of the fabric is between 200 TC and 2000 TC (where TC is thread count or threads per square inch).
- Turning to the FIGURE, a flow chart of the method of manufacture of the lyocell-polyester fabric is seen. At 10, the lyocell fibers are chosen based on the desired count of the fabric. At 20, the fiber is opened and fed into the bale opener. Here the fibers are opened by beaters. Since the fiber length is uniform, beating is kept to a minimum. At 30, the fibers are converted into sliver form by carding. In carding, mild opening is given to the fiber, waste is removed and paralyzing of fibers takes place. In one aspect, because of standard length in fiber, waste will be a bare minimum and hence the resulting production in carding is large (40 kg/hour/carding). In one embodiment, carding is conducted at between 680 and 760 points/square inch.
- At 40, six to eight carding slivers are fed into the drawing zone and the uniformity of sliver is better than carding. It is processed through draw frame twice to get better results. At 50, the output of draw frame sliver is taken to a spinning machine such as a Simplex machine, and the output from Simplex machine is a roving with a mild twist. In one embodiment, the relative humidity is carefully maintained at between 40% and 50% during spinning. In one embodiment, the relative humidity is carefully maintained at between 44% and 46% during spinning for best results. The result of spinning is a roving hank at typically between 1.4 to 2.75 hanks/pound. Thereafter, at 60, the lyocell is taken to a ring frame for twisting the yarn. In one embodiment, the lyocell yarn is twisted at between 3.9 to 4.2 TM (twists multiplier). At 70, the ring cops are wound into a cone in an auto-coner after elimination of process faults in the yarn. If required, yarn is doubled in TFO for high end value added products.
- At 80, the polyester yarn used in the weft of the lyocell-polyester fabric is chosen. The weft count ranges from 15 Denier to 100 Denier. The number of filaments in the polyester yarn may vary based on the desired count and end product. It will be appreciated that the polyester yarn may be chosen at any point prior to weaving.
- The lyocell warp yarns are then prepared. In particular, the ends per inch in the warp are from 100 to 250. Based on the specific requirements, at 90, the number of ends in the warping machine and number of beams are decided. In one embodiment, the warp beams are produced with zero unwinding tension to minimize the loss in elongation during the process. The pressure applied on the warping beam during winding is maintained from 150 daN to 200 daN to prevent or minimize a change in the shape of the yarn. In one embodiment, the unwinding speed of the yarn from a full cone is started at approximately (plus or minus 10%) 250 meters per minute and after completing approximately 1500 meters length, the unwinding speed is increased to up to approximately 800 meters per minute.
- In one embodiment, at 100, strength is added to the lyocell warp yarn by applying modified starch to the lyocell yarn so it can withstand the stress and strain of weaving. In one embodiment, additional care is taken to minimize the slippage of the warp sheet in hot cylinders in sizing machine. The sizing add-on varies from 4% to 14% depending on the count, construction of the fabric and loom speed. In the drying cylinders used during the starch application, in one embodiment, the temperature is maintained between 115° C. to 145° C.
- At 110, the sized beams are taken to drawing-in where there is a sort change in the loom. The reed count used to produce the lyocell-polyester fabric is from 32 (dents per inch) to 74 (dents per inch) based on the thread count of the fabric. The warp yarn is drawn through droppers, healds (heddles) and reeds in the drawing-in process.
- At 120, the weaving process is conducted. In one embodiment, the drawn beam is taken from the drawing-in department to loom in the weaving department in case of a sort change in loom. In another embodiment, the beam is loaded and knotted with the previous warp in the loom. The lyocell-polyester fabric may be woven in plain, satin, twill, drill, stripes, herring bone and other dobby weaves, among other manners. In one embodiment, the lyocell-polyester fabric is woven in an air jet weaving machine using a satin weave. The speed of the weaving machines may vary widely. By way of example only, the speed may vary from 300 to 700 picks per minutes based on the count and construction of the fabric. The air consumption of the air jet machines is from 30 to 60 CFM. The lyocell-polyester fabric may also be produced in rapier, projectile and magnetic levitation bullet looms.
- As part of the
weaving process 120, the lyocell warp yarn is passed through the let-off back rest roller, warp stop motion, heald and reed. The woven fabric is passed through take up pressure rollers to cloth roll in the loom. The polyester weft yarn is drawn from its package to the feeding point in the loom via stop motions, guides and a weft accumulator. The determined length of the weft is set in the accumulator and inserted in the weaving machines by means of air or projectile or rapiers or magnetic levitation bullets. - In one embodiment, the fabric warp tensile strength of the resulting fabric is between 4 lbs and 15 lbs (ASTM D1424 method), and the fabric weft tensile strength is between 4 lbs and 20 lbs. In one embodiment, the fabric fill ratio is between 1:1 and 1:10.
- After weaving, the produced grey lyocell-polyester fabric may be taken from the loom to the warehouse for inspection and packing. Thereafter, the fabric may be sent to a processing department for subsequent processing and finishing. More particularly, the grey fabric received from weaving may be made into bigger batches in rolls as per the order length. Thereafter, it may be processed through a singeing process to remove protruding fibers in the fabric. Both the front and back sides of the fabric may be singed. Afterwards, the fabric may be desized, where the size applied on the yarn in preparation for weaving is removed. Then processed fabric may then be passed through scouring and washing processes. If desired, the fabric may be treated with caustic soda, or it may be processed through a mercerizing machine.
- The fabric is then ready for dyeing, such that the color is applied on the fabric. In one embodiment, a jigger dyeing machine is used to dye the fabric. Alternatively, the fabric may be dyed using a cold pad batch (CPB) or continuous dyeing range (CDR) dyeing machine. Thereafter, the dyed fabric may be subject to finishing where one or more of a softner, resin, antipilling agent and silicon softner may be added. In one embodiment, the finished fabric has a good hand feel.
- In one embodiment, the fabric produced with lyocell in warp and polyester in weft is used for producing the bed linens in various sizes. The bed linens are labeled according to the thread count of fabrics used; from 200 TC to 2000 TC. It will be appreciated that the lyocell-polyester fabric may be used to make other fabric products.
- The lyocell-polyester fabric having a lyocell warp yarn count between Ne40/1 and Ne120/1 or between Ne40/2 and Ne120/2 and a polyester weft yarn count between 15 denier and 100 denier, where the fabric is woven from 100 to 250 ends per inch in the warp and 100 to 1800 picks per inch in the weft and the thread count of the fabric is between 200 TC and 2000 TC, and where the lyocell yarn is spun in an environment where the relative humidity is carefully maintained at between 40% and 50% during spinning, has surprising advantageous characteristics including low shrinkage, good durability, a desirable softness, a cool feel due to its moisture-wicking properties, and an excellent uniformity in color when dyed.
- There have been described and illustrated herein several embodiments of a lyocell-polyester fabric and a method of manufacturing the same. While particular embodiments have been described, it is not intended that the disclosure and claims be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular machines have been disclosed in the making of the lyocell yarn, it will be appreciated that other machines could be used as well. In addition, while particular types of weaving machines have been disclosed, it will be understood that other weaving machines can be used. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.
Claims (9)
1. A fabric, comprising:
warp yarns consisting of lyocell fiber; and
weft yarns consisting of multifilament polyester, wherein
said fabric has a warp yarn count from Ne40 to Ne120, a weft yarn count from 15 D (denier) to 100 D, a thread count (TC) between 200 and 2000 with ends per inch in warp between 100 and 250 and picks per inch in weft being between 100 to 1800.
2. A fabric according to claim 1 , wherein:
said lyocell fiber is lyocell fiber resulting from being spun in an environment where the relative humidity is maintained at between 40% and 50%.
3. A fabric according to claim 2 , wherein:
said relative humidity is maintained at between 44% and 46% during spinning.
4. A fabric according to claim 2 , wherein:
said fabric has a warp tensile strength between 4 lbs and 15 lbs and said fabric has a weft tensile strength of between 4 lbs and 20 lbs.
5. A fabric, comprising:
warp yarns consisting of lyocell fiber, said lyocell fiber resulting from being spun in an environment where the relative humidity is maintained at between 40% and 50%; and
weft yarns consisting of multifilament polyester, wherein
said fabric has a warp yarn count from Ne40 to Ne120, a weft yarn count from 15 D (denier) to 100 D, a thread count (TC) between 200 and 2000.
6. A fabric according to claim 5 , wherein:
said fabric has a warp tensile strength between 4 lbs and 15 lbs and said fabric has a weft tensile strength of between 4 lbs and 20 lbs.
7. A method of making a fabric, comprising:
obtaining lyocell fibers;
carding the fibers to form slivers and processing the slivers in a draw frame;
spinning the processed slivers in a spinning machine;
twisting the spun fibers into a lyocell yarn;
obtaining a multifilament polyester yarn; and
weaving said lyocell yarn in warp and said polyester yarn in weft into said fabric where said fabric has a warp yarn count from Ne40 to Ne120, a weft yarn count from 15 D (denier) to 100 D, a thread count (TC) between 200 and 2000.
8. A method according to claim 7 , wherein:
said spinning is conducted in a controlled environment at between 40% and 50% relative humidity.
9. A method according to claim 8 , wherein:
said weaving is conducted with lyocell yarn ends per inch in warp between 100 and 250 and polyester yarn picks per inch in weft being between 100 to 1800.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IN6472CH2015 | 2015-12-02 | ||
IN6472/CHE/2015 | 2015-12-02 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20170159214A1 true US20170159214A1 (en) | 2017-06-08 |
Family
ID=58798174
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/995,648 Abandoned US20170159214A1 (en) | 2015-12-02 | 2016-01-14 | Lyocell-Polyester Fabric and Methods of Manufacture |
Country Status (1)
Country | Link |
---|---|
US (1) | US20170159214A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20160369433A1 (en) * | 2015-06-16 | 2016-12-22 | Mount Vernon Mills, Inc. | Method for making a finished fabric |
CN113151955A (en) * | 2020-01-22 | 2021-07-23 | 上海鼎天时尚科技股份有限公司 | Dyeing and finishing method of lyocell filament fabric |
US11208742B2 (en) | 2016-12-10 | 2021-12-28 | Sachin JHUNJHUNWALA | Textile fabric fabricated of twill weave sheeting |
CN113897782A (en) * | 2021-10-23 | 2022-01-07 | 潍坊迅纺新材料科技有限公司 | Preparation method of antibacterial fabric |
Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5981409A (en) * | 1997-12-18 | 1999-11-09 | Seiren Co., Ltd. | Fabric for dust- and waterproof clothes |
US7682994B2 (en) * | 2004-08-04 | 2010-03-23 | Lightex Limited | Breathable fabric |
US20100330351A1 (en) * | 2007-12-20 | 2010-12-30 | Lenzing Ag | Yarns, high wear resistance fabrics and objects made therefrom |
US20110223398A1 (en) * | 2010-03-09 | 2011-09-15 | Valley Forge Fabrics, Inc. | Upholstery and Wall Panel Weight Woven Fabrics |
US20130055490A1 (en) * | 2011-09-02 | 2013-03-07 | E. I. Du Pont De Nemours And Company | Article of thermal protective clothing |
US20130196135A1 (en) * | 2012-01-20 | 2013-08-01 | Shulong Li | Fiber blend, spun yarn, textile material, and method for using the textile material |
US20140075659A1 (en) * | 2012-09-14 | 2014-03-20 | Milliken & Company | Yarn, textile material, and garment comprising the same |
US20140323999A1 (en) * | 2011-12-01 | 2014-10-30 | Convatec Technologies Inc. | Wound dressing for use in vacuum therapy |
US20150267323A1 (en) * | 2014-03-19 | 2015-09-24 | Springs Creative Products Group, Llc | Decorative mattress border fabric with inherent flame barrier |
US20170088985A1 (en) * | 2015-09-25 | 2017-03-30 | Welspun India Limited | Chambray fabric, bedding articles, and related manufacturing methods |
-
2016
- 2016-01-14 US US14/995,648 patent/US20170159214A1/en not_active Abandoned
Patent Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5981409A (en) * | 1997-12-18 | 1999-11-09 | Seiren Co., Ltd. | Fabric for dust- and waterproof clothes |
US7682994B2 (en) * | 2004-08-04 | 2010-03-23 | Lightex Limited | Breathable fabric |
US20100330351A1 (en) * | 2007-12-20 | 2010-12-30 | Lenzing Ag | Yarns, high wear resistance fabrics and objects made therefrom |
US20110223398A1 (en) * | 2010-03-09 | 2011-09-15 | Valley Forge Fabrics, Inc. | Upholstery and Wall Panel Weight Woven Fabrics |
US20130055490A1 (en) * | 2011-09-02 | 2013-03-07 | E. I. Du Pont De Nemours And Company | Article of thermal protective clothing |
US20140323999A1 (en) * | 2011-12-01 | 2014-10-30 | Convatec Technologies Inc. | Wound dressing for use in vacuum therapy |
US20130196135A1 (en) * | 2012-01-20 | 2013-08-01 | Shulong Li | Fiber blend, spun yarn, textile material, and method for using the textile material |
US20140075659A1 (en) * | 2012-09-14 | 2014-03-20 | Milliken & Company | Yarn, textile material, and garment comprising the same |
US20150267323A1 (en) * | 2014-03-19 | 2015-09-24 | Springs Creative Products Group, Llc | Decorative mattress border fabric with inherent flame barrier |
US20170088985A1 (en) * | 2015-09-25 | 2017-03-30 | Welspun India Limited | Chambray fabric, bedding articles, and related manufacturing methods |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20160369433A1 (en) * | 2015-06-16 | 2016-12-22 | Mount Vernon Mills, Inc. | Method for making a finished fabric |
US11208742B2 (en) | 2016-12-10 | 2021-12-28 | Sachin JHUNJHUNWALA | Textile fabric fabricated of twill weave sheeting |
CN113151955A (en) * | 2020-01-22 | 2021-07-23 | 上海鼎天时尚科技股份有限公司 | Dyeing and finishing method of lyocell filament fabric |
CN113897782A (en) * | 2021-10-23 | 2022-01-07 | 潍坊迅纺新材料科技有限公司 | Preparation method of antibacterial fabric |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP2791404B1 (en) | Stretchable and dimensionally stable woven fabric made from polytrimethylene terephthalate based core spun yarns. | |
US8910461B2 (en) | Size-covered composite yarns and method for making same | |
CN101932761A (en) | Stretch wovens with separated elastic yarn system | |
US20170159214A1 (en) | Lyocell-Polyester Fabric and Methods of Manufacture | |
US20190323152A1 (en) | Ultra soft fabric and process of manufacturing same | |
US20110192488A1 (en) | Method for manufacturing towels of low-twist yarns | |
CN109989158A (en) | A kind of tencel interwoven textile cloth and its processing technology based on polylactic acid | |
CN107700034A (en) | A kind of acetic acid interwoven fabric manufacture method of tencel two | |
AU2021266240A1 (en) | High thread/ yarn count woven textile fabric and process of preparation thereof | |
CN102677261B (en) | Anti-breakage cuprammonium fabric and production method thereof | |
Sardag et al. | The effects of heat-setting on the properties of polyester/viscose blended yarns | |
US20180347077A1 (en) | Hygro Textile Structures And Related Processes | |
KR20080099548A (en) | Method to make elastic fabric comprising spandex and hard yarn | |
CN110295432A (en) | One kind can take fabric and its weaving process in the stamp aramid fiber blended fire prevention summer | |
US11613831B2 (en) | High thread/yarn count woven textile fabric and process of preparation thereof | |
CN112030309B (en) | Acetate fiber fabric and production process thereof | |
EP4253619A1 (en) | Preparation of engineered fabrics with superior absorption properties | |
CN113201844A (en) | Production method of high-elasticity jacquard cloth | |
TR202020515A2 (en) | A Method Providing Dimensional Stability in Carpet Production | |
CN113463249A (en) | High stretch yarn non-twisting interweaved fabric and processing method | |
CN117888259A (en) | Pseudo-classic jean fabric and manufacturing method thereof | |
NZ769569B2 (en) | High thread/ yarn count woven textile fabric and process of preparation thereof | |
CN114369893A (en) | Spun silk and flax blended fabric, blending process and equipment | |
CN116856100A (en) | Weaving method of polylactic acid filament fabric | |
CN113584677A (en) | Nerve-soothing woven fabric and preparation method thereof |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: L.S. MILLS LIMITED, INDIA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:SUNDARARAJAN, MANIVANNAN;REEL/FRAME:037709/0428 Effective date: 20160210 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |