US20220064823A1 - Hybrid Materials & Methods - Google Patents

Hybrid Materials & Methods Download PDF

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Publication number
US20220064823A1
US20220064823A1 US17/463,414 US202117463414A US2022064823A1 US 20220064823 A1 US20220064823 A1 US 20220064823A1 US 202117463414 A US202117463414 A US 202117463414A US 2022064823 A1 US2022064823 A1 US 2022064823A1
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Prior art keywords
yarn
hybrid
hybrid fabric
fabric
welded
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US17/463,414
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English (en)
Inventor
Luke Michael Haverhals
Shokoofeh Ghasemi
Aaron Kenneth Amstutz
Margaret Kathryn Firman
Spencer Jacob Null
Steven John Zika
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Natural Fiber Welding Inc
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Natural Fiber Welding Inc
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Priority to US17/463,414 priority Critical patent/US20220064823A1/en
Assigned to Natural Fiber Welding, Inc. reassignment Natural Fiber Welding, Inc. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FIRMAN, MARGARET KATHRYN, NULL, SPENCER JACOB, ZIKA, STEVEN JOHN, AMSTUTZ, AARON KENNETH, GHASEMI, Shokoofeh, HAVERHALS, LUKE MICHAEL
Publication of US20220064823A1 publication Critical patent/US20220064823A1/en
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    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/04—Blended or other yarns or threads containing components made from different materials
    • D02G3/042—Blended or other yarns or threads containing components made from different materials all components being made from natural material
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
    • D04B1/16—Other fabrics or articles characterised primarily by the use of particular thread materials synthetic threads
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
    • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/01—Natural vegetable fibres
    • D10B2201/02—Cotton
    • 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
    • D10B2401/00—Physical properties
    • D10B2401/02—Moisture-responsive characteristics
    • 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
    • D10B2401/00—Physical properties
    • D10B2401/02—Moisture-responsive characteristics
    • D10B2401/022—Moisture-responsive characteristics hydrophylic
    • 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
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/01—Surface features
    • D10B2403/011—Dissimilar front and back faces

Definitions

  • the present disclosure related to hybrid materials, methods for producing hybrid materials, and products that may be made from those hybrid materials.
  • Taiwanese patent, TW201623712A discloses the blending of different fiber types into yarn and making a hybrid structure using those yarn combinations. That invention uses synthetic fibers with different fiber cross-sections. It is reported that blending fibers with different diameters will help improve the drying behavior of the fabric. The fabrics made using this method are reported to dry faster.
  • McMurray B. U.S. Pat. No. 7,465,683B2 worked on the two-sided warp knitted fabric, which has different yarns on different sides of the fabric. This effect has been achieved by using different guide bars and feeding different yarns to different guide bars specifically by combining the synthetic yarns with different surface properties in a fabric construction with different layers.
  • FIG. 1 is a graphical representation of the vertical wicking performance of welded and conventional cotton yarns.
  • FIG. 2 is a graphical representation of the vertical wicking performance of various jersey fabrics along the wale direction made from different ratios of welded cotton yarn and conventional cotton yarn.
  • FIG. 3 is a graphical representation of the vertical wicking performance of various jersey fabrics along the course direction made from different ratios of welded cotton yarn and conventional cotton yarn.
  • FIG. 4 is a graphical representation of the absorbency of various fabrics made from different ratios of welded cotton yarn and conventional cotton yarn.
  • FIG. 5A provides a schematic representation of an illustrative embodiment of a hybrid material configured as a hybrid fabric, wherein a fabric pattern and layers of different yarn types (welded and conventional) are visible for this illustrative embodiment of a hybrid fabric.
  • FIG. 5B provides a schematic representation of an illustrative embodiment of a hybrid material configured as a hybrid fabric, wherein a fabric pattern and layers of different yarn types are visible for this illustrative embodiment of a hybrid fabric.
  • FIG. 6 is a graphical representation of the vertical wicking performance in the course direction of various double pique fabrics made from different ratios of welded cotton yarn and conventional cotton yarn.
  • FIG. 7 is a graphical representation of the vertical wicking performance in the wale direction of various double pique fabrics made from different ratios of welded cotton yarn and conventional cotton yarn.
  • FIG. 8 is another graphical representation of the vertical wicking performance at ten minutes in the wale direction of various double pique fabrics made from different ratios of welded cotton yarn and conventional cotton yarn.
  • FIGS. 9A & 9B are schematic representations of moisture transfer across a fabric and moisture spreading on both sides of the fabric constructed entirely of conventional cotton yarn with the technical face down and technical face up, respectively.
  • FIGS. 10A & 10B are schematic representations of moisture transfer across a fabric and moisture spreading on both sides of the fabric constructed entirely of welded cotton yarn with the technical face down and technical face up, respectively.
  • FIGS. 11A & 11B are schematic representations of moisture transfer across the illustrative embodiment of a hybrid fabric and moisture spreading on both sides of the hybrid fabric shown in FIG. 5A (Combination A) with the technical face down and technical face up, respectively.
  • FIGS. 12A & 12B are schematic representations of moisture transfer across the illustrative embodiment of a hybrid fabric and moisture spreading on both sides of the hybrid fabric shown in FIG. 5B (Combination B) with the technical face down and technical face up, respectively.
  • FIG. 13 is a graphical representation of the one-way moisture transfer performance for various double pique fabrics made from different ratios of welded cotton yarn and conventional cotton yarn.
  • FIG. 14 is a graphical representation of the moisture spreading speed difference on the technical face compared to the technical back for various double pique fabrics made from different ratios of welded cotton yarn and conventional cotton yarn.
  • FIG. 15 is a graphical representation of the drying rate for various double pique fabrics made from different ratios of welded cotton yarn and conventional cotton yarn.
  • FIG. 16 is a graphical representation of the pilling ranking on the technical back for various double pique fabrics made from different ratios of welded cotton am and conventional cotton yarn.
  • FIG. 17 is a graphical representation of the breathability for various double pique fabrics made from different ratios of welded cotton yarn and conventional cotton yarn.
  • FIG. 18 is a graphical representation of the absorbency for various double pique fabrics made from different ratios of welded cotton yarn and conventional cotton yarn.
  • the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other components, integers or steps.
  • “Exemplary” means “an example of” and is not intended to convey an indication of a preferred or ideal embodiment. “Such as” is not used in a restrictive sense, but for explanatory purposes.
  • Weight substrate and/or “welded yarn” may be used to refer to a finished composite comprised of at least one natural substrate in which one or more individual fibers and/or particles have been fused or welded together via a process solvent acting upon biopolymers from either those fibers and/or particles and/or action upon another natural material within the substrate.
  • Yielding as used herein may refer to joining and/or fusion of materials by intimate intermolecular association of polymer.
  • Biopolymer refers to naturally occurring polymer (produced by life processes) as opposed to all polymers that may be synthetically derived from naturally occurring materials.
  • hybrid material may be configured as hybrid fabric structure and may be made of regular cotton yarn blended with a welded yarn or differently welded yarns blended together. It is contemplated that such a hybrid fabric in certain embodiments thereof may be configured as a “plated structure” as that term is generally used in the textile industry without limitation unless otherwise indicated in the following claims.
  • the yarn used in a hybrid material may be welded using any of the methods and/or structures disclosed in U.S. Pat. No. 10,982,381 and/or U.S. Pat. Pub. No. 2019/0106814 or any other suitable method and/or structure without limitation unless otherwise indicated in the following claims.
  • the hybrid fabric structure may be a hybrid fabric made with different ratios of welded yarn.
  • the structure may be designed in a way that improves the hybrid fabric moisture management performance (among other improvements to the hybrid fabric, such as reduced clinginess, reducing pilling, increased breathability, etc. without limitation unless otherwise indicated in the following claims) by inducing a synergistic effect of yarn blends.
  • the hybrid fabric structure may be a knit fabric in which the yarns can be engineered to be mostly present in one side of the hybrid fabric or be in the form of a sandwich inside the structure without limitation unless otherwise indicated in the following claims.
  • the resulting structure may have a significantly higher moisture transfer rate toward the outer surface of the hybrid fabric as compared to non-hybrid fabrics (those constructed of yarns that do not have differential properties, e.g., those constructed of 100% conventional yarn or 100% welded yarns that are welded but have relatively uniform morphologies and welding characteristics among the various welded yarns), and this property can be configured such that the resulting hybrid fabric has a moisture spreading speed higher on one side compared to that of the other side.
  • the blended hybrid structure may have moisture performance higher than that of a fabric made of conventional cotton yarn or a fabric made of 100% uniformly welded yarn in terms of absorbency, vertical wicking, moisture spreading speed, and/or one-way moisture transfer.
  • the hybrid fabrics have been found to wick more than four times faster than the regular cotton fabric.
  • specific moisture transfer characteristics of a given embodiment of a hybrid material are not limiting unless otherwise indicated in the following claims.
  • the hybrid fabric exhibits improved moisture performance.
  • fabrics with industrially acceptable moisture performance are produced using synthetic fibers or natural fiber with chemical finish.
  • a hybrid fabric according to the present disclosure may be constructed of 100% cotton with no chemical finishes, coatings, waxes, etc. while simultaneously exhibiting exceptional moisture properties that are nearly equal to, equal to, or greater than the corresponding properties found in fabrics of the prior art.
  • the scope of the present disclosure is not limited to exceptional moisture properties but extends to any property and/or characteristic of the hybrid fabric (e.g., hand, clinginess, resistance to pilling, etc.) without limitation unless otherwise indicated in the following claims.
  • the exceptional moisture properties of the hybrid fabric may be imparted thereto from the synergistic effect of combining two different types of yarns, which in this illustrative embodiment may consist of a conventional yarn and a welded yarn, into a single hybrid fabric.
  • a hybrid fabric may be comprised of two welded yarns, wherein one or more characteristics of a first welded yarn are different that the corresponding characteristic(s) of a second welded yarn. Accordingly, the scope of the hybrid fabric disclosed herein is not limited to embodiments of hybrid fabrics containing welded and conventional yarns blended together or differently welded yarns blended together unless otherwise indicated in the following claims.
  • any of the yarns used in a hybrid fabric configured according to the present disclosure may be produced from recycled fibers, virgin fibers, and/or combinations thereof without limitation unless otherwise indicated in the following claims.
  • hybrid fabric is a knit structure that may be a blend of welded cotton yarn and conventional cotton yarn that shows improvement in the moisture wicking and absorbency as well as the one-way moisture transfer and moisture spreading speed on different sides of the hybrid fabric.
  • the hybrid fabric may be configured such that the moisture transfer directionality is tunable to specify the location, rate, and/or direction at which the moisture transfer through the hybrid fabric occurs without limitation unless otherwise indicated in the following claims.
  • moisture transfer properties e.g., absorption rate, spreading rate, drying rate, etc.
  • other characteristics of the hybrid fabric e.g., reduced dinginess, desired hand, hairiness, elasticity, pilling, etc.
  • moisture transfer properties e.g., absorption rate, spreading rate, drying rate, etc.
  • other characteristics of the hybrid fabric e.g., reduced dinginess, desired hand, hairiness, elasticity, pilling, etc.
  • a hybrid fabric made of pure cotton without use of any chemical modification may be configured to have moisture performance (among other characteristics without limitation unless otherwise indicated in the following claims) that is superior to fabric constructed of conventional cotton.
  • An illustrative embodiment of a hybrid fabric construction may be engineered in a manner that the welded cotton yarn with conventional cotton blends in the structure of the hybrid fabric.
  • the blended structure may show synergistic increases in various moisture management properties, moisture wicking, air permeability, drying rate, reduction of clinginess, and/or pilling without limitation unless otherwise indicated in the following claims.
  • Hybrid fabrics made by blending welded and conventional cotton yarns exhibit higher vertical wicking compared to that of fabrics made with 100% welded yarn or 100% conventional cotton yarn.
  • An illustrative embodiment of the hybrid fabric may be designed to have the welded yarn mostly on one side thereof as opposed to having the welded yarn mostly in the middle of the structure.
  • hybrid fabrics having the welded yarn primarily on different sides of the hybrid fabrics, respectively were shown to have opposite one-way moisture transfer and spreading speeds on both sides of the hybrid fabric, and it is contemplated that this tunability may expand the number of applications for hybrid fabrics.
  • Various embodiments of a hybrid fabric may have vertical wicking significantly higher than that of a fabric made from all welded yarn among additional advantageous characteristics without limitation unless otherwise indicated in the following claims. This shows there may be a synergistic behavior of blending a conventional cotton yarn and a welded yarn, and/or blending two differently welded yarns together unless otherwise indicated in the following claims, in the hybrid fabric structure.
  • FIG. 1 A graphical representation of the measured vertical wicking performance of a welded cotton yarn bundle and a conventional cotton yarn bundle at the yarn level is shown in FIG. 1 , wherein the wicking distance in millimeters is shown versus time. Comparing the plots in FIG. 1 shows that welded yarn has significantly higher vertical wicking than the regular control cotton yarn.
  • the data collected to create the graph in FIG. 1 is shown below in Table 1. As calculated from the observed data recorded in Table 1, the average wicking rate for the welded yarn bundle over the entire 30-minute test was 3.9 mm/min and for the conventional yarn bundle was 0.8 mm/min, whereas the rate at ten minutes for the welded yarn bundle was 3.5 mm/min and the rate for the conventional yarn bundle was 1 nun/min.
  • the welded yarn bundle wicks at an average rate of approximately 4.7 times faster than that of the conventional yarn bundle and a 10-minute rate of approximately 3.2 times faster than that of the conventional yarn bundle.
  • other values of a differential in this metric between a welded yarn bundle and a conventional yarn bundle are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
  • the welded yarn bundle may wick at an average rate of approximately 1, 1.5, 2, 2.5, 3, 3,5 4, 5, or 6 times that of a corresponding conventional yarn bundle and/or may have a 10-minute rate of 1, 1.5, 2, 2.5, 3, or 3.5 times that of a corresponding conventional yarn bundle without limitation unless otherwise indicated in the following claims.
  • Blending the welded yarn with conventional yarn in various illustrative embodiments of a hybrid fabric structure was found to result in a hybrid fabric with synergistic improvement in the performance of the hybrid fabric compared to fabrics constructed of 100% conventional yarn or 100% welded yarn. Generally, the improvement was most evident in the moisture management of the hybrid fabric, but the scope of the present disclosure is not so limited in unless otherwise indicated in the following claims.
  • Different illustrative embodiments of hybrid fabrics with a blend of the welded yarn and conventional yarn were made and the hybrid fabric performance in contact with moisture showed improvement in the properties compared to non-hybrid fabrics.
  • the blending may result in better moisture transfer as the difference in different yarn's hairiness and/or morphology may result in faster wicking in the non-hairy areas without limitation unless otherwise indicated in the following claims.
  • hybrid fabrics may be constructed by blending a first welded yarn having a specific set of characteristics with a second welded yarn having a second specific set of characteristics, wherein at least one characteristic for the first welded yarn is different than the corresponding characteristic for the second welded yarn by a certain amount.
  • a difference in hairiness and/or stiffness between the two welded yarns may provide the characteristic differential between the two welded yarns used to create an embodiment of the hybrid fabric that exhibits the desired properties (e.g., reduced dinginess, increased wicking rate, increased breathability, moisture directionality, moisture spreading speed, etc.) without limitation unless otherwise indicated in the following claims.
  • This differential in characteristics may impart to the hybrid fabric a number of desirable qualities, such as superior moisture management, reduced pilling, reduced dinginess, increased breathability, etc. without limitation unless otherwise indicated in the following claims.
  • the conventional cotton yarn and fabric constructed therefrom that was used to collect the experimental data disclosed herein was not finished and configured as a Greige yarn and/or Greige fabric.
  • the conventional yarn that was processed to create a welded cotton yarn used in the fabrics made entirely from welded yarn and the illustrative embodiments of hybrid fabrics disclosed herein was not finished and configured as a Greige yarn, as was the conventional yarn blended with welded yarn to create the illustrative embodiments of hybrid fabrics disclosed herein. All test and/or empirical data reported herein was obtained after a minimum of three wash cycles of the fabric, wherein the laundering procedure was performed according to AATCC LP1. However, other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • the welded yarn used to create a fabric constructed entirely of welded yarn and that used to create a hybrid fabric has been subject to generally the same welding process such that all the welded yarn is relatively uniform for a given fabric or hybrid fabric.
  • the scope of the present disclosure is not so limited and the yarn used to create welded yarns for hybrid fabrics and/or the conventional yarns blended with welded yarns to create hybrid fabrics may be differently configured (e.g., bleached, scoured, otherwise finished, combinations thereof, etc.) without limitation unless otherwise indicated in the following claims.
  • FIG. 2 A graphical representation of the vertical wicking performance (in millimeters n the wale direction of four different jersey fabrics made from different ratios of welded yarn to conventional yarn is shown in FIG. 2 at various points in time.
  • the vertical wicking performance as disclosed herein may be generally referred to as planar wicking performance without limitation unless otherwise indicated in the following claims.
  • the data collected to create the graph in FIG. 2 is shown below in Table 2, wherein the test was performed utilizing the AATCC 197 Test Method. However, other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • the average wicking rate over the entire 30-minute test and the rate at 10 minutes for the fabric constructed entirely of conventional yarn test were both 0.94 min/min, for the hybrid fabric constructed of 25% welded yarn and the remainder conventional yarn 4.3 and 4.6 min/min, for the hybrid fabric constructed of 50% welded yarn and the remainder conventional yarn 4.0 and 4.6 min/min, and for the fabric constructed entirely of welded yarn 1.9 and 1.9 min/min, respectively.
  • the hybrid fabric constructed of 25% welded yarn and the remainder conventional yarn wicks in this direction at an average rate of approximately 4.6 times faster and a 10-minute rate of approximately 4.8 times faster than the corresponding rates of the fabric constructed entirely of conventional yarn.
  • the hybrid fabric constructed of 50% welded yarn and the remainder conventional yarn wicks in this direction at an average rate of approximately 4.3 times faster and a 10-minute rate of approximately 4.9 times faster than the corresponding rates of the fabric constructed entirely of conventional yarn.
  • the hybrid fabric constructed of 25% welded yarn and the remainder conventional yarn wicks in this direction at an average rate of approximately 2.3 times faster and a 10-minute rate of approximately 2.4 times faster than the corresponding rates of the fabric constructed entirely of welded yarn.
  • the hybrid fabric constructed of 50% welded yarn and the remainder conventional yarn wicks in this direction at an average rate of approximately 2.2 times faster and a 10-minute rate of approximately 2.4 times faster than the corresponding rates of the fabric constructed entirely of welded yarn.
  • other values of a differential in this metric between a hybrid fabric and another fabric are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
  • the hybrid fabric may wick in the wale direction at an average rate and/or 10-minute rate that is 0.5, 1, 1.5, 2, or 2.5 times that of a corresponding fabric constructed entirely of conventional yarn without limitation unless otherwise indicated in the following claims.
  • FIG. 3 A graphical representation of the vertical wicking performance of jersey fabrics made from different ratios of welded yarn to conventional yarn in the course direction is shown in FIG. 3 , wherein vertical wicking in mm is again platted against time.
  • the data collected to create the graph in FIG. 3 is shown below in Table 3, wherein the test was performed utilizing the AATCC 197 Test Method.
  • Table 3 A graphical representation of the vertical wicking performance of jersey fabrics made from different ratios of welded yarn to conventional yarn in the course direction is shown in FIG. 3 , wherein vertical wicking in mm is again platted against time.
  • Table 3 The data collected to create the graph in FIG. 3 is shown below in Table 3, wherein the test was performed utilizing the AATCC 197 Test Method.
  • other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • 50% blended hybrid fabric i.e., half welded yarn and half conventional yarn
  • jersey hybrid fabric made with 50% welded yarn and the remainder conventional yarn exhibits more than two times higher vertical wicking than that of the fabric made from conventional cotton yarn at 10 minutes.
  • the hybrid fabric constructed of 25% welded yarn and the remainder conventional yarn wicks at an average rate of approximately 34% faster and a 10-minute rate of approximately 47% faster than the corresponding rates of the fabric constructed entirely of conventional yarn.
  • the hybrid fabric constructed of 50% welded yarn and the remainder conventional yarn wicks in this direction at an average rate of approximately 118% faster and a 10-minute rate of approximately 154% faster than the corresponding rates of the fabric constructed entirely of conventional yarn.
  • the hybrid fabric constructed of 25% welded yarn and the remainder conventional yarn wicks in this direction at an average rate of approximately 22% faster and a 10-minute rate of approximately 17% faster than the corresponding rates of the fabric constructed entirely of welded yarn.
  • the hybrid fabric constructed of 50% welded yarn and the remainder conventional yarn wicks in this direction at an average rate of approximately 99% faster and a 10-minute rate of approximately 103% faster than the corresponding rates of the fabric constructed entirely of welded yarn.
  • other values of a differential in this metric between a hybrid fabric and another fabric are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
  • the hybrid fabric may wick in the course direction at an average rate and/or 10-minute rate that is 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, or 200% faster than that of a corresponding fabric constructed entirely of conventional yarn without limitation unless otherwise indicated in the following claims.
  • FIG. 4 A graphical representation of the absorbency of various jersey fabrics made from different ratios of welded yarn to conventional yarn is shown in FIG. 4 .
  • the data collected to create the graph in FIG. 4 is shown below in Table 4, wherein the test was performed utilizing the AATCC 79 Test.
  • Table 4 The data collected to create the graph in FIG. 4 is shown below in Table 4, wherein the test was performed utilizing the AATCC 79 Test.
  • other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • hybrid fabric constructed of only 17% welded yarn and the remainder conventional yarn results in approximately a 68% decrease of the absorbency time.
  • a hybrid fabric constructed of 25% welded yarn and the remainder conventional yarn exhibits an even greater decrease measured at approximately an 81% decrease, whereas a hybrid fabric constructed of 50% welded yarn and the remainder conventional yarn exhibits still greater decrease measured at approximately 93%.
  • other values of a differential in this metric between a hybrid fabric and another fabric are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
  • the hybrid fabric may have an absorbency that represents a 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75.
  • the hybrid fabric may exhibit an absorbency time of 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second in other illustrative embodiments. This shows the synergistic effect for at least moisture management properties of blending welded yarn and regular cotton together in a hybrid fabric.
  • FIGS. 5A & 5B therein is shown a schematic representation of a double pique single knit fabric, which may be configured as a hybrid material (e.g., a hybrid fabric in this illustrative embodiment) having a portion of the yarns therein comprised of a welded yarn and a second portion of the yarns therein comprised of a conventional yarn (which may be raw or unwelded without limitation unless otherwise indicated in the following claims).
  • a hybrid material e.g., a hybrid fabric in this illustrative embodiment
  • 50% of the yarn is welded yarn and 50% is conventional cotton yarn.
  • the optimal ratio of welded yarn to conventional yarn may vary at least depending on the intended application for the hybrid fabric, and that ratio is therefor in no way limiting to the scope of the present disclosure unless otherwise indicated in the following claims.
  • the type of natural material used for either the welded yarn or conventional yarn e.g., cotton, wool, silk, hemp, etc.
  • the type of natural material used for either the welded yarn or conventional yarn may vary from one embodiment of a hybrid material as disclosed herein without limitation unless otherwise indicated in the following claims.
  • variables include but are not limited to: (1) configuration of the conventional yarn (e.g., chemical composition, physical attributes, ratio used in the hybrid fabric, etc.); (2) configuration of the welded yarn (e.g., chemical composition, physical attributes, ratio used in the hybrid fabric, degree and location of the welding, etc.; (3) fabric construction method (e.g., different types of knitting, weaving, plating, matting, etc.); (4) relative positions of the yarns, welded and unwelded with respect to one another, other components of the hybrid fabric, which surface constitutes the interior or exterior during intended use, etc.
  • configuration of the conventional yarn e.g., chemical composition, physical attributes, ratio used in the hybrid fabric, etc.
  • configuration of the welded yarn e.g., chemical composition, physical attributes, ratio used in the hybrid fabric, degree and location of the welding, etc.
  • fabric construction method e.g., different types of knitting, weaving, plating, matting, etc.
  • FIGS. 5A & 5B two illustrative embodiments of a hybrid fabric are shown therein, wherein the two illustrative embodiments provide two constructions of a hybrid fabric with the welded yarn being positioned primarily in the middle of the hybrid fabric in FIG. 5A and positioned primarily toward the bottom of the hybrid fabric in FIG. 5B (from the vantage shown on left side of FIG. 5B ).
  • the schematic representation of the yarns in a double pique fabric structure configured as a hybrid fabric as shown in FIGS. 5A & 5B wherein the welded yarns and conventional yarns are shown in different shading.
  • these two embodiments are for illustrative purposes only and a large number of additional embodiments exist that are included within the scope of the present disclosure unless otherwise indicated in the following claims.
  • the two different illustrative combinations of welded and conventional yarn shown in FIGS. 5A & 5B for illustrative embodiments of a hybrid fabric provide two different illustrative combinations of welded and conventional yarns, which in these illustrative embodiments may be comprised of cotton.
  • the optimal chemical composition of the materials used to construct a hybrid material and/or hybrid fabric may vary from one application to the next and is therefore in no way limiting to the scope of the present disclosure unless otherwise indicated in the following claims.
  • the two illustrative hybrid fabrics shown in FIGS. 5A & 5B provide examples of two differing pique fabrics with a first illustrative embodiment of construction shown in FIG.
  • FIG. 5A configured such that the welded yarn may be positioned primarily toward the interior of the hybrid fabric as compared to a second illustrative embodiment of construction shown in FIG. 5B showing a pique construction of a hybrid fabric wherein the welded yarn max be positioned primarily on the technical back of the hybrid fabric from the vantage shown on the left side of FIG. 5B .
  • the optimal construction of a hybrid fabric may vary from one application to the next and is therefor in no way limiting to the scope of the present disclosure unless otherwise indicated in the following claims.
  • FIG. 6 A graphical representation of the vertical wicking performance in the course direction of various pique fabrics made from different ratios of welded yarn to conventional yarn is shown in FIG. 6 .
  • the data collected to create the graph in FIG. 6 is shown below in Table 5, wherein the test was performed utilizing the AATCC 197 Test Method.
  • Table 5 The data collected to create the graph in FIG. 6 is shown below in Table 5, wherein the test was performed utilizing the AATCC 197 Test Method.
  • other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • the pique hybrid fabric constructed of 50% welded yarn and the remainder conventional yarn wicks in the course direction at an average rate of approximately 5.2 times faster and a 10-minute rate of approximately 3.7 times faster than the corresponding rates of the fabric constructed entirely of conventional yarn.
  • the pique hybrid fabric constructed of 50% welded yarn and the remainder conventional yarn wicks at an average rate of approximately 28% faster and a 10-minute rate of approximately 37.7% faster than the corresponding rates of the fabric constructed entirely of welded yarn.
  • other values of a differential in this metric between a hybrid fabric and another fabric are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
  • the hybrid fabric may wick in the course direction at an average rate and/or 10-minute rate that is i0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, or 5.5 times that of a corresponding fabric constructed entirely of conventional yarn without limitation unless otherwise indicated in the following claims.
  • FIG. 7 A graphical representation of the vertical wicking performance in the wale direction of various pique fabrics made from different ratios of welded yarn to conventional yarn is shown in FIG. 7 .
  • the data collected to create the graph in FIG. 7 is shown below in Table 6, wherein the test was performed utilizing the AATCC 197 Test Method.
  • Table 6 The data collected to create the graph in FIG. 7 is shown below in Table 6, wherein the test was performed utilizing the AATCC 197 Test Method.
  • other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • the pique hybrid fabric constructed of 50% welded yarn and the remainder conventional yarn wicks in the wale direction at an average rate of approximately 3.8 times faster and a 10-minute rate of approximately 2.5 times faster than the corresponding rates of the fabric constructed entirely of conventional yarn.
  • the pique hybrid fabric constructed of 50% welded yarn and the remainder conventional yarn wicks at an average rate of approximately 23% faster and a 10-minute rate of approximately 21% faster than the corresponding rates of the fabric constructed entirely of welded yarn.
  • comparing the wicking at 10 minutes shows that the hybrid fabric made using 50% welded yarn and 50% conventional yarn wicks more than two times faster than the fabric made entirely from the conventional cotton and also significantly faster than the fabric made entirely from welded yarn.
  • the hybrid fabric may wick in the wale direction at an average rate and/or 10-minute rate that is 0.5, 1, 1.5, 2, 2.5, 3, 3.5, or 4 times that of a corresponding fabric constructed entirely of conventional yarn without limitation unless otherwise indicated in the following claims.
  • FIG. 8 Another graphical representation of the vertical wicking performance in the course direction of various pique fabrics made from different ratios of welded yarn to conventional yarn is shown in FIG. 8 after ten minutes, wherein the specific hybrid fabric construction shown in FIGS. 5A & 5B was tested.
  • the data collected to create the graph in FIG. 8 is shown below in Table 7, wherein the test was performed utilizing the AATCC 197 Test Method.
  • test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • both the hybrid fabrics of Combination A and Combination B wicked a distance of approximately 4.7 times greater than that that of the fabric constructed entirely of conventional yarn in this direction.
  • Those hybrid fabrics also wicked a distance of approximately 19% and 18% further than that of the fabric constructed entirely of welded yarn.
  • This shows the synergistic effect of blending welded yarns and conventional yarns in the hybrid fabric structure.
  • the illustrative embodiments of construction of a pique hybrid fabric shown in FIGS. 5A & 5B (Combination A and B, respectively) were found to wick significantly faster than the fabric made entirely from conventional cotton yarn in the course direction and also significantly faster than the fabric made entirely from welded yarn.
  • the hybrid fabric may wick a distance at 10 minutes in the course direction that is 0.5, 1, 1.5, 2, 2.5, 3, 3,5, 4, 4.5, or 5 times that of a corresponding fabric constructed entirely of conventional yarn without limitation unless otherwise indicated in the following claims.
  • FIGS. 9A-12B A schematic depiction of moisture transfer across two different fabrics and two different hybrid fabrics is shown in FIGS. 9A-12B , wherein the fabrics and hybrid fabrics are shown with a wet surface/moisture source positioned above the respective fabrics and hybrid fabrics.
  • the oval above the fabric or hybrid fabric represents a moisture source/moisture adjacent that particular face of the fabric or hybrid fabric.
  • the technical back of the fabric or hybrid fabric is positioned adjacent the moisture source (which may be a wearer's skin for certain illustrative applications of a hybrid fabric without limitation unless otherwise indicated in the following claims) and the technical face thereof is positioned opposite the moisture source.
  • the moisture source which may be a wearer's skin for certain illustrative applications of a hybrid fabric without limitation unless otherwise indicated in the following claims
  • the technical face of the fabric or hybrid fabric is positioned adjacent the moisture source (which again may be a wearer's skin for certain illustrative applications of a hybrid fabric without limitation unless otherwise indicated in the following claims) and the technical back is positioned opposite the moisture source.
  • the trapezoid shape within the fabric or hybrid fabric represents the moisture transfer characteristics, wherein the length of either parallel side represents the relative spreading speed on that side/face of the fabric or hybrid fabric such that the difference in length of the parallel sides thereof represents the relative difference in spreading speed between the two sides/faces thereof (a longer side having a higher relative spreading speed than a shorter side). Accordingly, the longer the parallel side of the trapezoid, the greater the moisture spreading speed and vice versa. The greater the difference in length between the parallel sides of the trapezoid, the greater the relative difference in moisture spreading speed between the two faces of the fabric or hybrid fabric.
  • FIGS. 9A-12B these four different fabrics will perform differently when in contact with water and/or a moisture source.
  • the test was conducted on both sides of the fabrics and hybrid fabrics, and one would expect to see opposite results if a fabric or hybrid fabric exhibits directionality regarding moisture transfer otherwise the fabric and/or hybrid fabric is merely porous, and the force of gravity is primarily or exclusively the cause of transferring the moisture through the fabric or hybrid fabric.
  • the hybrid fabrics in FIGS. 11A-12B exhibit preferential one-way moisture transfer from one side to other (i.e., technical-face-to-technical-hack direction and vice versa) and higher moisture spreading speed at one side of the hybrid fabric than the other as described in further detail below.
  • FIGS. 9A & 9B A fabric constructed entirely of conventional cotton yarn is shown in FIGS. 9A & 9B with the technical face down and with the technical face up, respectively.
  • the small size of the trapezoid and the small difference between the lengths of the parallel sides therein as shown in FIGS. 9A & 9B indicate that and there is virtually no directionality in moisture transfer and a generally small moisture spreading speed for both sides of the fabric (e.g., technical face and technical back).
  • FIGS. 10A & 10B depict the moisture transfer across a fabric constructed of 100% welded yarn with the technical face down (e.g., adjacent the moisture source) and with the technical face up (e.g., opposite the moisture source). It is evident that there is a small directionality for moisture transfer toward. the technical face of the fabric. However, this directionality (and the delta of the spreading speed between both sides/faces) of moisture transfer are not tunable. The larger size of the trapezoid here compared to that in FIGS.
  • FIGS. 11A & 11B The first illustrative embodiment of construction of a pique hybrid fabric is shown in FIGS. 11A & 11B (Combination A from FIG. 5A ) and the second illustrative embodiment thereof (Combination B from FIG. 5B ) is shown in FIGS. 12A & 12B , wherein the orientation is the same as that previously described for FIGS. 9A & 9B .
  • FIGS. 11A & 11B depict the moisture transfer across the hybrid fabric shown in FIG. 5A (50% welded yarn and 50% conventional yarn) with the technical face down and with the technical face up, respectively.
  • the parallel side of the trapezoid on the technical face is longer than that on the technical hack, and there is a relatively large difference in the lengths of the parallel sides of the trapezoid compared to those shown in FIGS. 9A-10B ).
  • this directionality (and the delta of the spreading speed between both sides/faces) of moisture transfer are tunable unlike those properties as observed in the fabric constructed entirely from welded yarn and/or those in the fabric constructed entirely from conventional yarn.
  • FIGS. 12A & 12B depict the moisture transfer across the hybrid fabric shown in FIG. 5B (50% welded yarn and 50% conventional yarn) with the technical face down and with the technical face up, respectively.
  • the parallel side of the trapezoid on the technical back is longer than that on the technical face, and there is a relatively large difference in the lengths of the parallel sides of the trapezoid compared to those shown in FIGS. 9A-10B ).
  • this directionality (and the delta of the spreading speed between both sides/faces) of moisture transfer are tunable unlike those properties as observed in the fabric constructed entirely from welded yarn and/or those of the fabric constructed entirely from conventional yarn.
  • the results observed in both hybrid fabrics may be attributable to the superior moisture management performance/properties of the hybrid fabric as well as the ability to tune certain characteristics to optimize the performance of the hybrid fabric for a specific application in contrast to both fabrics constructed entirely of conventional yarn and those constructed entirely of welded yarn.
  • FIGS. 5A & 5B A graphical representation of the one-way moisture transfer rate of the hybrid fabrics shown in FIGS. 5A & 5B (Combination A and Combination B, respectively) is shown and compared with that of the fabric made entirely of welded yarn and that of the fabric made entirely of conventional yarn in FIG. 13 (measured with both the technical face down and the technical face up).
  • the data collected to create the graph in FIG. 13 is shown below in Table 8, wherein the test was performed utilizing the AATCC 195 Test Method.
  • other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • the hybrid fabrics of Combination A and Combination B exhibited a difference of one-way moisture transfer with the technical face down compared to that with the technical face up of 246.4 and 154.2, respectively.
  • the pique fabric constructed entirely of conventional yarn exhibits a difference of only 67.15 and the pique fabric constructed entirely of welded yarn exhibits a difference of only 54.54. That is, the hybrid fabric of Combination A exhibited a one-way moisture transfer rate differential when tested on the technical face compared to When tested on the technical back that was approximately 3.6 times higher than that differential for the pique fabric constructed entirely of conventional yarn and approximately 4.5 times higher than that differential for the pique fabric constructed entirely of welded yarn.
  • the hybrid fabric of Combination B exhibited a one-way moisture transfer rate differential when tested on the technical face compared to when tested on the technical back that was approximately 2.3 times higher than that differential for the pique fabric constructed entirely of conventional yarn and approximately 2.8 times higher than that differential for the pique fabric constructed entirely of welded yarn.
  • the differential in one-way moisture transfer of the technical face compared to the technical back for the pique fabric constructed entirely of conventional yarn was only approximately 49%, that of both Combination A and Combination B for the pique hybrid fabrics was much greater than 50%, with one value for each being negative and the reverse value being positive.
  • other values of a differential in this metric between a hybrid fabric and another fabric are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
  • the differential in one-way moisture transfer of the technical face compared to that of the technical back may be 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100% without limitation unless otherwise indicated in the following claims. Additionally, this differential may be 0.5, 1.0, 1.5, 2, 2.5, 3, or 3.5 times higher than that of a corresponding fabric constructed entirely of conventional yarn unless otherwise indicated in the following claims.
  • FIGS. 5A & 5B A graphical representation of the moisture spreading speed delta of the hybrid fabrics shown in FIGS. 5A & 5B (Combination A and Combination B, respectively) is shown and compared with that of the fabric made entirely of welded yarn and that of the fabric made entirely of conventional yarn in FIG. 14 (measured with both the technical face down and the technical face up).
  • the data collected to create the graph in FIG. 14 is shown below in Table 9, wherein the test was performed utilizing the AATCC 195 Test Method.
  • other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • the delta spreading speed with the technical face down for the fabric constructed entirely of conventional yarn was ⁇ 0.242 mm/s
  • for the fabric constructed entirely of welded yarn was ⁇ 0.415 mm/s
  • for the first illustrative embodiment of construction of a pique hybrid fabric (Combination A, shown in FIG. 5A ) constructed of 50% welded yarn and the remainder conventional yarn was 1.422 mm/s
  • for the second illustrative embodiment of construction of a pique hybrid fabric (Combination B, shown in FIG. 5B ) constructed of 50% welded yarn and the remainder conventional yarn was ⁇ 0.836 mm/s.
  • the measured delta spreading speed with the technical face up for the fabric constructed entirely of conventional yarn, the first illustrative embodiment of construction of a pique hybrid fabric shown in FIG. 5A , the second illustrative embodiment of construction of a pique hybrid fabric shown in FIG. 5B , and the fabric constructed entirely of welded yarn were ⁇ 0.273, 0.1586, ⁇ 0.7611, and 0.9573 mm/s, respectively,
  • both the pique hybrid fabrics of Combination A and Combination B exhibited a much higher delta in the spreading speed with the technical face down compared to with the technical face up compared to that of both the pique fabric constructed entirely of conventional yarn and the pique fabric constructed entirely of welded yarn.
  • Combination A and Combination B exhibited a delta in spreading speed between top and bottom surfaces with the technical face down compared to that with the technical face up of 2.183 and 1.793, respectively.
  • the pique fabric constructed entirely of conventional yarn exhibits a difference of only 0.031 and the fabric constructed entirely of welded yarn exhibits a difference of only 0.573.
  • the hybrid fabric of Combination A exhibited a delta in the spreading speed when tested on the technical face compared to when tested on the technical back that was approximately 70 times greater than that differential for the pique fabric constructed entirely of conventional yarn and approximately 3.8 times higher than that differential for the pique fabric constructed entirely of welded yarn.
  • the hybrid fabric of Combination B exhibited a delta in spreading speed when tested on the technical face compared to when tested on the technical back that was approximately 57 times higher than that differential for the pique fabric constructed entirely of conventional yarn and approximately 3.1 times higher than that differential for the pique fabric constructed entirely of welded yarn.
  • the delta in spreading speed of the top and bottom surface of the hybrid fabric when tested on the technical face compared to the technical back for the pique fabric constructed entirely of conventional yarn was only approximately 11%, that of both Combination A and Combination B for the pique hybrid fabrics was much greater than 15%, with one value for each being negative and the reverse value being positive.
  • a differential in this metric between a hybrid fabric and another fabric are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
  • the delta between the spreading speed of the technical face compared to that of the technical back may be 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 185, 190, 195, 200% or even higher without limitation unless otherwise indicated in the following claims.
  • this differential may be 0.5, 1.0, 1.5, 2, 2.5, 3, or 3.5 times higher than that of a corresponding fabric constructed entirely of conventional yarn unless otherwise indicated in the following claims.
  • the fabric constructed entirely of conventional yarn exhibits a constant delta, which is an indication of the fabric being porous and not providing directionality in transfer of moisture. While the fabric constructed entirely of welded yarn exhibits two opposite deltas, which is an indication of the directionality in the transfer of moisture through the structure of the hybrid fabric. It is important to notice that this delta is small and is not tunable for a fabric constructed one type of yarn (e.g., a fabric made 100% of one type of welded yarn, wherein the welding process results in relatively uniform characteristics along the length of the welded yarn or fabric made 100% of conventional yarn). Blending two different yarns with different hairiness and surface properties has resulted in two hybrid fabrics with higher deltas and opposite directionalities for transfer of water. The moisture management may be tested by placing a given amount of water on one surface of the hybrid fabric and measuring the time and the amount of water that spreads on each side of the hybrid fabric as well as the amount of moisture transferred through the thickness of the hybrid fabric.
  • a pique hybrid fabric may be constructed to have two different sides (sometimes referred to herein as a “technical face” and a “technical back”). Accordingly, it has been observed that the illustrative embodiment of construction referred to as “Combination B” will preferentially transfer water from technical face to technical back (technical face up positive), and thus may be especially suitable for an application wherein the technical back may be positioned as the outside of the hybrid fabric.
  • Combination A will preferentially transfer water from technical back to technical face (technical face down positive), and thus may be especially suitable for an application wherein the technical face may be positioned as the outside of the hybrid fabric.
  • FIGS. 5A & 5B A graphical representation of the dry rate of the hybrid fabrics shown in FIGS. 5A & 5B (Combination A and Combination B, respectively) is shown and compared with that of the fabric made entirely of welded yarn and that of the fabric made entirely of conventional yarn in FIG. 15 (measured with both the technical face down and the technical face up).
  • the data collected to create the graph in FIG. 15 is shown below in Table 10, wherein the test was performed utilizing the AATCC 201 Test Method.
  • other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • the dry rate for the fabric constructed entirely of conventional yarn was 0.65 mL/hr
  • for the fabric constructed entirely of welded yarn was 0.73 mL/hr
  • for both the hybrid fabrics (Combination A and Combination B, shown in FIGS. 5A & 5B , respectively) constructed of 50% welded yarn and the remainder conventional yarn was 0.77 mL/hr.
  • both the hybrid fabrics of Combination A and Combination B dried at a rate of approximately 18% faster than that that of the fabric constructed entirely of conventional yarn.
  • Those hybrid fabrics also dried at a rate of approximately 5% faster than that of the fabric constructed entirely of welded yarn.
  • Contrasting the drying rate of the two hybrid fabrics (Combination A and Combination B) with those of the fabric constructed of 100% conventional yarn and the fabric constructed of 100% welded yarn indicates that the hybrid fabrics exhibit an increased the drying rate compared to the other fabrics.
  • other values of a differential in this metric between a hybrid fabric and another fabric are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
  • the dry rate may be 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100% higher than that of a corresponding fabric constructed entirely of conventional yarn and/or may be 0.60, 0.65, 0.70, 0.75, or 0.80 mL/hr unless otherwise indicated in the following claims.
  • FIGS. 5A & 5B A graphical representation of the pilling of the hybrid fabrics shown in FIGS. 5A & 5B (Combination A and Combination B, respectively) is shown and compared with that of the fabric made entirely of welded yarn and that of the fabric made entirely of conventional yarn in FIG. 16 (measured on the technical back).
  • the data collected to create the graph in FIG. 16 is shown below in Table 11, wherein the test was performed utilizing the ISO 12945-2 procedure.
  • other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • the technical back of the various fabrics and hybrid fabrics were tested, as it is contemplated that the technical back may be configured as the exterior of a garment constructed of the fabric or hybrid fabric for many applications.
  • the technical back and/or technical face may be used for different applications and the orientation thereof for any hybrid fabric is in no way limiting unless otherwise indicated in the following claims.
  • other desirable characteristics exhibited by welded yarns previously known or later discovered may be imparted to hybrid fabrics comprised of a welded yarn alone or in combination without limitation unless otherwise indicated in the following claims.
  • FIGS. 5A & 5B A graphical representation of the breathability of the hybrid fabrics shown in FIGS. 5A & 5B (Combination A and Combination B, respectively) is shown and compared with that of the fabric made entirely of welded yarn and that of the fabric made entirely of conventional yarn in FIG. 17 .
  • the data collected to create the graph in FIG. 17 is shown below in Table 12. wherein the test was performed utilizing the ASTM D737 protocol. However, other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • the air permeability is shown in cubic feet per minute. As calculated from the observed data recorded in Table 12, the air permeability for the fabric constructed entirely of conventional yarn was 199 cfm, for the fabric constructed entirely of welded yarn was 538 cfm, for both the hybrid fabrics (Combination A and Combination B, shown in FIGS. 5A & 5B , respectively) constructed of 50% welded yarn and the remainder conventional yarn was 273 and 301 cfm, respectively.
  • the illustrative embodiments of construction of pique hybrid fabrics of Combination A and Combination B have an air permeability approximately 37% and 51% greater, respectively, than that that of the fabric constructed entirely of conventional yarn.
  • the fabric constructed entirely of welded yarn exhibits the highest breathability (i.e., measured air permeability) and the fabric constructed entirely of conventional yarn exhibits the lowest breathability.
  • the hybrid fabrics are in between those two values, with Combination B slightly higher than Combination A.
  • other values of a differential in this metric between a hybrid fabric and another fabric are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
  • the air permeability may be anywhere between 210 cfm to 500 cfm and/or have an air permeability that is 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100% higher than that of a corresponding fabric constructed entirely of conventional yarn unless otherwise indicated in the following claims.
  • FIGS. 5A & 5B A graphical representation of the absorbency of the two hybrid fabrics shown in FIGS. 5A & 5B (Combination A and Combination B, respectively) is shown and compared with that of a corresponding pique fabric made entirely of welded yarn and that of a corresponding pique fabric made entirely of conventional yarn in FIG. 18 .
  • the data collected to create the graph in FIG. 18 is shown below in Table 13. wherein the test was performed utilizing the AATCC 79 Test on the technical face of both pique hybrid fabrics shown in FIGS. 5A & 5B and those constructed entirely of conventional yarn and welded yarn.
  • other test methods, protocols, and/or procedures may be used without limitation unless otherwise indicated in the following claims.
  • the illustrative embodiments of construction of pique hybrid fabrics of Combination A and Combination B have an absorbency approximately 25 times and 17 times faster, respectively, than that that of the fabric constructed entirely of conventional yarn.
  • the fabric constructed entirely of welded yarn exhibits the highest absorbency.
  • other values of a differential in this metric between a hybrid fabric and another fabric are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
  • the absorbency may be 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, or 24 times that of a corresponding fabric constructed entirely of conventional yarn without limitation unless otherwise indicated in the following claims.
  • the hybrid fabric may exhibit an absorbency time of 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second in other illustrative embodiments.
  • hybrid materials may be configured as hybrid fabrics.
  • Those hybrid fabrics may be constructed by blending welded yarn and a conventional yarn.
  • the welded yarn and/or conventional yarn may be comprised of a naturally occurring biopolymer (e.g., cellulose, lignin, silk proteins, etc.), and in one illustrative embodiment the conventional yarn and welded yarn may be comprised entirely of a biopolymer such that no or virtually no synthetic materials are present in the hybrid fabric.
  • specific examples and experimental data may be attributable to hybrid fabrics constructed of a welded cotton yarn and a conventional cotton yarn, the scope of the present disclosure is not so limited and applies to any hybrid fabric exhibiting the desired characteristics unless otherwise indicated in the following claims.
  • the illustrative embodiments of hybrid fabrics may exhibit a significant increase the performance of the hybrid fabric compared to fabrics constructed with 100% conventional yarns or 100% welded yarns within a range of blending ratios. It is observed that in terms of vertical wicking and absorbency, even a hybrid fabric comprised of only 17% of welded yarn can significantly change the hybrid fabric performance compared to other fabrics.
  • the comparison between the vertical wicking of yarn bundles (as shown in FIG. 1 ) of the welded cotton and conventional cotton shows that the welded yarn wicks water more than three times faster than the conventional cotton yarn. Also, comparison of the vertical wicking of the pique fabrics ( FIGS.
  • both hybrid fabrics exhibit increased vertical wicking as compared to both the fabric constructed entirely of conventional yarn and that of the fabric constructed entirely of welded yarn. Additionally, the fabric made from the 100% welded yarn exhibits higher absorbency and higher vertical wicking as compared to the fabric made from 100% conventional yarn.
  • the pique hybrid fabrics may be designed in a variety of different combinations. As discussed above, the two illustrative embodiments of construction of pique hybrid fabrics disclosed herein were configured such that the placement of the yarns therein resulted in a first hybrid fabric wherein the welded yarn was primarily positioned on the back of the hybrid fabric and conventional yarn was primarily positioned on the front of the hybrid fabric. In a second illustrative embodiment of construction of a pique hybrid fabric the welded yarn was primarily positioned in the middle layer of the hybrid fabric and the conventional yarn was primarily positioned on the back of the hybrid fabric. However, other placements, orientations, positions, etc. of the welded yarn and conventional yarn may be used for a given embodiment of a hybrid fabric and the scope of the present disclosure is not so limited unless otherwise indicated in the following claims.
  • even feeder tuck stitches may be predominantly present on the back of the hybrid fabric.
  • the welded yarn may be preferentially placed on the even feeder tuck stitches or on the second repeat of the pattern (as shown at least in FIG. 5B ), and thus that yarn may be primarily positioned on the back of the hybrid fabric.
  • the welded yarn may be preferentially placed on the tuck stiches on the odd feeders or first repeat of the pattern and thus it may be primarily positioned on the middle of the hybrid fabric (as shown at least in FIG. 5A ).
  • the welded yarn may be characterized by relatively low hairiness, relative higher stiffness, and/or relative low water absorption into the yarn structure.
  • the hybrid fabric structure may wick the moisture through capillary movement of the water through inter-yarn spacing.
  • the presence of different yarn through the width of the hybrid fabric may induce faster moisture transfer through the width of the hybrid fabric and faster water absorbency through the width of the hybrid fabric.
  • the conventional yarns toward the middle of the hybrid fabric then may be able to help pull the water and transfer moisture away from the skin of the wearer of a garment from the technical face to the technical back of the pique hybrid fabric.
  • the conventional yarn in the technical back may help transfer the water from the technical back to the technical face of the hybrid fabric.
  • the regular yarn may wick by the absorption and wicking through the conventional yarn, which may provide faster absorption of the water from the wearer's skin (of a garment made with a hybrid fabric) and avoid/mitigate the feeling of the fabric clinging to the wearer.
  • the combination of the welded and conventional yarn in the both the jersey and pique hybrid fabrics results in synergistic increase in the vertical wicking of the hybrid fabrics by wicking in the capillary space created by the relatively stiffer welded yarns while the water is held in place by absorption within the yarn structure of the conventional yarns.
  • This combination of fast wicking and moisture holding is a unique characteristic of hybrid fabrics.
  • the actual mass of water uptake over time is superior to either that of a fabric made from 100% welded yarn and that of a fabric made from 100% conventional yarn.
  • the welded yarn that is used to construct a hybrid fabric is not limited to a specific morphology, degree of welding, apparatus and/or method used to construct the welded yarn, etc. and may include any welded yarns and/or methods for making same already known, disclosed herein, or later developed without limitation unless otherwise indicated in the following claims.
  • the yarns produced via a welding process used for a hybrid material as disclosed herein may be configured such that the chemical composition of a welded yarn is substantially the same as that of the corresponding conventional (e.g., raw, unwelded, etc.) substrate and/or yarn.
  • the chemical composition may be a biopolymer, and specifically may be cellulose, but other biopolymers may be used for other materials (e.g., wool, silk, etc.) without limitation unless otherwise indicated in the following claims.
  • any discrete process step and/or parameters therefor, and/or any apparatus for use therewith is not so limited so and extends to any beneficial and/or advantageous use thereof without limitation unless so indicated in the following claims.
  • any of the various features, components, functionalities, advantages, aspects, configurations, process steps, process parameters, etc, of a production process e.g., knitting weaving, etc.
  • a production process e.g., knitting weaving, etc.
  • any of the various features, components, functionalities, advantages, aspects, configurations, process steps, process parameters, etc, of a production process e.g., knitting weaving, etc.
  • a nearly infinite number of variations of the present disclosure exist. Modifications and/or substitutions of one feature, component, functionality, aspect, configuration, process step, process parameter, etc. for another in no way limit the scope of the present disclosure unless so indicated in the following claims.

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