Classifications

• • 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

• FIELD OF THE INVENTION 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 yam and making a hybrid structure using those yam 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. (US7465683B2) worked on the two-sided warp knitted fabric, which has different yams on different sides of the fabric. This effect has been achieved by using different guide bars and feeding different yams to different guide bars specifically by combining the synthetic yams with different surface properties in a fabric constmction with different layers.
• FIG. 1 is a graphical representation of the vertical wicking performance of welded and conventional cotton yams.
• 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 yam and conventional cotton yam.
• 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 yam and conventional cotton yam.
• FIG. 4 is a graphical representation of the absorbency of various fabrics made from different ratios of welded cotton yam and conventional cotton yam.
• FIG. 5 A 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 yam 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 yam 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 yam and conventional cotton yam.
• 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 yam and conventional cotton yam.
• 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 yam and conventional cotton yam.
• 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 yam 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 yam with the technical face down and technical face up, respectively.
• FIGS. 11 A & 1 IB 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. 5 A (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 yam and conventional cotton yam.
• 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 yam and conventional cotton yam.
• FIG. 15 is a graphical representation of the drying rate for various double pique fabrics made from different ratios of welded cotton yam and conventional cotton yam.
• 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 yam and conventional cotton yam.
• FIG. 17 is a graphical representation of the breathability for various double pique fabrics made from different ratios of welded cotton yam and conventional cotton yam.
• FIG. 18 is a graphical representation of the absorbency for various double pique fabrics made from different ratios of welded cotton yam and conventional cotton yam.
• 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 yam” 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 yam blended with a welded yam or differently welded yams 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 yam 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 yam.
• 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 yam blends.
• the hybrid fabric structure may be a knit fabric in which the yams 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 yams that do not have differential properties, e.g., those constructed of 100% conventional yam or 100% welded yams that are welded but have relatively uniform morphologies and welding characteristics among the various welded yams), 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 yam or a fabric made of 100% uniformly welded yam in terms of absorbency, vertical wi eking, 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 constmcted 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 yams, which in this illustrative embodiment may consist of a conventional yam and a welded yam, into a single hybrid fabric.
• yams which in this illustrative embodiment may consist of a conventional yam and a welded yam
• other illustrative embodiments of a hybrid fabric may be comprised of two welded yams, wherein one or more characteristics of a first welded yam are different that the corresponding characteristic(s) of a second welded yam.
• the scope of the hybrid fabric disclosed herein is not limited to embodiments of hybrid fabrics containing welded and conventional yams blended together or differently welded yams blended together unless otherwise indicated in the following claims.
• any of the yams 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 yam and conventional cotton yam 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 clinginess, desired hand, hairiness, elasticity, pilling, etc.
• reduced clinginess, desired hand, hairiness, elasticity, pilling, etc. also may be tunable to optimize those values for a specific application without limitation unless otherwise indicated in the following claims.
• 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 yam 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 yams exhibit higher vertical wicking compared to that of fabrics made with 100% welded yam or 100% conventional Lac yam.
• An illustrative embodiment of the hybrid fabric may be designed to have the welded yam mostly on one side thereof as opposed to having the welded yam mostly in the middle of the structure.
• hybrid fabrics having the welded yam 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 wi eking significantly higher than that of a fabric made from all welded yam 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 Lac yam and a welded yam, and/or blending two differently welded yams 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 Lac yam bundle and a conventional Lac yam bundle at the yam 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 yam has significantly higher vertical wicking than the regular control Lac yam.
• Table 1 The data collected to create the graph in FIG. 1 is shown below in Table 1.
• the average wicking rate for the welded yam bundle over the entire 30-minute test was 3.9 mm/min and for the conventional yam bundle was 0.8 mm/min, whereas the rate at ten minutes for the welded yam bundle was 3.5 mm/min and the rate for the conventional yam bundle was 1 mm/min. Accordingly, the welded yam bundle wicks at an average rate of approximately 4.7 times faster than that of the conventional yam bundle and a 10-minute rate of approximately 3.2 times faster than that of the conventional yam bundle.
• a differential in this metric between a welded yam bundle and a conventional yam bundle are included within the scope of the present disclosure without limitation unless otherwise indicated in the following claims.
• the welded yam 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 yam 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 yam bundle without limitation unless otherwise indicated in the following claims.
• Blending the welded yam with conventional yam 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 constmcted of 100% conventional yam or 100% welded yam. 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 yam and conventional yam 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 yam’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 yam having a specific set of characteristics with a second welded yam having a second specific set of characteristics, wherein at least one characteristic for the first welded yam is different than the corresponding characteristic for the second welded yam by a certain amount.
• a difference in hairiness and/or stiffness between the two welded yams may provide the characteristic differential between the two welded yams used to create an embodiment of the hybrid fabric that exhibits the desired properties (e.g., reduced clinginess, increased wi eking 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 clinginess, increased breathability, etc. without limitation unless otherwise indicated in the following claims.
• the conventional cotton yam and fabric constructed therefrom that was used to collect the experimental data disclosed herein was not finished and configured as a Greige yam and/or Greige fabric.
• the conventional yam that was processed to create a welded cotton yam used in the fabrics made entirely from welded yam and the illustrative embodiments of hybrid fabrics disclosed herein was not finished and configured as a Greige yam, as was the conventional yam blended with welded yam 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 yam used to create a fabric constmcted entirely of welded yam and that used to create a hybrid fabric has been subject to generally the same welding process such that all the welded yam is relatively uniform for a given fabric or hybrid fabric.
• the scope of the present disclosure is not so limited and the yam used to create welded yams for hybrid fabrics and/or the conventional yams blended with welded yams 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) in the wale direction of four different j ersey fabrics made from different ratios of welded yam to conventional yam 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 yam test were both 0.94 mm/min, for the hybrid fabric constructed of 25% welded yam and the remainder conventional yam 4.3 and 4.6 mm/min, for the hybrid fabric constructed of 50% welded yam and the remainder conventional yam 4.0 and 4.6 mm/min, and for the fabric constructed entirely of welded yam 1.9 and 1.9 mm/min, respectively.
• the hybrid fabric constructed of 25% welded yam and the remainder conventional yam 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 yam.
• the hybrid fabric constructed of 50% welded yam and the remainder conventional yam 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 yam.
• the hybrid fabric constructed of 25% welded yam and the remainder conventional yam 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 yam.
• the hybrid fabric constructed of 50% welded yam and the remainder conventional yam 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 yam.
• 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 yam without limitation unless otherwise indicated in the following claims. Table 2.
• FIG. 1 A graphical representation of the vertical wi eking performance of jersey fabrics made from different ratios of welded yam to conventional yam in the course direction is shown in FIG.
• the hybrid fabric constmcted of 25% welded yam and the remainder conventional yam 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 constmcted entirely of conventional yam.
• the hybrid fabric constructed of 50% welded yam and the remainder conventional yam 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 constmcted entirely of conventional yam.
• the hybrid fabric constructed of 25% welded yam and the remainder conventional yam 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 constmcted entirely of welded yam.
• the hybrid fabric constmcted of 50% welded yam and the remainder conventional yam 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 yam.
• 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 constmcted entirely of conventional yam 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 yam to conventional yam 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 A graphical representation of the absorbency of various jersey fabrics made from different ratios of welded yam to conventional yam is shown in FIG. 4.
• the hybrid fabric may have an absorbency that represents a 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95% decrease in absorbency time compared to that of a corresponding fabric constructed entirely of conventional yam 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. This shows the synergistic effect for at least moisture management properties of blending welded yam 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 yams therein comprised of a welded yam and a second portion of the yams therein comprised of a conventional yam (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 yam is welded yam and 50% is conventional cotton yam.
• the optimal ratio of welded yam to conventional yam 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 yam or conventional yam e.g., cotton, wool, silk, hemp, etc.
• the type of natural material used for either the welded yam or conventional yam 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 yam (e.g., chemical composition, physical attributes, ratio used in the hybrid fabric, etc.); (2) configuration of the welded yam (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 yams, 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 yam e.g., chemical composition, physical attributes, ratio used in the hybrid fabric, etc.
• configuration of the welded yam 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. 5 A & 5B two illustrative embodiments of a hybrid fabric are shown therein, wherein the two illustrative embodiments provide two constmctions of a hybrid fabric with the welded yam being positioned primarily in the middle of the hybrid fabric in FIG. 5 A and positioned primarily toward the bottom of the hybrid fabric in FIG. 5B (from the vantage shown on left side of FIG. 5B).
• 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 yam shown in FIGS. 5 A & 5B for illustrative embodiments of a hybrid fabric provide two different illustrative combinations of welded and conventional yams, 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. 5 A & 5B provide examples of two differing pique fabrics with a first illustrative embodiment of constmction shown in FIG.
• FIG. 5A configured such that the welded yam may be positioned primarily toward the interior of the hybrid fabric as compared to a second illustrative embodiment of constmction shown in FIG. 5B showing a pique construction of a hybrid fabric wherein the welded yam may 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 yam to conventional yam 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 yam and the remainder conventional yam 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 yam.
• the pique hybrid fabric constmcted of 50% welded yam and the remainder conventional yam 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 constmcted entirely of welded yam.
• 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 constmcted entirely of conventional yam without limitation unless otherwise indicated in the following claims.
• the illustrative embodiment of a pique hybrid fabric constructed of 50% welded yam and 50% conventional yam was found to wick almost four times faster than the fabric made entirely from conventional cotton in the course direction and also significantly faster than the fabric made entirely from welded yam.
• FIG. 7 A graphical representation of the vertical wicking performance in the wale direction of various pique fabrics made from different ratios of welded yam to conventional yam 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 A graphical representation of the vertical wicking performance in the wale direction of various pique fabrics made from different ratios of welded yam to conventional yam is shown in FIG. 7.
• 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 yam and the remainder conventional yam 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 yam.
• the pique hybrid fabric constructed of 50% welded yam and the remainder conventional yam 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 constmcted entirely of welded yam.
• the hybrid fabric made using 50% welded yam and 50% conventional yam 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 yam.
• 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, 2.5, 3, 3.5, or 4 times that of a corresponding fabric constmcted entirely of conventional yam without limitation unless otherwise indicated in the following claims. Table 6.
• FIG. 8 Another graphical representation of the vertical wicking performance in the course direction of various pique fabrics made from different ratios of welded yam to conventional yam is shown in FIG. 8 after ten minutes, wherein the specific hybrid fabric construction shown in FIGS. 5 A & 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.
• other 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 yam 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 yam.
• 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 yam in the course direction and also significantly faster than the fabric made entirely from welded yam.
• 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 yam 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.
• 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-back 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 yam 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. 9 A & 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 yam 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. 9 A & 9B indicates that the fabric constructed entirely of welded cotton exhibits higher moisture spreading speeds on both sides of the fabric (e.g., technical face and technical back) compared to that of the fabric constructed entirely of conventional yam.
• the small difference in the lengths of the parallel sides of the trapezoid as shown in FIGS. 10A & 10B indicate that there is virtually no directionality in moisture transfer from one side of the fabric to the other (e.g., technical-face-to-technical-back direction and vice versa).
• the first illustrative embodiment of construction of a pique hybrid fabric is shown in FIGS. 11 A & 1 IB (Combination A from FIG. 5 A) 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. 11 A & 1 IB depict the moisture transfer across the hybrid fabric shown in FIG. 5A (50% welded yam and 50% conventional yam) with the technical face down and with the technical face up, respectively, it is evident that there is a large directionality for moisture transfer toward the technical face of the hybrid fabric (i.e., the parallel side of the trapezoid on the technical face is longer than that on the technical back, 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 constmcted entirely from welded yam and/or those in the fabric constmcted entirely from conventional yam.
• FIGS. 12A & 12B depict the moisture transfer across the hybrid fabric shown in FIG. 5B (50% welded yam and 50% conventional yam) 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 constmcted entirely from welded yam and/or those of the fabric constmcted entirely from conventional yam.
• 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 yam and those constmcted entirely of welded yam.
• the measured one-way moisture transfer with the technical face up for the fabric constructed entirely of conventional yam, 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 yam were 68.95%, -32.24%, -85.90%, and 110.18%, respectively.
• 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 yam exhibits a difference of only 67.15 and the pique fabric constmcted entirely of welded yam 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 yam and approximately 4.5 times higher than that differential for the pique fabric constructed entirely of welded yam.
• 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 yam and approximately 2.8 times higher than that differential for the pique fabric constructed entirely of welded yam.
• the differential in one-way moisture transfer of the technical face compared to the technical back for the pique fabric constmcted entirely of conventional yam 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.
• 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 oneway 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.
• 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 yam unless otherwise indicated in the following claims.
• FIGS. 5 A & 5B Combination A and Combination B, respectively
• FIGS. 5 A & 5B Combination A and Combination B, respectively
• 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.
• Table 9 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 measured delta spreading speed with the technical face up for the fabric constructed entirely of conventional yam, the first illustrative embodiment of constmction of a pique hybrid fabric shown in FIG. 5A, the second illustrative embodiment of constmction of a pique hybrid fabric shown in FIG. 5B, and the fabric constructed entirely of welded yam 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 yam and the pique fabric constructed entirely of welded yam.
• 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 yam exhibits a difference of only 0.031 and the fabric constructed entirely of welded yam 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 yam and approximately 3.8 times higher than that differential for the pique fabric constructed entirely of welded yam.
• 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 yam and approximately 3.1 times higher than that differential for the pique fabric constructed entirely of welded yam.
• 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 yam 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 yam unless otherwise indicated in the following claims.
• the fabric constructed entirely of conventional yam 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 yam 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 yam (e.g., a fabric made 100% of one type of welded yam, wherein the welding process results in relatively uniform characteristics along the length of the welded yam or fabric made 100% of conventional yam).
• a fabric constructed one type of yam e.g., a fabric made 100% of one type of welded yam, wherein the welding process results in relatively uniform characteristics along the length of the welded yam or fabric made 100% of conventional yam.
• Blending two different yams 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. 5 A & 5B A graphical representation of the dry rate of the hybrid fabrics shown in FIGS. 5 A & 5B (Combination A and Combination B, respectively) is shown and compared with that of the fabric made entirely of welded yam and that of the fabric made entirely of conventional yam 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 yam was 0.65 mL/hr
• for the fabric constructed entirely of welded yam 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 yam and the remainder conventional yam 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 constmcted entirely of conventional yam.
• Those hybrid fabrics also dried at a rate of approximately 5% faster than that of the fabric constructed entirely of welded yam. Contrasting the drying rate of the two hybrid fabrics (Combination A and Combination B) with those of the fabric constructed of 100% conventional yam and the fabric constructed of 100% welded yam 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 yam 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. 5 A & 5B A graphical representation of the pilling of the hybrid fabrics shown in FIGS. 5 A & 5B (Combination A and Combination B, respectively) is shown and compared with that of the fabric made entirely of welded yam and that of the fabric made entirely of conventional yam 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 yams previously known or later discovered may be imparted to hybrid fabrics comprised of a welded yam alone or in combination without limitation unless otherwise indicated in the following claims.
• FIGS. 5 A & 5B A graphical representation of the breathability of the hybrid fabrics shown in FIGS. 5 A & 5B (Combination A and Combination B, respectively) is shown and compared with that of the fabric made entirely of welded yam and that of the fabric made entirely of conventional yam 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.
• ASTM D737 protocol ASTM D737 protocol
• the air permeability is shown in cubic feet per minute.
• the air permeability for the fabric constructed entirely of conventional yam was 199 cfm
• the fabric constructed entirely of welded yam was 538 cfm
• both the hybrid fabrics (Combination A and Combination B, shown in FIGS. 5A & 5B, respectively) constructed of 50% welded yam and the remainder conventional yam 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 yam.
• the fabric constructed entirely of welded yam exhibits the highest breathability (i. e. , measured air permeability) and the fabric constructed entirely of conventional yam 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 yam 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 yam and that of a corresponding pique fabric made entirely of conventional yam 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. 5 A & 5B and those constructed entirely of conventional yam and welded yam.
• Table 13 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 yam and that of a corresponding pique fabric made entirely of conventional yam in FIG. 18.
• Table 13 The
• the illustrative embodiments of constmction 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 constmcted entirely of conventional yam. As is evident from FIG. 18, the fabric constmcted entirely of welded yam 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 yam 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 yam and a conventional yam. Further, in the illustrative embodiments of hybrid fabrics disclosed herein, the welded yam and/or conventional yam may be comprised of a naturally occurring biopolymer (e.g., cellulose, lignin, silk proteins, etc.), and in one illustrative embodiment the conventional yam and welded yam may be comprised entirely of a biopolymer such that no or virtually no synthetic materials are present in the hybrid fabric. Although specific examples and experimental data may be attributable to hybrid fabrics constructed of a welded cotton yam and a conventional cotton yam, 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.
• a naturally occurring biopolymer e.g., cellulose, lignin, silk proteins, etc.
• the illustrative embodiments of hybrid fabrics may exhibit a significant increase in the performance of the hybrid fabric compared to fabrics constructed with 100% conventional yams or 100% welded yams within a range of blending ratios. It is observed that in terms of vertical wi eking and absorbency, even a hybrid fabric comprised of only 17% of welded yam can significantly change the hybrid fabric performance compared to other fabrics.
• the comparison between the vertical wi eking of yam bundles (as shown in FIG. 1) of the welded cotton and conventional cotton shows that the welded yam wicks water more than three times faster than the conventional cotton yam. Also, comparison of the vertical wicking of the pique fabrics (FIGS.
• 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 yams therein resulted in a first hybrid fabric wherein the welded yam was primarily positioned on the back of the hybrid fabric and conventional yam was primarily positioned on the front of the hybrid fabric. In a second illustrative embodiment of constmction of a pique hybrid fabric the welded yam was primarily positioned in the middle layer of the hybrid fabric and the conventional yam was primarily positioned on the back of the hybrid fabric. However, other placements, orientations, positions, etc. of the welded yam and conventional yam 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 yam 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 yam may be primarily positioned on the back of the hybrid fabric.
• the welded yam 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. 5 A).
• the welded yam may be characterized by relatively low hairiness, relative higher stiffness, and/or relative low water absorption into the yam structure.
• the hybrid fabric structure may wick the moisture through capillary movement of the water through inter-yam spacing.
• the presence of different yam 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 yams 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 yam in the technical back may help transfer the water from the technical back to the technical face of the hybrid fabric.
• the regular yam may wick by the absorption and wicking through the conventional yam, 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 yam 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 yams while the water is held in place by absorption within the yam structure of the conventional yams.
• 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 yam and that of a fabric made from 100% conventional yam.
• the welded yam 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 yam, etc. and may include any welded yams and/or methods for making same already known, disclosed herein, or later developed without limitation unless otherwise indicated in the following claims.
• the yams produced via a welding process used for a hybrid material as disclosed herein may be configured such that the chemical composition of a welded yam is substantially the same as that of the corresponding conventional (e.g., raw, unwelded, etc.) substrate and/or yam.
• 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.
• the characteristics of the hybrid fabrics reported and measured herein will not significantly degrade even after a large number of laundry cycles at least because those characteristics may be a result of a fundamental change in the morphology of one of the yams used in the hybrid fabric and NOT a result of finishing techniques, chemical treatments, etc. and/or any other method or apparatus that may degrade after a specific number of laundering cycles 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.
• a hybrid fabric may be embodied as: a. a first yam; b. a second yam, wherein said first and second yam are engaged with one another to constmct said hybrid fabric, wherein said hybrid fabric exhibits an absorbency time of 10 seconds or less, wherein said hybrid fabric exhibits a first moisture spreading speed on a first face that is at least 25% greater than a second moisture spreading speed on a second face, and wherein said hybrid fabric is made of a biopolymer.
• hybrid fabric according to embodiments 1-5 and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as having a planar wi eking rate of at least 2.5 mm per minute.
• hybrid fabric according to embodiments 1-13 and having all the features and structures disclosed, either separately or as combined therein, wherein a dry rate of said hybrid fabric is at least 0.7 mL/hr.
• hybrid fabric according to embodiments 1-26, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as substantially completely made from said biopolymer.
• a hybrid fabric may be embodied as: a. a first yam; b. a second yam, wherein said first and second yam are engaged with one another to construct said hybrid fabric, wherein said hybrid fabric exhibits an absorbency time of 10 seconds or less, wherein said hybrid fabric a planar wi eking rate of at least 2.5 mm per minute, and wherein said hybrid fabric is made of a biopolymer.
• hybrid fabric according to embodiments 30-35, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as ajersey knit fabric.
• hybrid fabric according to embodiments 30-54 and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as constructed into a garment.
• a garment may be embodied as: a. an outside surface, wherein said outside surface exhibits a pilling rank of at least
• said outside surface has a first moisture spreading speed; b. an inside surface, wherein said inside surface has a second moisture spreading speed, wherein a differential of said first moisture spreading speed and said second moisture spreading speed is at least 25%, and wherein said garment is made of a biopolymer.
• a garment may be embodied as: a. an outside surface, wherein said outside surface exhibits a pilling rank of at least 3.5; b. an inside surface, wherein a first moisture transfer from said outside surface to said inside surface is at least 50% different than a second moisture transfer from said inside surface to said outside surface, and wherein said garment is made of a biopolymer.
• a hybrid fabric may be embodied as: a. a first yam having a first planar wicking rate; b. a second yam having a second planar wicking rate, wherein said first planar wicking rate is at least 100% different than said second planar wicking rate, wherein said first and second yam are engaged with one another to construct said hybrid fabric, wherein said hybrid fabric exhibits an absorbency time of 10 seconds or less, and wherein said hybrid fabric is made of a biopolymer.
• hybrid fabric according to embodiments 100 - 105, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as a jersey knit fabric.
• hybrid fabric according to embodiments 100 - 106, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as a pique knit fabric.
• hybrid fabric according to embodiments 100-112, and having all the features and structures disclosed, either separately or as combined therein, wherein a dry rate of said hybrid fabric is at least 0.7 mL/hr.
• hybrid fabric according to embodiments 100-114, and having all the features and structures disclosed, either separately or as combined therein, wherein a first face of said hybrid fabric is further defined as having a pilling rank of at least 3.5.
• hybrid fabric according to embodiments 100-120, and having all the features and structures disclosed, either separately or as combined therein, wherein said first yam is positioned primarily on an interior portion of said hybrid fabric.
• a hybrid fabric may be embodied as: a. a first yam having a planar wi eking rate of less than 2 mm per minute; b. a second yam having a second planar wicking rate of at least 3 mm per minute, wherein said first and second yam are engaged with one another to construct said hybrid fabric, wherein said hybrid fabric exhibits an absorbency time of 10 seconds or less.
• hybrid fabric according to embodiments 130-133, and having all the features and structures disclosed, either separately or as combined therein, wherein said biopolymer is further defined as cellulose.
• hybrid fabric according to embodiments 130-135, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as a jersey knit fabric.
• hybrid fabric according to embodiments 130-136, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as a pique knit fabric.
• 146. The hybrid fabric according to embodiments 130-145, and having all the features and structures disclosed, either separately or as combined therein, wherein said pilling rank is further defined as determined using an ISO 12945-2 test protocol.
• hybrid fabric according to embodiments 130-154, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as constmcted into a garment.
• hybrid fabric according to embodiments 130-155, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as substantially completely made from said biopolymer.
• hybrid fabric according to embodiments 130-156, and having all the features and structures disclosed, either separately or as combined therein, wherein a first one-way moisture transfer from a first face of said hybrid fabric to a second face for said hybrid fabric is at least 50% different than a second one-way moisture transfer from said second face to said first face.
• a hybrid fabric may be embodied as: a. a first yam; b. a second yam, wherein said first and second yam are engaged with one another to construct said hybrid fabric having a first face and a second face, wherein said hybrid fabric exhibits an absorbency time of 10 seconds or less, wherein a first moisture transfer from said first face to said second face is at least 50% different than a second moisture transfer from said second face to said first face, and wherein said hybrid fabric is made of a biopolymer.
• the hybrid fabric according to embodiment 160 and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric exhibits a first moisture spreading speed on said first face that is at least 25% greater than a second moisture spreading speed on said second face.
• hybrid fabric according to embodiments 160-166, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as a jersey knit fabric.
• hybrid fabric according to embodiments 160-167, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as a pique knit fabric.
• hybrid fabric according to embodiments 160-170, and having all the features and structures disclosed, either separately or as combined therein, wherein a breathability of said hybrid fabric is at least 200 efin.
• hybrid fabric according to embodiments 160-174, and having all the features and structures disclosed, either separately or as combined therein, wherein a dry rate of said hybrid fabric is at least 0.7 mL/hr.
• hybrid fabric according to embodiments 160 - 188, and having all the features and structures disclosed, either separately or as combined therein, wherein said first oneway moisture transfer and said second one way-moisture are further defined as determined based on an AATCC 195 test protocol.
• a hybrid fabric may be embodied as: a. a first surface, wherein said first surface exhibits a pilling rank of at least 3.5, and wherein said first surface has a first moisture spreading speed; b. a second surface, wherein said second surface has a second moisture spreading speed, wherein a differential of said first moisture spreading speed and said second moisture spreading speed is at least 25%, and wherein said hybrid fabric is made of a biopolymer.
• hybrid fabric according to embodiments 1-5, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as constructed of cotton.
• hybrid fabric according to embodiments 1-6 and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as having a planar wi eking rate of at least 2.5 mm per minute.
• hybrid fabric according to embodiments 1-15, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as substantially completely made from said biopolymer.
• hybrid fabric according to embodiments 1-19, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as a pique fabric.
• hybrid fabric according to embodiments 1-21, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as comprising a first yam and a second yam, wherein said first yam is positioned primarily on said technical back of said hybrid fabric.
• hybrid fabric according to embodiments 1-23, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as used in a garment having an interior surface and an exterior surface, and wherein said technical back is positioned adjacent said exterior surface.
• hybrid fabric according to embodiments 1-26, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as used in a garment having an interior surface and an exterior surface, and wherein said technical back is positioned adjacent said interior surface.
• a hybrid fabric may be embodied as: a. a first yam; b. a second yam, wherein said first and second yam are engaged with one another to construct said hybrid fabric, wherein said hybrid fabric exhibits an absorbency time of 10 seconds or less, wherein said hybrid fabric a planar wi eking rate of at least 2.5 mm per minute, and wherein said hybrid fabric is made of a biopolymer.
• biopolymer is further defined as a naturally occurring biopolymer.
• hybrid fabric according to embodiments 1-8, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as having no chemical finishes applied thereto.
• hybrid fabric according to embodiments 1-11, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as substantially completely made from said biopolymer.
• hybrid fabric according to embodiments 1-16, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as a knit fabric.
• hybrid fabric according to embodiments 1-17 and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as a jersey knit fabric.
• hybrid fabric according to embodiments 1-18, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric further comprises: c. a first surface having a first moisture spreading speed; and, d. a second surface having a second moisture spreading speed, wherein a differential of said first moisture spreading speed and said second moisture spreading speed is at least 25%.
• hybrid fabric according to embodiments 1-23, and having all the features and structures disclosed, either separately or as combined therein, wherein said hybrid fabric is further defined as used in a garment having an interior surface and an exterior surface, and wherein said technical back is positioned adjacent said exterior surface.
• 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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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Knitting Of Fabric (AREA)
• Professional, Industrial, Or Sporting Protective Garments (AREA)
• Mechanical Engineering (AREA)
• Agricultural Chemicals And Associated Chemicals (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)

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• 2021
  • 2021-08-30 TW TW110132133A patent/TW202212659A/zh unknown
  • 2021-08-31 WO PCT/US2021/048559 patent/WO2022047426A1/en unknown
  • 2021-08-31 US US17/463,414 patent/US20220064823A1/en not_active Abandoned
  • 2021-08-31 US US17/463,355 patent/US20220064828A1/en active Pending
  • 2021-08-31 EP EP21862993.9A patent/EP4204614A1/en active Pending
  • 2021-08-31 AU AU2021334025A patent/AU2021334025A1/en active Pending

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