Woven fabric that looks and performs like a knitted fabric and method of making thereof

Patent metadata

Field	Value
Publication number	US-2018127902-A1
Application number	US-201815862809-A
Country	US
Kind code	A1
Filing date	Jan 5, 2018
Priority date	Feb 26, 2010
Publication date	May 10, 2018
Grant date	—

Abstract

A fabric with wefts that include hard yarns and elastomeric yarns in a predetermined arrangement such that at least one hard yarn is alternately arranged with at least one elastomeric yarn, the elastomeric yarns having a greater shrinkage ratio than that of the hard yarns; the hard yarns form under portions and over portions with respect to warps, said under portions being formed when said hard yarns pass along the back side of the warps and defining loop portions, and said over portions being formed when the hard yarns pass along the front side of the warps and define connection portions, wherein for each hard yarn, the number of warps passed by the loop portion is at least 6, and the elastomeric yarns form under portions and over portions with respect to said warps in a weave that is tighter than the weave of the hard yarns.

First claim

What is claimed is:

1 . An article, comprising:
a fabric ( 101 ) having a front side ( 102 ) and a back side ( 103 ) and including a plurality of warp yarns ( 104 ) and a plurality of weft yarns ( 105 , 106 ) woven together in a pattern, wherein the weft yarns include first, hard, yarns ( 106 ) and second, elastomeric, yarns ( 105 ) arranged in a predetermined arrangement comprising at least one hard yarn alternately arranged with at least one elastomeric yarn, the elastomeric yarns ( 105 ) having a greater shrinkage ratio than a shrinkage ratio of the hard yarns ( 106 ), wherein the hard yarns form alternately arranged under portions ( 107 ) and over portions ( 108 ) with respect to said warp yarns ( 104 ), said under portions ( 107 ) being formed when said hard yarns pass along the back side of the warp yarns ( 104 ) and defining loop portions ( 107 a ), and said over portions being formed when said hard yarns pass along the front side of the warp yarns and defining connection portions ( 108 a ), wherein for each hard yarn ( 106 ), an average number of warp yarns ( 104 ) passed by the loop portions ( 107 a ) is at least 6, wherein the elastomeric yarns ( 105 ) form alternately arranged under portions ( 109 ) and over portions ( 110 ) with respect to said warp yarns ( 104 ) in a weave that is tighter than the weave of the hard yarns ( 106 ).

2 . The article according to claim 1 , wherein the number of warp yarns ( 104 ) passed by the loop portion ( 107 a ) is at least 6 times the number of warp yarns passed by the connection portions ( 108 a ).

3 . The article according to claim 1 , wherein the loop portions ( 107 a ) are in substantially less tension than the over and under portions ( 110 , 109 ) formed by the elastomeric yarns ( 105 ).

4 . The article according to claim 1 , wherein the loop portions ( 107 a ) are in at least one of equilibrium and compression.

5 . The article according to claim 1 , wherein the loop portions ( 107 a ) of adjacent hard yarns ( 106 ) form a pattern extending in a diagonal direction with respect to the warp yarns ( 104 ) and the weft yarns.

6 . The article of claim 1 , wherein the connection portion of adjacent hard yarns form a pattern extending in a diagonal direction with respect to the warp yarns and the weft yarns.

7 . The article of claim 1 , wherein the fabric stretches in a diagonal direction with respect to the warp yarns and weft yarns.

8 . The article of claim 1 , wherein the weave pattern of the hard yarns ( 106 ) is different from the weave pattern of the elastomeric yarns ( 105 ).

9 . The article of claim 1 , wherein the weave pattern of the elastomeric yarns ( 105 ) is a twill pattern.

10 . The article of claim 1 , wherein after the weaving, but before a shrinking the predetermined arrangement comprises a warp density between approximately 20 and 70 warps/cm, inclusive.

11 . The article of claim 1 , wherein after three home washes the predetermined arrangement comprises a warp density between approximately 25 and 80 warps/cm.

12 . The article of claim 1 , wherein after the weaving, but before a shrinking the predetermined arrangement comprises a warp density between approximately 25 and 60 warps/cm.

13 . The article of claim 1 , wherein after three home washes the predetermined arrangement comprises a warp density between approximately 30 and 65 warps/cm, inclusive.

14 . The article of claim 1 , wherein after the weaving, but before a shrinking the predetermined arrangement comprises a warp density between approximately 30 and 50 warps/cm.

15 . The article of claim 1 , wherein after three home washes the predetermined arrangement comprises a warp density between approximately 35 and 55 warps/cm, inclusive.

16 . The article of claim 1 , wherein after the weaving, but before a shrinking the predetermined arrangement comprises a weft density between 30 and 90 wefts/cm, inclusive.

17 . The article of claim 1 , wherein after three home washes the predetermined arrangement comprises a weft density between approximately 35 and 95 wefts/cm, inclusive.

18 . The article of claim 1 , wherein after the weaving, but before a shrinking the predetermined arrangement comprises a weft density between approximately 40 and 80 wefts/cm, inclusive.

19 . The article of claim 1 , wherein after three home washes the predetermined arrangement comprises a weft density between approximately 45 and 85 wefts/cm, inclusive.

20 . The article of claim 1 , wherein after the weaving, but before a shrinking the predetermined arrangement comprises a weft density between approximately 50 and 70 wefts/cm.

21 . The article of claim 1 , wherein after three home washes the predetermined arrangement comprises a weft density between approximately 55 and 75 wefts/cm, inclusive.

22 . The article of claim 1 , wherein in the warp yarns have an English cotton number between approximately Ne 10 and Ne 30, inclusive.

23 . The article of claim 1 , wherein the warp yarns have an English cotton number between approximately Ne 15 and Ne 25, inclusive.

24 . The article of claim 1 , wherein the hard yarns have an English cotton number between approximately Ne 10 and Ne 70, inclusive, preferably an English cotton number between approximately Ne 15 and Ne 50, inclusive.

25 . The article of claim 1 , wherein the elastomeric yarns have a denier between approximately 40 and 140 denier, preferably between approximately 50 and 90 denier, inclusive.

26 . The article of claim 1 , wherein the stretching ratio of said second, elastomeric, yarns ( 105 ) is at least 10% greater than the stretching ratio of said first, hard, yarns ( 106 ).

27 . The article of claim 1 , wherein the warp yarns ( 104 ) are indigo dyed yarns, preferably ring-dyed yarns.

28 . The article of claim 1 , wherein the ratio of warp yarns ( 104 ) passed by the loop portion ( 107 a ) to the connection portion ( 108 a ) is between approximately 6:1 and 24:1, inclusive.

29 . The article of claim 1 , wherein the ratio of elastomeric yarns ( 105 ) to hard yarns ( 106 ) is between approximately 2:1 and 1:5, inclusive.

30 . The article of claim 1 , wherein the ratio of elastomeric yarns ( 105 ) to hard yarns ( 106 ) is between approximately 1:2 and 1:3, inclusive.

31 . The article of claim 1 , wherein for a corresponding amount of warp yarns ( 104 ) in a weave report the ratio of the number of over portions ( 110 ) obtained by an up and down movement of an elastomeric yarn ( 105 ) is 2 to 12 times the amount of over portions ( 108 ) obtained by an up and down movement of a hard yarn ( 106 ).

32 . The article of claim 1 , wherein the elastomeric under portions ( 109 ) are substantially covered by the loop portions ( 107 a ), wherein the elastomeric under portions ( 109 ) are difficult to see and feel when the fabric ( 101 ) is in a relaxed state.

33 . The article of claim 1 , wherein the loop portions ( 107 a ) substantially prevent the warp yarns ( 104 ) passed over by the connection portions from contacting a surface covered by the fabric.

34 . The article of claim 1 , wherein the ratio of the average number of warp yarns passed by the loop portions to a warp density is between approximately 0.2 and 0.7, inclu

Assignees

• Sanko Tekstil Isletmeleri San Ve Tic As

Inventors

• Yenici Hamit
• Korkmaz Fatima
• Erkus Ertug
• Udul Ahmet

Classifications

• Y10T442/3024

  Including elastic strand or strip · CPC title

• D03D27/04

  Weft pile fabrics · CPC title

• D03D17/00 Primary

  Woven fabrics having elastic or stretch properties due to manner of weaving (fabrics using stretchable or elastic threads D03D15/56) · CPC title

• D03D13/008

  characterised by weave density or surface weight · CPC title

• D03D13/004 Primary

  with weave pattern being non-standard or providing special effects · CPC title