Stretch wovens with a control yarn system

Patent metadata

Field	Value
Publication number	US-9982372-B2
Application number	US-201314397832-A
Country	US
Kind code	B2
Filing date	Mar 26, 2013
Priority date	Mar 30, 2012
Publication date	May 29, 2018
Grant date	May 29, 2018

Abstract

An article including a woven fabric comprising warp yarns and weft yarns, wherein at least one of either the warp yarns or the weft yarns includes: (a) a corespun elastic base yarn having a denier and including staple fiber and an elastic fiber core; and (b) a separate control yarn selected from the group consisting of a single filament yarn, a multiple filament yarn, a composite yarn, and combinations thereof; having a denier greater than zero to about 0.8 times the denier of the corespun elastic base yarn; wherein the woven fabric includes (1) a ratio of corespun base yarn ends to control yarn ends of up to about 6:1; or (2) a ratio of corespun base yarn picks to control yarn picks of up to about 6:1; or (3) both a ratio of corespun base yarn ends to control yarn ends of up to about 6:1; and a ratio of corespun base yarn picks to control yarn picks of up to about 6:1.

First claim

The invention claimed is:

1. An article comprising a woven fabric comprising warp yarns and weft yarns, wherein at least one of either the warp yarns or the weft yarns includes:
(a) a corespun elastic base yarn having a denier and comprising staple fiber and an elastic fiber core; and
(b) a separate control yarn comprising polyester bicomponent filament having a linear density of about 10 denier to about 450 denier;
wherein the woven fabric includes
(1) a ratio of corespun base yarn ends to control yarn ends of up to about 6:1; or
(2) a ratio of corespun base yarn picks to control yarn picks of up to about 6:1; or
(3) both a ratio of corespun base yarn ends to control yarn ends of up to about 6:1; and a ratio of corespun base yarn picks to control yarn picks of up to about 6:1.

2. The article of claim 1 , wherein the weft yarns include the corespun elastic base yarn and said separate control yarn.

3. The article of claim 1 , wherein the warp yarns include the corespun elastic base yarn and said separate control yarn.

4. The article of claim 1 , wherein both of the warp yarns and the weft yarns include the corespun elastic base yarn and said separate control yarn.

5. The article of claim 1 , wherein at least one of either the warp yarns or the weft yarns has a ratio of the denier of the corespun base yarn to the denier of the separate control yarn of about 3:1 to about 10:1.

6. The article of claim 1 , wherein the ratio of corespun base yarn ends or picks to control yarn ends or picks, respectively, of about 1:1 to about 4:1.

7. The article of claim 1 , wherein the corespun base yarn comprises a fiber selected from the group consisting of wool, linen, silk, polyester, nylon, olefin, cotton, and combinations thereof.

8. The article of claim 1 , wherein the amount of elastic fiber core in the corespun base yarn is about 0.5% to about 20% by weight of the warp or weft yarns.

9. The article of claim 1 , wherein the elastic fiber core comprises spandex.

10. The article of claim 1 , wherein the fabric has a weaving pattern selected from the group consisting of plain, twill, satin, and combinations thereof.

11. The article of claim 10 , wherein the fabric weaving pattern for the corespun base yarn and the control yarn is the same.

12. The article of claim 1 , wherein the fabric has stretch in the weft direction of about 10% to about 45%.

13. The article of claim 1 , wherein the elastic fiber core has a linear density of about 10 denier to about 300 denier.

14. The article of claim 1 , wherein said article is a garment.

15. A method for making an article comprising a woven fabric comprising weaving warp yarns and weft yarns, wherein at least one of either the warp yarns or the weft yams includes:
(a) a corespun elastic base yarn having a denier and comprising staple fiber and an elastic fiber core; and
(b) a separate control yarn comprising polyester bicomponent filament having a linear density of about 10 denier to about 450 denier;
wherein the woven fabric includes
(1) a ratio of corespun base yarn ends to control yarn ends of up to about 6:1; or
(2) a ratio of corespun base yarn picks to control yarn picks of up to about 6:1; or
(3) both a ratio of corespun base yarn ends to control yarn ends of up to about 6:1; and a ratio of corespun base yarn picks to control yarn picks of up to about 6:1.

16. The method of claim 15 , wherein the corespun base yarn and the separate control yarn are joined during a warping process, a sizing process or during the weaving.

17. The method of claim 15 , wherein the corespun base yarn is joined with the separate control yarn during the weaving through a co-insertion method.

18. The method of claim 15 , where the fabric is finished in a piece dyeing or continuous dyeing process.

19. The method of claim 15 , wherein said fabric is prepared in the absence of a heat setting process.

20. The method of claim 15 wherein said article is a garment.

Assignees

• Invista North America Sarl
• Invista North America Sarl

Inventors

• Liao Tianyi
• Leung Raymond S P
• Nefodov Leonid

Classifications

• D10B2501/00

  Wearing apparel · CPC title

• D10B2321/02

  polyolefins · CPC title

• D10B2331/02

  polyamides (D10B2331/08 takes precedence) · CPC title

• D02G3/328

  containing elastane · CPC title

• Y10T442/3024

  Including elastic strand or strip · CPC title