BACKGROUND OF THE INVENTION
Field of Invention
[0001] This invention relates to an elastic yarn structure with substantial hollow structure.
The core is composed of dissolvable part (dissolvable core) and elastic part (main
elastic core) covered with single or multiple slivers, as well as fabrics containing
such yarns and garments made use of such fabric.
Description of Related Arts
[0002] The invention is particularly concerned with improvements of core-spun elastic yarns
performance, recovery of stretch fabric and easier recycle of such woven fabrics,
and comfortableness of stretch garments.
[0003] Recovery of stretch woven fabric is always a challenging topic for fabric designers,
as well as garment designers. Elastic yarn with synthetic fibers sheath could achieve
better recovery, but it carried glittery look as well as a hot synthetic hand those
are undesirable. Current best solution is dual core type spun yarns but those frequently
have obvious segments of filaments exposures in splices of yarn and sometimes on yarn
body as well which is due to spun process fluctuations. Such exposures of segments
of filament core are undesirable in apparel applications because light reflection
usually differed from sheath of yarn adopted and result in non-uniformities. Core
spun yarns with good recovery and without filament core exposure are still sought.
Fabric comprising such yarns and garments made from such fabric, which have lower
risk of filament core exposure and have good stretch recovery, good appearance and
hand, are also sought.
[0004] Due to pulling force of elastane, stretch woven fabric construction is more compact
compared with rigid (without stretch) woven fabric and lead to low breathability.
Wearing bad ventilation of garments made with stretch woven fabric is not good to
health as bacteria growth faster because of humidity and warmness, those feeling is
not good wearing experience either. Therefore, stretch woven fabric with good ventilation
and less see through is still sought.
[0005] Stretch woven fabric made with hollow stretch yarns, because of the loose yarn construction
carried, has higher breathability and softer hand those provided consumers more comfort
wearing experience as well as less see through under same final yarn size and construction.
Hollow stretch yarn provides a tunnel space so the drafted elastane inside could almost
freely rebound and achieve prompt recovery (shown as Figure 6) in garments after stretching
[0006] The stretch fabrics are required to recover after stretching. Artificial yarns (polyester
etc.) are commonly adopted to reduce frictions to obtain rapid recover. The cloth
produced keeps good shape while stretching. But the touch of the artificial yarn is
not as skin friendly as the natural yarn or the cellulose yarn. The dyeing and reflectivity
of the artificial yarn is not able to compete with the natural yarn.
[0007] The air permeability of the fabric is also important besides the resilience, which
is far from satisfactory. The gap of the duel core spun yarn or other elastic fabric
is small which lead to low air permeability and cause uncomfortable especially in
places such as underarm because of the accumulated humidity.
[0008] In order to reduce the weight of the clothes, the superfine yarns are adopted or
the density of the yarns is reduced, either of which cause the possible transparent
due to the reduced cover factor.
[0009] An elastic, air permeable, light weight, not see through yarn are required to meet
the needs.
SUMMARY OF THE PRESENT INVENTION
[0010] The present application is a substantial hollow stretch yarn construction with covering
fibers (shown as Figure 4), substantial hollow structure in central and at least one
core, fabric comprising such yarn and the garment made from such fabric.
[0011] The final yarn construction is achieved by removing dissoluble core of composite
core and substantially hollow space formed in central of yarn (shown as Figure 5).
The invention also covers a woven fabric from the hollow yarn, as well as garment
made from such fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012]
FIG. 1 is vertical section of the way composite core fed in parallel;
FIG. 2 is vertical section of the way composite core fed in ply yarn;
FIG. 3 is vertical section of the way composite core fed in core spun;
FIG. 4 showing a cross section of FIGs. 1 and 2;
FIG. 5 showing a cross section of FIG. 3; and
FIG. 6 is a cross section of final hollow stretch yarn formed regardless using any
feeding method above.
DETAILED DESCRIPTION OF THE INVENTION
[0013] According to the invention, main stretch core and dissolvable core is fed in the
central of yarn during spinning. The drafting ratio of main stretch core is ranged
230% to 350% according to technical needs; regardless it is parallel (shown as Figure
1) placement way or ply yarn way (shown as Figure 2) or spun yarn core. The dissolvable
core is under certain tension and drafting is below 5% as normally dissolvable fibers
elasticity is low.
[0014] This invention relates to main stretch core with hollow structure that comprise dissolvable
core with water-soluble vinylon or rayon and polyurethane filament(s). The invention
also relates to stretch woven fabrics comprising such core spun (shown as Figure 3)
yarn and the garments made from such fabric. The fabrics are substantially almost
free from core exposure, as the portion of dissoluble core would be removed by hot
water or hot alkaline bath in consequential fabric or garment processes. The final
hollow structure of yarn provided free space (shown as Figure 6) for main stretch
core moving and shrinking in core of yarn, thus stretch fabric's recovery is improved.
Because of interfering of the thick core in yarn spinning stage and the high shrinking
of stretch yarn of hollow stretch yarn, the final sheath of yarn is an imperfect tube
shape and result tinny path in fabric. Those tinny paths improved fabric breathability.
The final tube like construction improved yarn-covering factor and more efficient
in light reflection compared with stretch yarn with same final weight, less see-through
is achieved. Also, the final tube like structure provided fabric with thicker body
while without shoulder additional garment weight.
[0015] A dissolvable core comprises water-soluble vinylon fibers yarn or filament and/or
viscose rayon fibers and/or filament and filament(s) of polyurethane.
[0016] The dissolvable core would be totally or partially removed by hot water bath for
dissolvable vinylon or hot alkaline for viscose rayon during fabric finishing or garment
washing process, wherein a hollow yarn structure to be formed.
[0017] There are multiple ways for placing of dissoluble core and main stretch core. The
application could be in (a) parallel form; (b) twisted form; (c) covered yarn form
(shown as Figure 1, 2 and 3).
[0018] The total core occupied total yarn linear weight in the rage from about 10% to 40%.
The total yarn size can be ranged from about 4 to about 60 English cotton count.
[0019] The hollow stretch yarn may be used in either warp or weft direction or both to produce
warp stretch or weft stretch or bi-stretch woven fabrics.
[0020] There are no particular restrictions on the fibers or filament to be mixed with dissoluble
core to achieve other purpose.
[0021] The woven fabric of the invention can be any type construction, included but not
limited to plain weave, different types of twills, ribs, satins, dobby weaving, and
jacquards.
REFERENCE LIST
[0022]
covering sheath 1
dissolvable core 2
main stretch core 3
hollow space after dissolvable core removed 4
1. A process for producing a composite main stretch core (3) with substantially formed
with hollow structure after removed the dissolvable core (2). The process comprising
feeding of composite core and covered with a covering sheath (1).
2. The process of claim 1, wherein the main stretch core (3) is chosen from the group
comprising multiple filaments, spun yarn and composite thereof, and / or wherein the
covering sheath (1) is made of materials chosen from the group of natural fibers,
artificial fibers and synthetic fibers.
3. The process of claim 1, wherein the composite main stretch core (3) is made of a main
stretch core (3) and dissolvable core (2) chosen from the group of natural fibers,
artificial fibers and/or filaments, synthetic fibers and/or filaments and composite
thereof.
4. The process of one of the preceding claims, wherein the composite main stretch core
(3) is fed in the way chosen from parallel feeding, ply yarn form, or core spun and
composite thereof.
5. A process of removing the dissolvable core (2) of the composite main stretch core
(3) chosen from yarn stage, fabric stage, garment stage and composite thereof.
6. Hollow stretch yarns comprising an outer cover and one or more sets of stretch cores
which are inside the outer cover, wherein the stretch cores comprise main cores and
soluble cores.
7. The hollow stretch yarns of claim 6, wherein the soluble cores are parallel to the
main cores, or the main cores are twisted with the soluble cores, or the soluble cores
cover the main cores.
8. The hollow stretch yarns of claim 6 or 7, wherein the soluble cores are removed in
following processes for handling yarns, fabrics or clothes; wherein the soluble cores
are removed or partly removed in each section during different processes.
9. The hollow stretch yarns of claim 8, wherein the soluble cores and the main cores
are temporarily fill an inside of the outer cover; a gap is formed during the following
processing when the soluble cores are removed; the main cores are loosely contact
with the outer cover and obtain more stretchable space.
10. The hollow stretch yarns of one of claims 6 to 9, wherein the outer cover are yarns
selected from the group consisting of natural yarns, cellulose yarns and synthetic
yarns.
11. The hollow stretch yarns of one of claims 6 to 10, wherein the soluble cores contain
yarns selected from the group consisting of water soluble silks, water soluble fibers,
viscose and other materials.
12. The hollow stretch yarns of one of claims 6 to 10, wherein the soluble cores are spandex.
13. The hollow stretch yarns of one of claims 6 to 12, wherein a yarn wrap's fiber is
between 4 and 60 Ne (Number English).
14. The hollow stretch yarns of one of claims 6 to 13, wherein the soluble cores account
for 10% to 40% of all yarns which are adjustable based on different requirements.
15. The hollow stretch yarns, of one of claims 6 to 14, wherein the hollow stretch yarns
are applied in fabrics or cloths.