Composite textile fabric having moisture management characteristics

Abstract

 A composite textile fabric for wicking moisture away from the skin of the wearer and transporting moisture from its skin-side surface to the opposite surface. The fabric includes a first fabric layer which has been rendered hydrophilic in order to quickly wick perspiration and other body fluids away from the body surface of the user, and is constructed of fibers of a relatively high denier; and a second fabric layer which has been rendered hydrophilic, and is constructed of fibers of a relatively low denier in order to pull perspiration and other body fluids from the first fabric layer.

Description

BACKGROUND OF THE INVENTION

[0001] The present invention relates to a composite textile fabric, and more particularly to a composite fabric for wicking moisture away from the skin of the wearer and transporting moisture from the skin-side surface to the opposite-side surface of the fabric.

[0002] To facilitate absorption of the perspiration of the wearer, garments are preferably made of a textile fabric consisting of natural fiber such as cotton, silk or linen, or by a blend of natural and synthetic fibers. Such garments cannot quickly disperse the moisture into areas away from the skin, though they can absorb perspiration from the area of the skin. Perspiration-absorbed garments require a period of time to evaporate moisture. The moisture next to the skin over a period of time can cause a cold, clammy sensation as well as chafing, irritation and conditions conducive to bacteria, fungus and yeast growth, especially in the cases of athletic apparel and undergarments.

[0003] U.S. Pat. No. 5,217,782 issued to Moretz et al. on June 8, 1993 discloses a multi-layer moisture management fabric. The multi-layer moisture management fabric has particular application in being fabricated into panels which can be incorporated into the crotch area of undergarments for controlling leakage and spotting caused by minor to moderate urinary incontinence or that experienced by colostomy patients. The multi-layer fabric includes a relatively thick inner moisture permeable hydrophobic fabric layer for positioning next to the skin of the garment wearer. A first, relatively thin intermediate hydrophilic fabric layer is positioned adjacent the hydrophobic fabric layer on the side thereof away from the skin of the wearer. A second, relatively thick outer hydrophilic fabric layer is positioned adjacent the first hydrophilic fabric layer on the opposite side thereof from the hydrophobic fabric layer. The inner hydrophobic fabric is preferably constructed of a suitable non-absorbent fiber such as polyester. The first and second hydrophilic layers are preferably formed of a highly absorbent fiber such as Hydrofil brand nylon fiber marketed by Allied Fibers.

[0004] The inner fabric layer of the Patent No. 5,217,782 is hydrophobic and non-absorbent, and is intended primarily to keep the skin of the undergarment wearer dry. The first hydrophilic fabric layer is intended primarily as a "transport" layer which pulls the moisture from the hydrophobic layer and the underlying skin. The second hydrophilic fabric layer is intended primarily as a "storage" layer. Due to the hydrophobic and non-absorbent characteristics of the inner fabric layer, the multi-layer fabric is only suitable to be used to absorb a relatively large amount of fluid, like urine, and is unsuitable to efficiently and quickly wick a relatively small amount of fluid, like tiny drops of perspiration, away from an adjacent body surface.

SUMMARY OF THE INVENTION

[0005] Therefore, it is an object of the present invention to provide a composite textile fabric which has moisture management characteristics, and especially can quickly wick moisture, even a relatively amount of fluid, away from an adjacent body surface.

[0006] It is another object of the present invention to provide a composite textile fabric which can be fabricated as garments such as undergarments, athletic apparel, leisure garments, and the like.

[0007] It is yet another object of the present invention to provide a composite textile fabric which can be fabricated as linings of garments such as water-proof outerwear and the like.

[0008] It is yet another object of the present invention to provide garments such as undergarments, athletic apparel, leisure garments, and the like which are made of the composite textile fabric having moisture control properties and which are essentially indistinguishable in outward appearance from conventional garments of a similar type.

[0009] These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a composite textile fabric. The composite textile fabric comprises a first fabric layer constructed of fibers of a relatively high denier for wicking perspiration and other body fluids away from the body surface of the user; and a second fabric layer constructed of fibers of a second relatively low denier in order to pull perspiration and other body fluids from the first fabric layer.

[0010] According to one preferred embodiment of the present invention, the first and second fabric layers are formed integrally and concurrently by knitting or weaving. The first fabric layer has been rendered hydrophilic in order to quickly wick perspiration and other body fluids away from the body surface of the user, and the second fabric layer has been rendered hydrophilic.

[0011] According to another preferred embodiment of the present invention, each fabric layer is formed of polyester, nylon, acrylic fiber, or the like.

[0012] According to yet another preferred embodiment of the present invention, the denier of fibers constructing the first fabric layer is preferably not higher than 6D. The denier of fibers constructing the second fabric layer is lower than the denier of fibers of the first fabric layer, and preferably not higher than 3D.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present invention can be more fully understood by reference to the following description and accompanying drawings, which form an integral part of this application:

Fig. 1 is a schematically cross-sectional view of a composite textile fabric according to one preferred embodiment of the present invention;

Fig. 2 is a schematically cross-sectional view of a yarn used to construct a first fabric layer of the composite textile fabric of the present invention; and

Fig. 3 is a schematically cross-sectional view of a yarn used to construct a second fabric layer of the composite textile fabric of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Referring now specifically to the drawings, a composite textile fabric according to one preferred embodiment of the present invention is illustrated in Fig. 1, and shown generally at reference numeral 30. The composite textile fabric 30 includes a first fabric layer 12 and a second fabric layer 22 positioned adjacent the first fabric layer 12. The first and second fabric layers 12 and 22 may be preferably rendered hydrophilic by any suitable method which is well known by those skilled in the art.

[0015] The first hydrophilic fabric layer 12 is intended to be next to and in contact with the skin of the garment wearer, or to be closer to the skin than the second hydrophilic fabric layer 22. The first hydrophilic fabric layer 12 may be knitted or woven with a yarn 10, as shown in Fig. 2, that is preferably comprised of synthetic fiber such as polyester, nylon, acrylic or the like. Since the first fabric layer 12 is rendered hydrophilic, the wicking of moisture such as perspiration, urine or other body fluids, from the skin next to the first fabric layer 12 is enhanced.

[0016] The second hydrophilic fabric layer 22 may be knitted or woven with a yarn 20, as shown in Fig. 3, that is preferably comprised of synthetic fiber such as polyester, nylon, acrylic or the like. In accordance with the present invention, the first and second hydrophilic fabric layers 12 and 22 may be formed integrally and concurrently by, for example, knitting or weaving. Although each fabric layer is distinct and separate, each is integrated with each other. As a result, the composite textile fabric functions as a single unit.

[0017] Referring now to Figs. 2 and 3, the yarn 10 is constructed of fibers, such as filaments 100, and the yarn 20 is constructed of fibers, such as filaments 200. Preferably, the filaments 200 for the second hydrophilic fabric layer 22 are thinner, or have a lower denier, than the filaments 100 for the first hydrophilic fabric layer 12. This feature causes the second hydrophilic fabric layer 22 to have a stronger moisture absorbency of wicking ability than the first hydrophilic fabric layer 12. As such, the moisture quickly wicked from the skin surface by the first hydrophilic fabric layer 12 will be pulled from the first fabric layer 12 to the second hydrophilic fabric layer 22. This maintains the skin-side surface of the first fabric layer 12 in a dry condition, and thus creates a dry, comfortable sensation to the garment wearer.

[0018] Due to the hydrophilic characteristic and the strong wicking ability of the second fabric layer 22, the perspiration absorbed in the second fabric layer 22 will be diffused over a relatively large area. Thus, the water contained in the perspiration retained by the second fabric layer 22 is evaporated into the exposed air in the large area, so that the composite textile fabric can become dry in a shorter period of time than conventional fabrics do.

[0019] The filament denier of each fabric layer is selected based on the end use requirements for wetness control. The amount of each fabric layer is selected based on the desired weight of the composite textile fabric, the end use desired of the composite textile fabric and the requirements for transporting perspiration or other body fluids from the first fabric layer 12 to the second fabric layer 22.

[0020] In one preferred embodiment of the present invention, the denier of the filament 200 is preferably not higher than 3D. The denier of the filament 100 is higher than that of the filament 200, and preferably not higher than 6D.

[0021] Although the cross section of the filaments 100 and 200 is shown round in Figs. 2 and 3, it should be understood by those skilled in the art that the polyester, nylon or acrylic of the first or second fabric layer 12 or 22 may be either round or modified cross-section, and either spun or filament.

[0022] Obviously, the composite textile fabric of the present invention can be fabricated as garments such as undergarments, shirts, skirts, pants, athletic apparel, leisure garments, and the like. The garments are essentially indistinguishable in outward appearance from conventional garments of a similar type. The composite textile fabric can also be fabricated as linings of garments such as water-proof outerwear and the like. In this case, the composite textile fabric is provided with a breathable barrier layer on the side thereof away from the skin of the wearer. The breathable barrier layer may be adhered to the second fabric layer by conventional membrane-film lamination or transfer coating technology. The barrier layer may be microporous and hydrophilic or preferably non-porous and hydrophilic, prevents the outerwear from getting wet, and has a high moisture vapor-transmission rate.

[0023] Although the fabric of the present invention is preferably used as a garment textile fabric, it may also be used for other purposes such as the sweat band, sock or stocking, bra lining, glove or its lining, lining for sanitary napkin or diaper, lining for shoe, hat or cap, or head sweat band of hat or cap. During knitting or weaving, an elastic yarn may be additionally used to form the composite textile fabric of the present invention in order to increase the elasticity of the fabric.

[0024] While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention need not be limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures.

Claims

1. A composite textile fabric comprising:

a first fabric layer constructed of fibers of a relatively high denier for wicking perspiration and other body fluids away from the body surface of the user; and

a second fabric layer constructed of fibers of a relatively low denier in order to pull perspiration and other body fluids from said first fabric layer.

2. The fabric as claimed in claim 1, wherein said first fabric layer has been rendered hydrophilic in order to quickly wick perspiration and other body fluids away from the body surface of the user, and wherein said second fabric layer has been rendered hydrophilic.

3. The fabric as claimed in claim 2, wherein said first and second fabric layers are formed integrally and concurrently by knitting or weaving.

4. The fabric as claimed in claim 3, wherein said first fabric layer comprises a material selected from the group consisting of polyester, nylon and acrylic.

5. The fabric as claimed in claim 3, wherein said second fabric layer comprises a material selected from the group consisting of polyester, nylon and acrylic.

6. The fabric as claimed in claim 1, wherein said relatively high denier is preferably not higher than 6D.

7. The fabric as claimed in claim 1, wherein said relatively low denier is preferably not higher than 3D.

Drawing