NZ767219B2 - Improved woven fabric - Google Patents

Abstract

woven textile fabric including: 132 to 190 EPI cotton warp yarns; and multi-filament polyester weft yarns, wherein the cotton yarns have a cotton count of 30s to 80s, the multi-filament polyester yarns have a denier of 8D to 19D, the fabric has a high total thread count ranging from 500 to 3000, and proportion of the cotton in the fabric is 50% or above by weight of the fabric, and wherein the multi-filament polyester yarns are wound, substantially parallel to one another and substantially adjacent to one another, on a multi-pick yarn package at an angle between 15 to 25 degrees and at a type A shore hardness between 65 to 80 to enable simultaneous insertion of the multi-filament polyester yarns during a single pick insertion event of a pick insertion apparatus of a loom, further wherein said fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs. Fabric weaving using multi-ply polyester yarns can result significant in yarn breakage due to higher entanglement. The present invention provides for higher loom speeds and lower yarn breakage by weaving multi-filament polyester yarns such that they are substantially parallel and substantially adjacent to one another. nd proportion of the cotton in the fabric is 50% or above by weight of the fabric, and wherein the multi-filament polyester yarns are wound, substantially parallel to one another and substantially adjacent to one another, on a multi-pick yarn package at an angle between 15 to 25 degrees and at a type A shore hardness between 65 to 80 to enable simultaneous insertion of the multi-filament polyester yarns during a single pick insertion event of a pick insertion apparatus of a loom, further wherein said fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs. Fabric weaving using multi-ply polyester yarns can result significant in yarn breakage due to higher entanglement. The present invention provides for higher loom speeds and lower yarn breakage by weaving multi-filament polyester yarns such that they are substantially parallel and substantially adjacent to one another.

Description

IMPROVED WOVEN FABRIC FIELD OF THE INVENTION The t disclosure relates generally to the technical field of woven s.

More specifically, the present disclosure pertains to a woven textile fabric with higher thread count that exhibits low pilling tendency, while being economical.

BACKGROUND OF THE INVENTION Pilling is a condition that arises in fabrics due to the formation of little 'pills' of entangled fibers clinging to the fabric surface giving it an unsightly appearance. They are formed by a rubbing action on loose fibers, which are present on the fabric surface. It was originally a fault found mainly in knitted woollen goods made from soft twisted yarns. However, introduction of man-made fibers into clothing has aggravated its seriousness because these fibers are stronger than wool so that the pills remain ed to the fabric surface rather than breaking away as would be the case with the wool. g, in l, affects the appearance of fabrics and reduces the use performance of fabrics; however, it may not affect the durability or functionality of the fabric per se.

There are l ways to preclude pilling or decreasing pilling tendency of a fabric.

One solution is singeing process and spinning the yarn with a high number of twists per inch.

Other methods include chemically treatment of the fabric during the manufacturing process in order to reduce their propensity to pill. Sometimes polymeric coatings are also applied to bind fibers into the fabric surface and prevent initial fuzz from forming. However, all these method suffers from one or more limitations as would be apparent to persons d in the art.

Accordingly, there remains a long felt need in the art for a woven textile fabric with higher thread count that exhibits low g tendency. It is always desirable if such fabric would be economical.

OBJECTS OF THE ION An object of the present disclosure is to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

Another object of the present disclosure is to provide a woven fabric that has an increased thread count.

Another object of the present disclosure is to provide a woven fabric that exhibits sed strength and durability.

[0008] Another object of the present disclosure is to provide a new and improved woven fabric that can be manufactured in an easy, efficient and cost-effective manner.

Another object of the present disclosure is to provide a new and improved woven fabric that has enhanced aesthetic characteristics.

Another object of the present sure is to provide a new and improved woven fabric that can be used in a y of applications.

Further object of the present disclosure is to provide a woven fabric that exhibits low pilling tendency.

SUMMARY

[0012] The present disclosure relates generally to the technical field of woven fabrics.

More specifically, the present disclosure pertains to a woven textile fabric with higher thread count that exhibits low pilling tendency, while being economical.

An aspect of the t disclosure provides a woven textile fabric, said fabric comprising: 132 to 190 ends per square inch (EPI) cotton warp yarns; and multi-filament polyester weft yarns, n the cotton yarns have a cotton count of 30s to 80s, the multifilament polyester yarns have a denier of 8D to 50D, and the fabric has a high total thread count g from 500 to 3000, and wherein the filament polyester yarns are wound, substantially parallel to one another and substantially adjacent to one another, on a multi-pick yarn package at an angle between 15 and 30 degrees and at a type A shore hardness between 60 to 90 to enable simultaneous insertion of the multi-filament polyester yarns during a single pick ion event of a pick insertion tus of a loom. In an embodiment, the fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs.

In an embodiment, the cotton yarn comprises 100% cotton yarns or blend of cotton and any or a combination of a synthetic fiber and a natural fiber such that the blend has a cotton content of at least 90%. In an embodiment, the multi-filament ter yarns se 100% polyester multi-filament texturized yarns. In an embodiment, proportion of the cotton in the fabric is 50% or above by weight of the fabric. In an embodiment, the multi-filament polyester yarns have a denier of 8D to 30D. In an ment, the fabric comprises 368 to 2868 picks per square inch (PPI) multi-filament polyester yarns. In an embodiment, the multi-filament ter yarns comprise 7 to 28 filaments. In an embodiment, the fabric comprises any of a twill weave and a satin weave. In an embodiment, the cotton yarns have a cotton count of 40s to 60s. In an embodiment, the multi-filament polyester yarns are wound on the multi-pick yarn package at an angle between 15 and 25 degrees. In an embodiment, the multi-filament polyester weft yarns are wound on the multi-pick yarn package at a type A shore hardness between 65 to 80. In an embodiment, the multi-filament ter weft yarns are woven into the fabric in a group of at least two multi-filament ter weft yarns, said at least two multi-filament polyester weft yarns being substantially el to one another and substantially adjacent to one r.

DETAILED DESCRIPTION The ption that follows, and the ments described therein, is provided by way of illustration of an e, or examples, of particular embodiments of the principles and aspects of the present disclosure. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the disclosure.

The present disclosure relates generally to the technical field of woven fabrics.

More specifically, the present disclosure pertains to a woven textile fabric with higher thread count that exhibits low pilling tendency while being economical.

As used herein, a person skilled in the relevant art may generally understand the term "comprising" to generally mean the presence of the stated features, integers, steps, or components as ed to in the claims, but that it does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0018] All publications herein are incorporated by nce to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term ed herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

[0019] The expression “rating of 3 or above” as used throughout the present disclosure, in the context of the fabric tested for pilling after 1000 rubs, lly denotes low pilling tendency of the fabric being tested. In other words, when the g tendency of the finished fabric is measured by any of the standard methods such as ASTM D4970 or ISO 2:2014 and rated on a grade/rating of 1 – 5, the rating/grade 1 indicating very severe pilling and scale/rating/grade 5 indicating no pilling after the specified number of rubs, the fabric exhibits the rating of 3 or 4 or 5 after 1000 rubs or cycles, i.e. the finished fabric has low g tendency.

The term c” and “finished fabric”, as used herein throughout the t disclosure synonymously and interchangeably, in the context of the fabric being tested for pilling tendency or pilling resistance denotes the dyed, bleached or printed fabric, or otherwise a fabric that is substantially ready for use (e.g. er use) without need to be subjected to any r processing that can alter its pilling tendency or pilling resistance. For example, the raw woven fabric may be subjected to dying and/or ng and/or bleaching process(es) to produce the finished fabric. Such finished fabric is then subjected to the test for ement of pilling resistance or pilling tendency.

In some embodiments, the numbers expressing quantities used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical ters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The cal values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing ements.

The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein.

[0023] All methods described herein can be performed in any suitable order unless ise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) ed with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0024] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly es otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context y dictates otherwise.

Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as tions. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the ication is herein deemed to contain the group as modified thus ling the written

[0026] An aspect of the present disclosure provides a woven textile fabric, said fabric comprising: 132 to 190 ends per square inch (EPI) cotton warp yarns; and multi-filament polyester weft yarns, wherein the cotton yarns have a cotton count of 30s to 80s, the multifilament polyester yarns have a denier of 8D to 50D, and the fabric has a high total thread count ranging from 500 to 3000, and wherein the multi-filament polyester yarns are wound, substantially parallel to one another and substantially adjacent to one another, on a pick yarn package at an angle between 15 and 30 degrees and at a type A shore ss between 60 to 90 to enable simultaneous insertion of the filament ter yarns during a single pick ion event of a pick insertion tus of a loom.

In an embodiment, the fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs. Any of the methods as known to or appreciated by a person skilled in the art for testing of pilling resistance, such as ASTM D4970 and ISO 12945-2. In an ment, the fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs in accordance with ASTM D4970. In an embodiment, the fabric exhibits rating of 3 or above when the fabric is tested for pilling for 1000 rubs in accordance with ISO 12945-2:2014.

ASTM D4970 and ISO 12945-2 methods make use of a Martindale Tester, wherein the fabric (i.e. the finished fabric) being tested is rubbed face to face for a specified number of rubs/cycles, and the pill balls are evaluated using a photographic visual standard for comparison and given a 1 – 5 rating, wherein rating/grade 1 indicates very severe pilling and /grade 5 indicates no pilling.

In an embodiment, the cotton yarn comprises 100% cotton yarns. Alternatively, the cotton yarn may comprise blend of cotton and any or a combination of a synthetic fiber and a natural fiber such that the blend has a cotton t of at least 90%. In an ment, the multi-filament polyester yarns comprise 100% polyester multi-filament ized yarns.

In an embodiment, the proportion of the cotton in the fabric is 50% or above by weight of the . Simply put, the content/proportion of the cotton in the fabric is higher than that of the Polyester.

In an embodiment, the multi-filament polyester yarns have a denier of 8D to 30D.

In an embodiment, the fabric comprises 368 to 2868 picks per square inch (PPI) filament polyester yarns. In an embodiment, the multi-filament polyester yarns comprise 7 to 28 filaments.

[0031] In an embodiment, the fabric comprises any of a twill weave and a satin weave. In an embodiment, the fabric comprises a twill weave.

In an embodiment, the cotton yarns have a cotton count of 40s to 60s. In an embodiment, the filament polyester yarns are wound on the multi-pick yarn package at an angle (winding angle) between 15 and 25 degrees. In an ment, the multi-filament polyester weft yarns are wound on the multi-pick yarn package at a type A shore hardness between 65 to 80. In an embodiment, the multi-filament polyester weft yarns are woven into the fabric in a group of at least two multi-filament polyester weft yarns, said at least two multifilament polyester weft yarns being substantially parallel to one another and substantially adjacent to one another.

[0033] Table 1 below illustrates properties of the fabric, realized in accordance with embodiments of the present disclosure.

Table 1: Properties of the Fabric Sample Polyester Polyester Cotton Cotton Feel Pilling Tensile Total No. Weft filaments Yarn content Factor (1-5) Strength thread (Denier) Count (%) (1-5) (1-10) Count 1 12 14 50 54 3 4 7 1500 2 15 14 50 52 3 3 6 1500 3 14 7 60 58 5 4 7 800 4 17 7 60 52 4 3 6 800 10 14 60 60 5 3 8 2000 6 20 7 60 48 3 2 5 800 7 20 14 60 40 2 1 6 2000 8 21 14 50 48 1 1 4 1500 As can be seen from the Table 1 above, when the cotton content of the fabric falls below 50% (i.e. the proportion of cotton in the fabric is less than that of the Polyester), the fabric exhibits high pilling tendency (or low resistance to pilling).

[0035] Table 2 and 3 below illustrates effects of Type A shore hardness and winding angle of the multi-filament polyester weft yarns on the instances of yarn breakage and speed of the g, which eventually exerts profound effect on the cost of production of the fabric.

Table 2: Effect of Type A Shore Hardness Sample Type A Winding Instances of Instances of Average No. shore angle intermingling yarn approximate hardness (average, per ge weaving bobbin/spool) (average, per speed ) bobbin/spool) 1 35 19 200 100 50 2 50 19 125 66 100 3 60 19 30 15 350 4 65 19 5 3 500 70 19 2 2 600 6 80 19 7 4 450 7 90 19 15 10 300 8 100 19 200 100 50 Table 3: Effect of Winding Angle Sample Winding Type A Instances of Instances of Average No. angle shore ingling yarn imate hardness (average, per breakage weaving bobbin/spool) (average, per speed (loom) bobbin/spool) 1 10 70 150 90 50 2 15 70 25 12 300 3 20 70 2 2 600 4 25 70 10 6 500 30 70 35 20 275 6 35 70 90 50 125 As can be seen from the Table 2 and 3 above, winding angle and Type A shore hardness of the multi-filament polyester yarns exerts a pronounced effect on the instances of intermingling of yarns, and optimization of winding angle and Type A shore hardness affords dramatic reduction in instances of intermingling and yarn breakage without compromising unwinding speed of the yarn.

The fabric of the t invention exhibits low tendency of pilling, while achieving the balance between feel, pilling resistance and the e strength. Further, the fabric of the present invention is significantly economical owing to, at least, reduced wastage during the production and/or increased speed of weaving due to lower instances of yarn breakage.

While some embodiments of the present disclosure have been rated and described, those are completely exemplary in nature. The disclosure is not limited to the embodiments as elaborated herein only and it would be apparent to those skilled in the art that numerous cations besides those y described are possible without departing from the inventive concepts . All such cations, s, variations, substitutions, and equivalents are completely within the scope of the present sure. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.

The foregoing description of the specific ments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be ced with modification within the spirit and scope of the appended claims.

ADVANTAGES The present disclosure provides to me or ameliorate at least one of the disadvantages of the prior art and/or provides a useful alternative.

The present disclosure provides a woven fabric that has an increased thread count.

[0042] The present disclosure provides a woven fabric that exhibits increased strength and durability.

The present disclosure provides a new and improved woven fabric that can be manufactured in an easy, efficient and ffective manner.

The present disclosure provides a new and improved woven fabric that has enhanced aesthetic characteristics.

The present disclosure provides a new and improved woven fabric that can be used in a y of ations.

The present disclosure provides a woven fabric that exhibits low pilling tendency.

Claims (6)

1. A woven textile fabric, said fabric comprising: 132 to 190 ends per square inch (EPI) cotton warp yarns; and multi-filament polyester weft yarns, wherein the cotton yarns have a cotton count of 50s to 60s, the filament polyester yarns have a denier of 8D to 19D, the fabric having a high total thread count ranging from 500 to 3000, and proportion of the cotton in the fabric being 50% or above by weight of the fabric, and wherein the multi-filament polyester yarns are wound, substantially el to one another and substantially adjacent to one another, on a multi-pick yarn package at an angle between 15 and 25 degrees and at a type A shore hardness between 65 to 80 to enable simultaneous insertion of the multi-filament ter yarns during a single pick insertion event of a pick insertion apparatus of a loom, further wherein said fabric exhibits rating of 3 or above when the fabric is tested for pilling after 1000 rubs.

2. The fabric as claimed in claim 1, wherein the cotton yarn comprises 100% cotton yarns or blend of cotton and any or a combination of a synthetic fiber and a natural fiber such that the blend has a cotton content of at least 90%.

3. The fabric as claimed in claim 1, wherein the filament polyester yarns comprise 100% polyester multi-filament texturized yarns.

4. The fabric as claimed in claim 1, wherein the fabric comprises 368 to 2868 picks per square inch (PPI) multi-filament polyester yarns, and wherein the multi-filament polyester yarns comprise 7 to 28 nts.

5. The fabric as claimed in claim 1, wherein the fabric is of a twill weave.

6. The fabric as claimed in claim 1, wherein the multi-filament polyester weft yarns are woven into the fabric in a group of at least two multi-filament polyester weft yarns, said at least two filament polyester weft yarn being substantially parallel to one another and substantially adjacent to one another