Fabric and a method of making the fabric

Abstract

The present invention is based on the realization that improved wicking of liquid from an inner face to an outer face of a fabric can be achieved by a fabric structure where the inner face of the fabric has a substantially uniform hydrophobicity and where the inner face is formed by hydrophobic yarn that is assembled in a manner that allows the liquid to penetrate between hydrophobic yarn and make contact with hydrophilic yarn that forms at least part of the outer face of the fabric. When liquid penetrates the inner face and makes contact with the hydrophilic yarn, liquid is able to be drawn through the inner face to the outer face of the fabric. Although the hydrophobic and hydrophilic yarns and may be made from any one or a blend of man-made or synthetic fibers, and natural fibers, it is preferred that the yarns and the fully formed fabric be made entirely of cotton fibers. The fabric is suitable for use in a wide range of applications including underwear. Another application involves laminating the fabric to a functional film such as a waterproof and / or windproof breathable membrane to produce functional outerwear garments.

Description

RELATED APPLICATIONS [0001] This application is a continuation-in-part of International Patent Application No. PCT / AU2005 / 001638, designating the United States, filed on Oct. 21, 2005, which claims the benefit of U.S. Provisional Application No. 60 / 621,943, filed on Oct. 22, 2004.FIELD OF THE INVENTION [0002] The present invention relates to a new fabric and a method of making the fabric that is capable of transferring liquid from an inner face to an outer face of the fabric by wicking. According to one particular preferred embodiment of the present invention, the fabric consists entirely of cotton fibers and is suitable for making sports garments or under garments that help keep a person dry and comfortable. BACKGROUND OF THE INVENTION [0003] Cotton fiber in its raw state is coated by naturally occurring waxes that make it hydrophobic. Once this coating is removed, by scouring for example, the fiber surface is strongly hydrophilic—more so than any non-cellulosic fiber. This high su...

AI Technical Summary

Benefits of technology

[0007] The present invention is based on the realization that improved wicking of liquid from an inner face to an outer face of a fabric can be achieved by a fabric structure where the inner face of the fabric has a substantially uniform hydrophobicity and where the inner face is formed by hydrophobic yarn that is assembled in a manner that allows the liquid to penetrate the inner face and make contact with hydrophilic yarn that forms at least part of the outer face of the fabric. When liquid penetrates the inner face and makes contact with the hydrophilic yarn, the liquid can be drawn through the inner face to the outer face of the fabric.

Problems solved by technology

This high surface energy brings positive benefits, but in some conditions, significant disadvantages.

However, in conditions where large amounts of sweat are excreted, liquid bridges are formed between the skin and fabric, thereby causing the fabric to stick and drag on the skin during movement, a phenomenon known as “wet cling”.

Cotton fabrics hold more liquid than equivalent fabrics of other fibers when saturated and therefore take significantly longer to dry.

In reality, control of the coating process described in the U.S. application is extremely difficult as during application the hydrophobic agent will tend to follow the same path into the fabric as sweat would normally use, blocking off much of the wicking capability.

During wear, once the fabric is saturated, the wicking windows will also be wet so the fabric is unlikely to feel dry against the skin.

As the sweat is distributed homogeneously throughout all parts of the fabric not affected by the hydrophobic treatment, fabrics of this type cannot be considered to be true differential wicking structures.

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