Wonder Fabric

Abstract

A novel textile material particularly a wonder fabric comprising of a see-through construction of plurality of yarns intersecting one another at certain angles hydro-laminated thereof with pseudo yarns formed out of staple fibers and mechanical cross linking of yarns on at least one side under specific conditions thereof resulting into a durable and multi functional material suitable for home and apparel textile applications is disclosed herein. A process for production and apparatus thereof are also disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation-in-part application under 35 U.S.C. §120 of U.S. patent application Ser. No. 12 / 569,784, filed on Sep. 29, 2009, entitled “Wonder Fabric”, and which claims the benefit of Indian Patent Application No. 2226 / MUM / 2009, filed on Sep. 24, 2009, entitled “Wonder Fabric”. The contents of the above applications are hereby all incorporated by reference in their entireties.FIELD OF INVENTION[0002]This invention generally relates to a novel textile material, more particularly wonder fabric, comprising of a see-through construction of plurality of yarns intersecting one another at certain angles, hydro-laminated thereof with pseudo yarns formed out of staple fibers and mechanical cross linking of yarns on at least one side under specific conditions thereof, resulting into a durable and multifunctional material suitable for home, upholstery and apparel textile applications. The process for production and apparatus th...

AI Technical Summary

Benefits of technology

The invention is about creating a new type of fabric that looks like traditional textile fabrics used for home, apparel, and upholstery. The fabric has a unique construction with intersecting yarns and pseudo yarns that are hydro-laminated, making it stable and acceptable for various applications. The fabric also has properties like strength, durability, and ease of care / wrinkle-free, recovery from creases, and dimensional stability. The fabric is made by using a special weaving process that involves creating an open fabric with see-through and unstable construction.

Problems solved by technology

Knitted fabrics lack in their strength and durability.

Both the traditional textile manufacturing processes are highly expensive and labor intensive.

On the other hand raw material cost is continuously increasing and labor cost is also increasing.

Year by year here also labor cost is steadily increasing and the solution of shifting of the traditional textile manufacturing base is not remaining cost advantageous.

With fibers like cotton, impact of raw material cost on total cost is very high.

However, cost is directly dependent upon fiber length.

Also, it is very difficult to get all the fabric properties to the best level.

Always it's a compromised approach followed for optimization of fabric properties.

The wrinkle behavior improves with increased add-on of chemicals and with this increased chemical add-on, remaining fabric properties go bad.

In this case, if one desires to have remaining properties also best, then there is a need for long and strong fiber meaning high cost.

Since they hamper fabric properties like strength, feel, etc., one needs to use expensive long and strong fibers.

This adds further to the cost.

This is based upon its unique yarn structure most suitable for apparel and home textiles and also none of other spinning technologies are able to offer this yarn structure.

However, ring spinning is the slowest among various yarn manufacturing technologies.

Though ring spun yarn structure is the best, still there exists a limitation on fiber selection.

Similarly, Ne 60 / 1 yarn with strength of 16 Rkm can not run efficiently on high speed / wider Air Jet loom.

This way technology has put a restriction on possibility of raw material value engineering.

Though one wishes for value engineering and meet market needs, it is very difficult.

However, nonwovens are not perfect like woven or knitted fabrics and so far are not suitable for direct use in home and apparel textiles.

Nonwovens lack in important aspects like look, drape and fall, abrasion and pilling resistance required for home and apparel textile.

All these properties are not possible to be attained at the same time.

For example, if bonding amount is improved so as to improve pilling resistance will hamper the hand feel and drape.

However, this will hamper the strength and pilling resistance.

However, commercial success of this is limited.

Also, this fabric being originally a nonwoven lacks in pilling resistance.

This fabric lacks in quick recovery from elastic deformations.

If used in bottom weights, this limitation of the fabric results in cup formation at knees.

This problem can be resolved through chemical adhesives, but then results in to making fabric very stiff and uncomfortable to wear.

This product lacks in strength and durability required for its use into textile applications like home and apparel textile.

Application of all such products is mostly limited to disposable products.

This improves textile fabrics but at a high cost when compared to traditional textile finishing process.

Therefore, we do not see its commercial advantage and application.

However, this is a disposable product and also adds to the cost of basic product.

Application is limited to bandage cloth which is used once and never washed and used again.

This composite in its original format is not a durable product.

This product is not suitable for apparel or home textile application.

However, this composite has a limitation of wash durability.

Also, there are limitations in entanglement of individual fibers with the fibers from yarns of base fabric.

This poses a risk of entanglement of fibers from web amongst themselves and thereby resulting into problem of missed out entanglement between fibers from web and fibers from yarn of base fabric thereby resulting in delamination and poor durability and life.

Also, it does not reveal great commercial advantage over the present textile fabrics.

However, this product was 100% synthetic and had a sueded leather touch which is not appreciated always.

Also it lacked the traditional textile fabric look which people are familiar with.

Also, it was expensive and did not get a commercial success.

As seen from prior arts and above, sufficient successful attempts are not made so far as to create an alternate to durable traditional textiles used for home, upholstery and apparel application.

Woven or knitted fabric is manufactured with lightest possible construction to the extent that it is having a see through effect and is completely unstable.

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