Sweat-repellent fabrics with moisture management function

Abstract

This article describes an example of a knitted or woven fabric with moisture management functionality, comprising a surface fabric layer with a durable water-repellent (DWR) additive, forming a hydrophobic outer surface, and a back fabric layer with a highly hydrophilic second yarn, forming a moisture-retaining core to absorb moisture and diffuse it to the inner surface of the back fabric layer. Due to the addition of the DWR additive to the first yarn, the outer layer (surface layer) of the fabric is hydrophobic, while the inner layer (back layer) is highly hydrophilic, absorbing moisture and diffusing it to the inside of the back layer, allowing it to dry faster and thus keeping the outer surface of the surface fabric layer dry, thereby reducing the occurrence of water / liquid stains on the outer surface of the surface fabric layer.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application 63 / 173,093, filed April 9, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application provides a fabric with a moisture management function that can reduce wet (liquid) spots, such as sweat spots, water spots, or blood spots, on the fabric surface. Background Technology

[0004] Fabrics designed for athletic activities are envisioned to maximize physical performance by significantly controlling body temperature and keeping moisture away from the body. The current challenge is creating clothing that typically exhibits properties that enhance performance without compromising appearance and / or comfort. Moisture from sweat produced during physical exertion can form undesirable wet spots on the surface of clothing. For wearers, having fabrics that reduce wet spots is incredibly convenient, allowing them to exercise, shop, or have coffee without worrying about sweat stains. Commuters also desire fabrics that don't leave sweat marks on their clothes during hot, humid days.

[0005] Therefore, there is a strong desire for an improved fabric that can reduce the appearance of wet spots on the surface. Summary of the Invention

[0006] On one hand, the present invention provides a knitted or woven fabric with moisture management function. The fabric includes: a surface fabric layer having a durable water-repellent (DWR) additive, which forms a substantially hydrophobic outer fabric surface; a back fabric layer composed of a hydrophilic second yarn, which forms a moisture-retaining core to absorb moisture and diffuse moisture to the inner surface of the back fabric layer; and connecting yarns that bond the surface fabric layer and the back fabric layer together.

[0007] In one embodiment, the first yarn is spun by using a DWR additive within the yarn.

[0008] In another embodiment, the first yarn is finished with DWR additive.

[0009] In one supplementary embodiment, the fabric is a weft-knitted or warp-knitted fabric, or a woven fabric.

[0010] In one respect, the moisture regain of the back fabric layer is between 4% and 18%.

[0011] On the other hand, the first yarn is a synthetic polymer selected from nylon, polyester, polypropylene, acrylic, or any combination thereof.

[0012] In another embodiment, the first yarn is nylon 6.6 with a denier range of 20D-100D and a filament count of 10-186.

[0013] On the other hand, the surface fabric layer also includes a third yarn connected to the first yarn, such that the third yarn is located inside the surface fabric layer and the first yarn is located outside the surface fabric layer.

[0014] In one aspect, the second yarn comprises natural or regenerated cellulose fibers selected from cotton, silk, wool, modal, micromodal, viscose rayon, lyocell, cupro, rayon, regenerated cellulose fibers, regenerated protein fibers, and any combination thereof.

[0015] In one embodiment, the third type of yarn is an elastic fiber.

[0016] In another embodiment, the elastic fiber has a denier between 10D and 70D.

[0017] In one supplementary embodiment, the surface fabric layer is a composite blend of a synthetic polymer with DWR additives and elastic fibers woven together.

[0018] On the other hand, the back fabric layer also includes a fourth yarn connected to the second yarn, such that the fourth yarn is located inside the back fabric layer and the second yarn is located outside the back fabric layer.

[0019] In one respect, the second yarn is a hydrophilic synthetic polymer selected from nylon, modified polyester, modified polypropylene, modified acrylic, and combinations thereof.

[0020] On the other hand, the fourth yarn is an elastic fiber.

[0021] In one respect, elastic fibers have deniers between 10D and 70D.

[0022] In another embodiment, the second fabric layer is a composite blend of natural or regenerated cellulose fibers and elastic fibers.

[0023] In another embodiment, the back fabric layer is brushed or napped to increase its surface area.

[0024] On the other hand, the connecting yarn is at least a single strand.

[0025] In another embodiment, the connecting yarn is a synthetic polymer.

[0026] On the other hand, the connecting yarn is an elastic fiber.

[0027] In another aspect, the outer surface of the surface fabric layer is finished with a durable water-repellent (DWR) coating.

[0028] In another aspect, the outer surface of the back fabric layer undergoes a sweat-wicking final treatment.

[0029] In one aspect, the fabric is knitted using a double-knitted structure.

[0030] In one aspect, the fabric is a single-layer knitted fabric.

[0031] In one respect, the fabric is a braided warp-knitted fabric.

[0032] In one aspect, the fabric is a double-woven woven fabric.

[0033] In another embodiment, the fabric is a pique fabric or a tricot fabric.

[0034] In one aspect, the present invention provides a garment article comprising a fabric as defined herein. Attached Figure Description

[0035] The following explanation will now be provided with reference to the accompanying drawings.

[0036] Figure 1 A schematic diagram of a double-knitted fabric according to an embodiment of the present invention is shown.

[0037] Figure 2 A schematic diagram of a sweat-free pique fabric according to one embodiment is shown, illustrating a four-layer structure or repeating pattern constituting the pique fabric.

[0038] Figure 3 A double-layer woven fabric according to one embodiment is shown.

[0039] Figure 4 A trico fabric structure according to one embodiment is shown. Detailed Implementation

[0040] According to this disclosure, a knitted or woven fabric with moisture management function is provided, comprising: a surface fabric layer including a first yarn having a durable water-repellent (DWR) additive or a DWR finishing layer, forming a hydrophobic or substantially hydrophobic outer surface; a back fabric layer including a highly hydrophilic second yarn, forming a moisture-retaining core to absorb moisture and diffuse it to the inner surface of the back fabric layer; and connecting yarns for bonding the surface fabric layer and the back fabric layer together. Moisture absorbed and diffused to the inner surface between the back fabric layer and the surface fabric layer evaporates through the surface fabric layer over time. Because the DWR additive or DWR finishing layer is added to the first yarn, the outer layer (surface layer) of the fabric is hydrophobic, while the inner layer (back layer) of the fabric is hydrophilic, which absorbs moisture and diffuses it to the inside of the back layer, causing it to dry faster and resulting in the drying of the outer surface of the surface fabric layer, thereby avoiding or reducing liquid spots on the outer surface of the surface fabric layer.

[0041] like Figure 1 As shown, fabric 10 includes a back layer (inner layer) 12 and a surface layer (outer layer) 14, wherein the former is a layer that is in close contact with the wearer's skin, while the latter corresponds to a layer of fabric 10 that faces outward and is away from the wearer's skin. Figure 1 As shown, in one embodiment, connecting yarn 16 binds the back fabric layer 12 and the surface fabric layer 14 together, thereby connecting the fabric 10 together. Moisture on the wearer's skin is pushed across the back fabric layer 12 and diffuses on the back of the fabric 10, generally from side A (wearer's skin) to side B (outer surface away from the wearer's skin). The absorbed moisture evaporates over time, leaving no sweat stains on the surface layer 14 of the fabric 10.

[0042] The surface fabric layer 14 includes a first yarn 23 that incorporates a durable water-repellent (DWR) additive or a DWR finishing layer, thus forming a hydrophobic outer fabric surface that avoids or reduces sweat stains on the outer surface of the fabric 10 during activities that involve sweating. For example, the first yarn 23 can be spun with a DWR additive therein, or the yarn 23 can have a DWR finishing layer. The back fabric layer 12 includes a second yarn 18 that is hydrophilic and forms a moisture-retaining core that absorbs moisture from the skin and diffuses it to the inner surface of the back fabric layer, allowing it to dry faster while keeping the outer surface of the surface fabric layer 14 dry and preventing sweat stains from being visible on the outside of the fabric 10.

[0043] exist Figure 1In the illustrated embodiment, the surface fabric layer 14 further includes a third yarn 24 knitted or woven together with the first yarn 23, such that the third yarn 24 is located inside the surface fabric layer 14, while the first yarn 23 is located outside the surface fabric layer 14. In some embodiments, the first yarn 23 may be a synthetic polymer, such as, but not limited to, nylon, polyester, polypropylene, acrylic, or any combination thereof. In one embodiment, the first yarn 23 may be nylon 6.6 with 15 to 100 denier (D) and 10 to 184 filaments (F) containing a DWR additive. The third yarn 24 may be an elastic fiber, such as 10D to 70D spandex. The third yarn may also be the same DWR yarn used for the surface. The surface fabric layer 14 may be a composite blend of a synthetic polymer with a DWR additive or a DWR finishing layer knitted together with elastic fibers. In different embodiments, the outer surface of the surface fabric layer 14 includes a DWR finishing layer.

[0044] The back fabric layer 12 includes a second yarn 18, which is hydrophilic and forms a high moisture regain, thereby forming the hydrophilic moisture regain core of the fabric 10. For example, the moisture regain of the second yarn 18 can be in the range of 4% to 18%. The second yarn 18 can be any suitable natural fiber or regenerated cellulose fiber. For example, the second yarn 18 can be selected from the group consisting of cotton, silk, wool, modal, micromodal, viscose rayon, lyocell, cupro, rayon, and any combination thereof. In some embodiments, the second yarn 18 can be a hydrophilic synthetic polymer, for example, the second yarn 18 can be selected from the group consisting of nylon, polyester, polypropylene, acrylic, and combinations thereof. The back fabric layer 12 also includes a fourth yarn 20 knitted or woven together with the second yarn 18, such that the fourth yarn 20 is located inside the back fabric layer 12 and the second yarn 18 is located outside the back fabric layer 12. The fourth yarn 20 can also be a synthetic polymer, such as an elastic fiber. For example, the fourth yarn 20 can be 30D or 40D spandex. In one embodiment, the back fabric layer 12 can be a composite blend of natural fibers, hydrophilic synthetic polymers, or regenerated cellulose fibers woven together with elastic fibers. The surface layer DWR yarn and the back layer hydrophilic yarn can be used alone without being woven with spandex. In another embodiment, the back fabric layer 12 can be a composite blend of a fully hydrophilic synthetic polymer (such as nylon) woven together with spandex. One way to increase the hydrophilicity of the back layer 12 is to increase its surface area. Therefore, it is conceivable that the outer side of the back fabric layer 12 (the side facing the skin) can be brushed or napped to increase its surface area.

[0045] The connecting yarn 16 bonds the surface fabric layer 14 and the back fabric layer 12 together, and may be at least a single strand. In one embodiment, the connecting yarn 16 may be an elastic fiber. For example, the connecting yarn 16 may be spandex of 10D to 70D. In some embodiments, the connecting yarn 16 may be a synthetic polymer, such as nylon, polyester, polypropylene, acrylic, polyacrylonitrile, or a combination thereof. Alternatively, the connecting yarn 16 may be a natural fiber, such as cotton, silk, wool, modal, micromodal, rayon, lyocell, viscose, or a combination thereof. The connecting yarn is preferably a herringbone structure located between the back fabric layer 12 and the surface fabric layer 14. The connecting yarn 16 may be single-strand or multi-strand. Each strand in a multi-strand connecting yarn 16 may have an independent herringbone structure. The connecting yarn 16 may also be a yarn with a DWR composition.

[0046] In one embodiment, the outer surface of the surface fabric layer 14 may be finished with a durable water-repellent (DWR) coating to further reduce water or sweat stains on the outer surface of the fabric 10. For example, after the surface fabric layer is finished, the DWR coating may be printed on the outer surface of the surface fabric layer 14. For example, the DWR coating may be printed by screen printing, inkjet printing, lamination, or spraying. In one embodiment, the DWR coating may have a predetermined pattern to draw moisture away from the surface fabric layer 14, thereby achieving rapid drying. In one embodiment, the outer surface of the back fabric layer 12 may be finished with a sweat-wicking coating, for example by adding a chemical finishing layer containing hydrophilic molecules that adheres to the outer surface of the back fabric layer 12.

[0047] In such Figure 3 Another embodiment shown includes a double-layer woven fabric in which a first yarn 23 also connects the surface fabric layer 14 to the back fabric layer 12. In this embodiment, the surface fabric layer 14 comprises yarns 23 finished with DWR (dihydrodynamic dyeing). Therefore, the back of the double-layer woven fabric is hydrophilic, while the surface layer is made of DWR yarns.

[0048] As described herein, in some embodiments, the fabric 10 employs a knitted structure, which may be a weft-knitted or warp-knitted structure. For example, the fabric may be a double-knitted structure (such as...). Figure 1 (as shown) or Trico warp knitting stitch structure (such as...) Figure 4 (As shown).

[0049] In another embodiment, a fabric 100 is disclosed, wherein the back layer comprises hydrophilic yarns 54. Figure 2In the illustrated embodiment, the hydrophilic yarn 54 is made of natural or regenerated cellulose fibers, preferably modal fibers or hydrophilic synthetic polymers. The connecting yarn 50 is a composite blend of a synthetic polymer with DWR additives and a DWR final treatment layer. The surface fabric layer comprises yarns 52 knitted or woven together with the connecting yarns 50 and a surface fabric or first yarn 56, such that yarn 52 is located inside the surface fabric layer and the first yarn 56 is located outside the surface fabric layer. Fabric 100 is a knitted fabric or a "piqué" fabric. In this context, "piqué" is a traditional weaving method with a waffle knit structure. The resulting double-layered weave structure can be seen from the fact that the number of yarns in the surface fabric layer is twice that of the back layer, thus creating raised and recessed areas in the material. This allows for the weaving of different patterns. In the illustrated embodiment, the piqué structure is a four-layer repeating pattern, but this structure can also have different repeating patterns without departing from the scope of the invention. First yarn 56 is a composite blend of a synthetic polymer with DWR additives and a DWR finishing layer. Yarn 52 is an elastic fiber, such as 5D spandex. Figure 2 It shows the four-line structure or repeating pattern that constitutes the pique fabric 100.

[0050] As described in this article, knitted fabrics with moisture management and no sweat stains on the surface can be used in any type of clothing, including shirts, headwear, coats, jackets, trousers, underwear, gloves, socks and footwear.

[0051] As shown in this article, the fabric's performance was tested, and the results of the Moisture Management (MMT) test confirmed that the salt solution used in the test could not penetrate into the fabric during the test. While the fabric is moisture-resistant, it is breathable, which is a desirable characteristic in terms of thermal comfort.

[0052] Based on the above results, the fabric presented in this paper clearly possesses unique engineering moisture-blocking properties.

[0053] Example I

[0054] Fabric test properties

[0055] The liquid moisture management properties of the textile fabric shown in the figure were tested using a Moisture Management Tester (MMT). The fabric was placed between two layers of sensors (top sensor and bottom sensor), with the fabric surface layer facing down. 0.2 mL of salt solution was applied to the back layer of the fabric (the side of the fabric in contact with the skin). Therefore, the "top layer" is the skin-contacting side / back layer of the fabric, and the "bottom layer" is the outer / surface layer of the fabric. The results are listed in Table 1 below.

[0056] Table 1

[0057] Liquid moisture management indicators average Standard deviation grade* Top layer wetting time, WTT (seconds) 2.93 1.02 5 Bottom wetting time, WTB (seconds) 120 0 1 Top-level absorption rate, ART (% / second) 55.8 6.2 4 Subsurface absorption rate, ARB (% / second) 0 0 1 Maximum wetting radius of the top layer, MWRT (mm) 25.0 0 5 Maximum wetting radius of the bottom layer, MWRB (mm) 0 0 1 Top-layer diffusion velocity, SST (mm / s) 4.62 1.06 5 Subsurface diffusion velocity, SSB (mm / s) 0 0 1 Unidirectional conveying capacity, R (%) -1100 50 1 Overall moisture management performance, OMMC 0 0 1

[0058] *The grade indicates a rating of textiles from 1 to 5, with 5 being the best, meeting the expected function, and 1 being the worst, not meeting the expected results of the material.

[0059] The liquid absorption properties of the fabric were tested, with the back side (skin contact surface) in contact with the applied test liquid (distilled water). The liquid absorption rate (absorption capacity of 20-80%) of the horizontal wicking fabric was measured in grams per second (g / sq.).

[0060] The airflow method was used to investigate the drying rate of textiles under absorbent conditions. The test conditions were: air temperature 21±1℃; relative humidity 65±2%; airflow direction: vertical airflow from the back of the fabric to the surface; airflow velocity before fabric installation was 2.5±0.5 m / s; airflow velocity after fabric installation was 0.10 m / s. Observations showed that water could not pass through the fabric.

[0061] The rapid drying method was also used because this test method determines the drying rate based on the evaporation rate produced under approximately the same water absorption capacity. The test sample was mounted on a hanging ring. A vertical airflow was passed through the fabric (the airflow was perpendicular to the fabric surface). The higher the drying rate of the fabric, the better its drying performance. The test conditions were: air temperature 21±1℃; relative humidity 65±2%; hot plate temperature 37±1℃, with the back of the fabric (the side in contact with the skin) in contact with the hot plate; wind speed 1.5±0.5 m / s (horizontal airflow passing through the fabric surface). The measured drying rate was 1.66 mL / h.

[0062] To measure the air permeability of the fabric, the following method was used to measure the fabric's drying rate: the fabric was exposed to a specified amount of water while simultaneously contacting a heating plate set at 37°C (simulating skin surface temperature). A horizontal airflow was present on the fabric surface. A higher drying rate indicates better drying performance. The test pressure was 125 Pa within a 38 cm² test area, and the measurement results are as follows.

[0063] Table 2

[0064] unit numerical values Breathability, average cfm 34.8 maximum breathability cfm 36.2 Minimum air permeability xfm 33.8 CV ％ 2.2

[0065] The total heat loss of the fabrics described herein was tested under standard conditions, with the following atmospheric conditions: air temperature: 25.0 ± 0.1 °C; relative humidity: 65 ± 4% RH; at least 12 hours (sample thickness ≤ 5 mm) / at least 24 hours (sample thickness > 5 mm).

[0066] The actual test conditions were: air temperature 25.0 ± 0.1℃; relative humidity 65 ± 3% RH; airflow velocity 1.0 ± 0.1 m / s (horizontal airflow over the fabric surface); hot plate temperature 35.0 ± 0.1℃; sample orientation: the sample was placed flat on the measuring device, usually with the side facing the human body facing the measuring device. The back of the fabric (skin contact surface) was in contact with the hot plate. The following are the measured values:

[0067] The average intrinsic thermal resistance of the sample itself, Rcf(K×m) 2 / W): 0.015

[0068] The average apparent intrinsic evaporation resistance of the sample, R ef A (kPa×m 2 / W): 0.002

[0069] Total heat loss, Q t (W / m 2 ): 796

[0070] While this disclosure has been described in conjunction with specific embodiments thereof, it will be understood that this disclosure is capable of further modifications, and this application is intended to cover any changes, uses or adaptations, including those that differ from the content of this disclosure but are known or customary in the art, applicable to the essential features described herein, and those within the scope of the appended claims.

Claims

1. A knitted fabric having moisture management functionality, comprising: a surface fabric layer comprising a first yarn having a durable water repellent (DWR) additive or a DWR finish layer, wherein the first yarn comprises a synthetic polymer, the first yarn forming an outer surface of the surface fabric layer; a back fabric layer comprising a hydrophilic second yarn forming a moisture wicking core to absorb moisture and spread the moisture onto an inner surface of the back fabric layer, the hydrophilic second yarn comprising natural or regenerated cellulose fibers; and a linking yarn for joining the surface fabric layer and the back fabric layer together in the knitted fabric such that an inner surface of the surface fabric layer faces the inner surface of the back fabric layer, wherein the linking yarn is a single strand of elastomeric fiber, wherein the surface fabric layer further comprises a third yarn that is braided with the first yarn such that the third yarn is on the inner surface of the surface fabric layer and the first yarn is on the outer surface of the surface fabric layer, wherein the third yarn is an elastomeric fiber having a denier between 10D and 70D; the back fabric layer further comprises a fourth yarn that is braided with the second yarn such that the fourth yarn is on the inner surface of the back fabric layer and the second yarn is on the outer surface of the back fabric layer, wherein the fourth yarn is an elastomeric fiber having a denier between 10D and 70D.

2. The knitted fabric of claim 1, wherein, the first yarn is spun using a DWR additive within the first yarn.

3. The knitted fabric of claim 1, wherein, the outer surface of the surface fabric layer is finished with a DWR coating.

4. The knitted fabric of claim 1, wherein, the synthetic polymer is selected from the group consisting of nylon, polyester, polypropylene, acrylic, and any mixtures or combinations thereof.

5. The knitted fabric of claim 4, wherein, the synthetic polymer of the first yarn is nylon 6.6, the first yarn has a denier range of 20D-100D and a thread count of 10 to 186.

6. The knitted fabric of any one of claims 1 to 4, wherein, the back fabric layer is napped or brushed to increase its surface area.

7. The knitted fabric of any one of claims 1 to 5, wherein, the fourth yarn is an elastomeric fiber having a denier of 30D to 40D.

8. The knitted fabric of any one of claims 1 to 5, wherein, the linking yarn has a denier in the range of 10D to 70D.

9. The knitted fabric of claim 8, wherein, the linking yarn forms a herringbone structure between the surface fabric layer and the back fabric layer.

10. The knitted fabric of any one of claims 1 to 5, wherein, the fabric is a weft-knitted or warp-knitted fabric.

11. The knitted fabric of any one of claims 1 to 4, wherein, the back fabric layer has a moisture regain in the range of 4% to 18%.

12. The knitted fabric of claim 10, wherein, the weft-knitted or warp-knitted fabric has a single-layer knitted structure or a double-sided knitted structure.

13. The knitted fabric of any one of claims 1 to 5, wherein, the outer surface of the back fabric layer is finished with a sweat conducting finish.

14. The knitted fabric of any one of claims 1 to 5, wherein, the fabric is a pique fabric or a tricot fabric.

15. An article of clothing comprising the fabric of any one of claims 1 to 14.

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