Breathable double-knit or interlock fabric with a single component material

Abstract

This invention relates to an elastic double-knit or interlock fabric made with improved breathability, and ease of recyclability compared to conventional elastic double-knit or interlock fabrics made with spandex, while maintaining the fabric weight, and the length and width stretch, characteristic of double-knit or interlock fabrics sold into athletic wear and intimate apparel markets.

Description

BREATHABLE DOUBLE-KNIT OR INTERLOCK FABRICBACKGROUND OF INVENTIONFIELD OF THE INVENTION

[0001] This invention relates to an elastic double-knit or interlock fabric made with improved breathability, and ease of recyclability compared to conventional elastic double-knit or interlock fabrics made with spandex, while maintaining the fabric weight, and the length and width stretch, characteristic of double-knit or interlock fabrics sold into athletic wear and intimate apparel markets.BACKGROUND

[0002] Knit fabrics are broadly used in active-wear because they easily deform, or stretch, by compressing or elongating the individual knit stitches (comprised of interconnected loops) that form the knit fabric. This ability to stretch in all directions by stitch rearrangement adds to the wearing comfort of garments made from knit fabrics, even when knit fabric are made of 100% non-elastic yarn, such as polyester, nylon, cotton or wool. However, the recovery force of such non-elastic yarn is not strong enough to rearrange the knit stiches after it is deformed. Therefore, knit fabric made with 100% non- elastic yarn may experience permanent deformation or "bagging" in certain garment areas such as at the knee part of pants, where more stretching occurs. To improve the recovery performance of knit fabric, co-knitting spandex with the companion non-elastic yarn is commonly used. The spandex increases the fabric stretch level and improves recovery power for shape retention and comfort to the wearer of garments made with such fabrics.

[0003] The spandex fiber typically is drafted to 200%-500% and co-knitted with non-elastic yarn. When the fabric is knitted, the recovery force from spandex will help maintain the structure of the knit stitches. However, a spandex co-knitted fabric can have an undesirable increased bulk and density. This can result in a fabric with lower comfort due to reduced breathability due to reduced air permeability, and it can also result in increased levels of trapped moisture.

[0004] Alternative methods of making stretch fabric in the art that do not use spandex can include non- elastomeric-elastic yarn such as textured polyethylene terephthalate (PET) stretch filament yarn, textured PPT stretch filament yarn, T400 yarn (polyethylene terephthalate / polytrimethylene terephthalate (PET / PTT) side-by-side bicomponent), or polybutylene terephthalate (PBT) stretch yarn are used. However, the recovery force of such non-elastomer-elastic yarns is often quite low, often about 10-20% of the recovery force of an equal denier spandex fiber. Therefore, to make a non-spandex stretch fabric having similar stretch properties as a spandex stretch fabric, the content of non- elastomeric-elastic yarn in non-spandex stretch fabric usually is at least 4 to 5 times more than the content of spandex in the spandex stretch fabric.

[0005] Comparing to single knit fabric, double-faced weft knit fabric is firmer and more stable. It makes fabric has softer hand feel, better garment dimensional stability and abrasion resistance. The doublelayer construction also makes fabric opaquer than single knit fabric, which effectively reduces "grin- through" issue. However, the double-layer construction has a negative impact on fabric breathability. For an elastic double-knit or interlock fabric with spandex, the air-permeability of fabric is affected by both the two-layer construction and the construction compacting effect from spandex fiber.

[0006] Additionally, when spandex is included in an elastic fabric construction, it can make the process of fiber separation at end of life for recycling more complicated. Therefore, there exists a need for a fabric with the opacity benefits of the double-knit or interlock construction, that also maintains the fabric weight, and the stretch and recovery properties similar to a spandex fabric, but without the decreased breathability, and without the complications of having a spandex fiber included for purposes of more facile fiber separation for recyclability.SUMMARY OF THE INVENTION

[0007] As described above, there is a need to produce an elastic double-knit or interlock fabric with better breathability and similar weight and stretch properties as elastic double-knit or interlock fabrics with spandex. Ideally, these knit fabrics are useful active wear and intimate wear, such as, but not limited to, bras, underwear, shaping wear, camisoles, leggings and sport bras.

[0008] A first aspect of the present invention is a double-knit or interlock fabric having one non- elastomeric-elastic yarn and one non-elastic yarn knitted together on dial needles to form one layer of knit fabric and having one non-elastomeric-elastic yarn and one non-elastic yarn knitted together on cylinder needles to form the other layer of fabric. One non-elastomeric-elastic yarn is also used to bind the two layers together. The non-elastomeric-elastic yarns cause the fabric to shrink and the yarns within to pull together during fabric and garment finishing process.

[0009] The content of non-elastomeric elastic yarn is higher than 10% and lower than 85% percentage by weight of total fabric weight.

[0010] According to some aspects, the elastic yarn is polyester bi-component filament including poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of polyethylene terephthalate), polyftrimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members, wherein the yarn denier is from about 20 to about 600 and the bicomponent filament is from about 5 weight percent to about 85 weight percent, based on total weight of the fabrics, and wherein the fabric is substantially free of grin-through of bi-component filament.BRIEF DESCRIPTION OF THE FIGURES

[0011] Figure 1 is the image of a circular knitting machine fed with one non-elastic yarn feed, a non- elastomeric elastic yarn feed on dial needles, one non-elastic yarn feed, a non-elastomeric elastic yarn feed on cylinder needles, and one non-elastomeric elastic yarn feed on cylinder needles.

[0012] Figure 2 is the stitch pattern to form a double jersey fabric.DETAILED DESCRIPTION OF THE INVENTION

[0013] "Elastic fiber" or "elastic yarn" refers to the fiber or the yarn with elastic and recovery properties. Elastic fiber or elastic yarn includes elastomeric fibers, such as, but not limited to, spandex, biconstituent filament, lastol filament, elastoester, and non-elastomeric-elastic fibers such as, but not limited to, polyester bi-component stretch fiber, textured PPT stretch filament, textured PET stretch filament, or PBT stretch filament. "Elastic yarn" and "elastic fiber" are used interchangeably in this context herein.

[0014] Elastomeric fibers are commonly used to provide stretch and elastic recovery in fabrics and garments. "Elastomeric fibers" are either a continuous filament (optionally a coalesced multifilament) ora plurality of filaments, free of diluents, which have a break elongation in excess of 100% independent of any crimp. An elastomeric fiber when (1) stretched to twice its length; (2) held for one minute; and (3) released, retracts to less than 1.5 times its original length within one minute of being released. As used in the text of this specification, "elastomeric fibers" means at least one elastomeric fiber or filament. Such elastomeric fibers include but are not limited to rubber filament, biconstituent filament and elastoester, lastol, and spandex.

[0015] "Spandex" is a manufactured filament in which the filament-forming substance is a long chain synthetic polymer comprised of at least 85% by weight of segmented polyurethane.

[0016] "Polyester bi-component filament" means a continuous filament comprising two polyester materials intimately adhered to each other along the length of the fiber, so that the fiber cross section is, for example, a side-by-side, eccentric sheath-core or other suitable cross-section from which useful crimp can be developed. The polyester bicomponent filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members, having an after heat-set crimp contraction value of from about 10% to about 80%. Crimp contraction is determined as described in US 7,310,932 B2 ('932 Patent), which is incorporated by reference in its entirety.

[0017] "Non-elastomeric-elastic fibers" means a stretch filament without containing elastomeric fiber. The recoverable stretch must be higher than 15% as tested by ASTM D6720-07. Examples include textured PTT, textured PET, bi-component stretch fiber, or PBT. These yarns develop additional crimp upon exposure to temperatures above standard room temperature (20°C).

[0018] "Grin-through" describes the exposure in a fabric of and elastic yarn to view when stretched. Grin-through can manifest itself as an undesirable glitter. If a choice must be made, low grin through on the face side is more desirable than low grin-through on the back side.

[0019] "Draft" refers to the amount of stretch applied to the spandex during use in knitting or covering or twisting with another fiber. The draft of a fiber is directly related to the elongation (stretching) applied to the fiber (e.g. 100% elongation corresponds to 2x draft, 200% elongation corresponds to 3x draft, etc).

[0020] "Hard yarn" means a knitting yarn, which does not contain an elastic yarn, such as a spun cotton yarn, textured polyester filament or a nylon synthetic fiber.

[0021] Articles of the present invention may be used in a variety of fabric or garment types including sportswear, underwear and undergarments such as bras, form-fitting wear, athletic wear, dance wear and other forms of apparel. These articles provide form fit and comfort due to their relatively lightweight, stretch and recovery properties and breathability.Elastic Fiber Content

[0022] The inventive articles and fabrics may have an elastic fiber content of about 25% to about 60%, about 30% to about 50%, or about 55% to about 45% percentage by weight of the article or fabric.Fabric Recovery Force and elongation

[0023] Fabric tensile testing is performed according to ASTM D4964-96. The samples were conditioned for 16 hours at 70° F and 65% relative humidity. Fabric tensile tests were performed by cycling to 50% elongation at 200% per minute. The fabric recovery force at 30% elongation on the third cycle is recorded as fabric recovery force.

[0024] Fabrics were evaluated for % elongation under 7 kg load force in the fabric weft and warp directions.

[0025] The fabric recovery forces for the inventive articles / fabrics may range in the warp direction from about 175 to about 400 gram-force, and about 200 to about 250 gram-force; and may range in the weft direction from about 100 to about 275 gram-force, about 125 to about 250 gram-force, and about 130 to about 200 gram-force.

[0026] The inventive elongation properties of the inventive articles / fabrics may range from about 40% to about 90%, about 50% to about 85%, and about 60% to about 75%.

[0027] Fabric air permeability was measured according to ASTM D737, using a TEXTEST FX 3300 machine, Zurich Switzerland.

[0028] The air permeability of the inventive articles / fabrics may range from about 25 to about 150 cfm, about 35 to about 120 cfm and about 50 to about 100 cfm.

[0029] In one aspect of the invention there is provided an article which includes a double-knit or interlock fabric having a two-face construction wherein one layer of fabric comprises yarns knitted on the dial needles and the other layer of fabric comprises yarns knitted on the cylinder needles, wherein, the two layers of fabrics further comprises yarns on the cylinder needles, and wherein the yarns fed into at least one of the dial needles or the cylinder needles comprise a non-elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion, with one non-elastomeric- elastic yarn, and the yarns fed into at least one of the dial needles or the cylinder needles comprise either a non-elastic yarn or a non-elastomeric elastic yarn feed to the cylinder needles.

[0030] Desirably articles of the invention include a double-knit or interlock fabric having two-face construction wherein one layer of fabric comprises yarns knitted on the dial needles and the other layer of fabric comprises yarns knitted on the cylinder needles, wherein the two layers of fabrics further comprises yarns on the cylinder needles, and wherein the yarns fed to the dial needles comprise a non- elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion, with one non- elastomeric-elastic yarn, and the yarns fed to the cylinder needles comprise one non-elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion with one non-elastomeric elastic yarn feed to the cylinder needles.

[0031] In one desirable aspect of the invention the non-elastomeric-elastic yarn includes a polyester bicomponent filament comprising poly(trimethylene terephthalate) and at least one polymer selected from polyethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such polymers, having a yarn denier from about 20 to about 600.

[0032] In one aspect of the invention the fabric does not include any spandex yarns.

[0033] In one aspect of the invention the non-elastic yarn is polyester, nylon, or cotton, or a blended yarn that includes at least 50% of one or more of these yarn fiber types. For example, the blended yarn may include 50-90% of these yarn fiber types; 60-80% of these yarn fiber types; and 70-85% of these yarn fiber types.

[0034] In another aspect of the invention the elastic fiber content is 25 to 60% percentage by weight of the article.

[0035] In another aspect of the invention the recovery of the article in the warp direction is 175 to 400 gram-force, and in the weft direction is 100 to 275 gram-force.

[0036] In yet another aspect of the invention the elongation of the article is 40 to 90%.

[0037] In yet another aspect of the invention the fabric has an air permeability of 5 to 120 cfm.

[0038] In still another aspect of the invention the non-elastic yarn is dyed before knitting.

[0039] In another aspect of the invention the non-elastic yarn is indigo dyed yarn.

[0040] In another aspect of the invention the non-elastic yarn comprises a yarn that is dyed to a color and the non-elastomeric elastic yarn is not dyed or dyed to a different color.

[0041] In yet another aspect to the invention one or more of the yarns possess one of more of the following properties: moisture management, thermal resistance, anti-bacterial ability and soft-hand properties.

[0042] In another aspect of the invention the fabric is made by using a circular knit machine, a seamless machine, or a flat knit machine.

[0043] In another aspect of the invention a fabric having a two-face construction including a first face, a second face, and a binding yarn, wherein at least one of said first face and said second face comprises a non-elastic yarn and a non-elastomeric elastic yarn; and the other of said first face and said second face comprises a yarn selected from the group consisting of a non-elastic yarn, a non-elastomeric elastic yarn, and combinations thereof.

[0044] In another aspect of the invention the elastic fiber content is 25 to 60% percentage by weight of the article.

[0045] In another aspect of the invention the recovery of the article in the warp direction is 175 to 400 gram-force, and in the weft direction is 100 to 275 gram-force.

[0046] In another aspect of the invention the elongation of the article is 40 to 90%.

[0047] In another aspect of the invention the article has an air permeability of 5 to 120 cfm.

[0048] In yet another aspect of the invention there is provided a method of making an elastic doubleknit or interlock fabric having improved breathability, ease of recyclability over conventional fabrics of this type, while maintaining the fabric weight, and the length and width stretch, comprising:knitting a first layer of fabric on dial needles and a second layer of fabric on cylinder needles, wherein the two layers of fabric comprise yarns on the cylinder needles; and wherein the yarns fed into at least one of the dial needles or the cylinder needles comprise a non-elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion, with one non-elastomeric- elastic yarn, and the yarns fed into at least one of the dial needles or the cylinder needles comprise either a non-elastic yarn or a non-elastomeric elastic yarn feed to the cylinder needles.

[0049] Turning to the figures, Figure 1 is a circular knitting machine where the numbered components correspond to the following:10 Cylinder12 Dial14 Feed 2 cam block16 Cylinder yarn18 Feed 1 cam blocks20 Cam block 222 Cam block 124 Feed 3 Cam blocks26 Binding yarn28 Dial yarn30 Feed 2 cam blocks

[0050] Figure 2 provides a chart showing the yarn construction for a double jersey knit made on the circular knitting machine of Figure 1 and in accordance with the inventive articles / fabrics of the present invention.ClausesClause 1. An article comprising a double-knit or interlock fabric having two-face construction wherein one layer of fabric comprises yarns knitted on the dial needles and the other layer of fabric comprises yarns knitted on the cylinder needles, wherein, the two layers of fabrics further comprises yarns on the cylinder needles, and wherein the yarns fed into at least one of the dial needles or the cylinder needles comprise a non-elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion, with one non-elastomeric- elastic yarn, and the yarns fed into at least one of the dial needles or the cylinder needles comprise either a non-elastic yarn or a non-elastomeric elastic yarn feed to the cylinder needles.Clause 2. An article according to clause 1 including a double-knit or interlock fabric having two-face construction wherein one layer of fabric comprises yarns knitted on the dial needles and the other layer of fabric comprises yarns knitted on the cylinder needles, wherein the two layers of fabrics further comprises yarns on the cylinder needles, and wherein the yarns fed to the dial needles comprise a non- elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion, with one non- elastomeric-elastic yarn, and the yarns fed to the cylinder needles comprise one non-elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion with one non-elastomeric elastic yarn feed to the cylinder needles.Clause 3. The article of any one of clauses 1-2, wherein the non-elastomeric-elastic yarn is a polyester bicomponent filament comprising poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of polyethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members, wherein the yarn denier is from about 20 to about 600.Clause 4. The article of any one of clauses 1-3, wherein the yarn fed to the cylinder needles comprises a non-elastomeric-elastic yarn.Clause 5. The article of any one of clauses 1-4, wherein the fabric does not contain any spandex yarns.Clause 6. The article of any one of clauses 1-5, wherein the non-elastic yarn is polyester, nylon, or cotton, or a blended yarn that includes at least 50% of one or more of these yarn fiber types.Clause 7. The article of any one of clauses 1-6, wherein the elastic fiber content is 25 to 60% by weight of the article.Clause 8. The article of any one of clauses 1-7, wherein the recovery of the article in the warp direction is 175 to 400 gram-force, and in the weft direction is 100 to 275 gram-force.Clause 9. The article of any one of clauses 1-8, wherein the elongation of the article is 40 to 90%.Clause 10. The article of any one of clauses 1-9 having air permeability of 5 to 120 cfm.Clause 11. The article of any one of clauses 1-10, wherein the non-elastic yarn is dyed before knitting.Clause 12. The article of any one of clauses 1-11, wherein the non-elastic yarn is indigo dyed yarn.Clause 13. The article of any one of clauses 1-12, wherein the non-elastic yarn comprises a yarn that is dyed to a color and the non-elastomeric elastic yarn is not dyed or dyed to a different color.Clause 14. The article of any one of clauses 1-13, wherein one or more of the yarns has moisture management, thermal resistance, anti-bacteria ability, and soft hand properties.Clause 15. The article of any one of clauses 1-14, wherein the fabric is made by using a circular knit machine, a seamless machine, or a flat knit machine.Clause 16. A fabric having a two-face construction comprising a first face, a second face, and a binding yarn, wherein at least one of said first face and said second face comprises a non-elastic yarn and a non- elastomeric elastic yarn; and the other of said first face and said second face comprises a yarn selected from the group consisting of a non-elastic yarn, a non-elastomeric elastic yarn, and combinations thereof.Clause 17. The article of clause 16, wherein the elastic fiber content is 25 to 60% percentage by weight of the article.Clause 18. The article of any one of clauses 16-17, wherein the recovery of the article in the warp direction is 175 to 400 gram-force, and in the weft direction is 100 to 275 gram-force.Clause 19. The article of any one of clauses 16-18, wherein the elongation of the article is 40 to 90%.Clause 20. The article of any one of clauses 16-19, having air permeability of 5 to 120 cfm.Clause 21. A method of making an elastic double-knit or interlock fabric having improved breathability, ease of recyclability over conventional fabrics of this type, while maintaining the fabric weight, and the length and width stretch, comprising: knitting a first layer of fabric on dial needles and a second layer of fabric on cylinder needles, wherein the two layers of fabric comprise yarns on the cylinder needles; and wherein the yarns fed into at least one of the dial needles or the cylinder needles comprise a non-elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion, with one non-elastomeric- elastic yarn, and the yarns fed into at least one of the dial needles or the cylinder needles comprise either a non-elastic yarn or a non-elastomeric elastic yarn feed to the cylinder needles.Clause 22. An article according to any combination of any one of clauses 1-21.

[0051] The features and advantages of the present invention are more fully shown by the following examples which are provided for purposes of illustration and are not to be construed as limiting the invention in any way.EXAMPLES

[0052] Examples 1-5 are comparison fabrics made, which are not representative of the present invention, and are marked accordingly. Examples of fabrics made in accordance with the present invention are shown in examples 6-8.EXAMPLE 1 (Comparison)

[0053] A double jersey fabric was made by: 70 denier / 88 filament polyester yarn plaited with 20 denier LYCRA® spandex fiber on dial needles and same set of yarns on cylinder needles to form both layers of fabric. A 20 denier LYCRA® spandex fiber on cylinder needles to bind the two layers together. The draft of all LYCRA® spandex fiber in the fabric during knitting is 3.25X.EXAMPLE 2 (Comparison)

[0054] A double jersey fabric was made by: 50 denier / 72 filament polyester yarn on dial needles and same set of yarns on cylinder needles to form both layers of fabric. A 20 denier LYCRA® spandex fiber on cylinder needles to bind the two layers together. The draft of all LYCRA® spandex fiber in the fabric during knitting is 3.25X.EXAMPLE 3 (Comparison)

[0055] A double jersey fabric was made by: 50 denier / 72 filament polyester yarn on dial needles and same set of yarns on cylinder needles to form both layers of fabric. A 30 denier LYCRA® spandex fiber on cylinder needles to bind the two layers together. The draft of all LYCRA® spandex fiber in the fabric during knitting is 3.25X.EXAMPLE 4 (Comparison)

[0056] A double jersey fabric was made by: 50 denier / 72 filament polyester yarn on dial needles and 50 denier / 72 filament polyester yarn plaited with 30 denier LYCRA® spandex fiber on cylinder needles to form both layers of fabric. A 20 denier Nylon yarn on cylinder needles to bind the two layers together. The draft of all LYCRA® spandex fiber in the fabric during knitting is 3.25X.EXAMPLE 5 (Comparison)

[0057] A double jersey fabric was made by: 50 denier / 72 filament polyester yarn plaited with 20 denier LYCRA® spandex fiber on dial needles and 50 denier / 72 filament polyester yarn plaited with 20 denier LYCRA® spandex fiber on cylinder needles to form both layers of fabric. A 20 denier Nylon yarn on cylinder needles to bind the two layers together. The draft of all LYCRA® spandex fiber in the fabric during knitting is 3.25X.EXAMPLE 6 (Inventive)

[0058] A double jersey fabric was made by: 70 denier / 88 filament polyester yarn plaited with 20 denier LYCRA® T400 fiber (polyester bi-component fiber) on dial needles to knit one layer of fabric and 20 denier LYCRA® T400 fiber on cylinder needles to knit the other layer of fabric. A 20 denier LYCRA® T400 fiber on cylinder needles to bind the two layers together.EXAMPLE 7 (Inventive)

[0059] A double jersey fabric was made by: 20 denier LYCRA® T400 fiber (polyester bi-component fiber) on dial needles to knit one layer of fabric and 70 denier / 88 filament polyester yarn plaited with 20 denier LYCRA® T400 fiber on cylinder needles to knit the other layer of fabric. A 15 denier nylon fiber on cylinder needles to bind the two layers together.EXAMPLE 8 (Inventive)

[0060] A double jersey fabric was made by: 70 denier / 88 filament polyester yarn plaited with 20 denier LYCRA® T400 fiber (polyester bi-component fiber) on dial needles to knit one layer of fabric and 70 denier / 88 filament polyester yarn plaited with 20 denier LYCRA® T400 fiber on cylinder needles to knit the other layer of fabric. A 20 denier LYCRA® T400 fiber on cylinder needles to bind the two layers together.Table 1 Fabric Examples 1 through 8

[0061] As noted from Table 1 showing the properties of the comparative fabric constructions and the inventive fabric constructions, the fabric recovery properties of the inventive fabrics 6-8 are substantially less in both the warp and weft directions as compared to the comparative fabric constructions not made in accordance with the invention.

[0062] Additionally, the balance of other properties such as elongation and air permeability properties are achieved in the inventive fabrics as shown in Table 1, while in some cases keeping the fabric weight substantially the same as the conventional comparative fabrics.

Claims

ClaimsWhat is claimed is:

1. An article comprising a double-knit or interlock fabric having two-face construction wherein one layer of fabric comprises yarns knitted on the dial needles and the other layer of fabric comprises yarns knitted on the cylinder needles, wherein, the two layers of fabrics further comprises yarns on the cylinder needles, and wherein the yarns fed into at least one of the dial needles or the cylinder needles comprise a non-elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion, with one non-elastomeric- elastic yarn, and the yarns fed into at least one of the dial needles or the cylinder needles comprise either a non-elastic yarn or a non-elastomeric elastic yarn feed to the cylinder needles.

2. An article comprising a double-knit or interlock fabric having two-face construction wherein one layer of fabric comprises yarns knitted on the dial needles and the other layer of fabric comprises yarns knitted on the cylinder needles, wherein the two layers of fabrics further comprises yarns on the cylinder needles, and wherein the yarns fed to the dial needles comprise a non-elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion, with one non-elastomeric-elastic yarn, and the yarns fed to the cylinder needles comprise one non-elastic yarn combined by plaiting or twisting, or entanglement, or coinsertion with one non-elastomeric elastic yarn feed to the cylinder needles.

3. The article of claim 2, wherein the non-elastomeric-elastic yarn is a polyester bi-component filament comprising poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of polyethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination of such members, wherein the yarn denier is from about 20 to about 600.

4. The article of claim 2, wherein the yarn fed to the cylinder needles comprises a non-elastomeric- elastic yarn.

5. The article of claim 2, wherein the fabric does not contain any spandex yarns.

6. The article of claim 2, wherein the non-elastic yarn is polyester, nylon, or cotton, or a blended yarn that includes at least 50% of one or more of these yarn fiber types.

7. The article of claims 1 or 2 wherein the elastic fiber content is 25 to 60% percentage by weight of the article.

8. The article of claims 1 or 2 wherein the recovery of the article in the warp direction is 175 to 400 gram-force, and in the weft direction is 100 to 275 gram-force.

9. The article of claims 1 or 2 wherein the elongation of the article is 40 to 90%.

10. The article of claims 1 or 2 having air permeability of 5 to 120 cfm.

11. The article of claim 2, wherein the non-elastic yarn is dyed before knitting.

12. The article of claim 2, wherein the non-elastic yarn is indigo dyed yarn.

13. The article of claim 2, wherein the non-elastic yarn comprises a yarn that is dyed to a color and the non-elastomeric elastic yarn is not dyed or dyed to a different color.

14. The article of claim 2, wherein one or more of the yarns has moisture management, thermal resistance, anti-bacteria ability, and soft hand properties.

15. The article of claim 2, wherein the fabric is made by using a circular knit machine, a seamless machine, or a flat knit machine.

16. A fabric having a two-face construction comprising a first face, a second face, and a binding yarn, wherein at least one of said first face and said second face comprises a non-elastic yarn and a non- elastomeric elastic yarn; and the other of said first face and said second face comprises a yarn selected from the group consisting of a non-elastic yarn, a non-elastomeric elastic yarn, and combinations thereof.

17. The article of claim 16, wherein the elastic fiber content is 25 to 60% percentage by weight of the article.

18. The article of claim 17, wherein the recovery of the article in the warp direction is 175 to 400 gramforce, and in the weft direction is 100 to 275 gram-force.

19. The article of claim 18, wherein the elongation of the article is 40 to 90%.

20. The article of claim 19, having air permeability of 5 to 120 cfm.

21. A method of making an elastic double-knit or interlock fabric having improved breathability, ease of recyclability over conventional fabrics of this type, while maintaining the fabric weight, and the length and width stretch, comprising: knitting a first layer of fabric on dial needles and a second layer of fabric on cylinder needles, wherein the two layers of fabric comprise yarns on the cylinder needles; and wherein the yarns fed into at least one of the dial needles or the cylinder needles comprise a non-elastic yarn combined by plaiting or twisting, or entanglement, or co-insertion, with one non-elastomeric- elastic yarn, and the yarns fed into at least one of the dial needles or the cylinder needles comprise either a non-elastic yarn or a non-elastomeric elastic yarn feed to the cylinder needles.

22. An article according to any combination of claims 1-21.

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