Bamboo-Containing Fabric and Method of Production

Abstract

A fabric is disclosed as including bamboo-containing yarns, copper-based yarns and spandex yarns. A method of producing a fabric is further disclosed as including knitting bamboo-containing yarns together with copper-based yarns and spandex yarns.

Description

FIELD OF THE INVENTION

[0001] This invention relates to a bamboo-containing fabric and method of its production.BACKGROUND OF THE INVENTION

[0002] Fabric with copper-based yarns and method of forming same are already known, for example, in U.S. Pat. Nos. 10,266,969 B2 and 11,008,675 B1 issued to Fisher, the content of which being incorporated herein by reference in their entirety as if fully set forth herein.

[0003] Despite the advantageous properties of such existing copper-based yarns and fabric made of such yarns, further research and development have been undertaken to seek to enhance the eco-friendliness, comfort, and / or other advantageous characteristics of such fabric.

[0004] It is thus an object of the present invention to provide a fabric and a method of producing a fabric, so as to enhance or provide further advantages, or at least to provide a useful alternative to the trade and public.SUMMARY OF THE INVENTION

[0005] According to a first aspect of the present invention, there is provided a fabric including at least one or more bamboo-containing yarns; and one or more copper-based yarns.

[0006] According to a second aspect of the present invention, there is provided a method of producing a fabric, including knitting at least one bamboo-containing yarn together with at least one copper-based yarn.DESCRIPTION OF THE EMBODIMENTS

[0007] Bamboos are evergreen perennial flowering plants in the subfamily Bambusoideae from the grass family. Bamboo is one of the fastest-growing plants in the world, due to a unique rhizome-dependent system. Certain species of bamboo can grow 910 mm within 24 hours, at a rate of almost 40 mm an hour (i.e. growth of around 1 mm every 90 seconds). Giant bamboos are the largest members of the grass family.

[0008] As a fiber, bamboo is a natural cellulosic regenerated biodegradable environmentally-friendly textile material. It is a green fiber and has the inherent properties of anti-bacterial and ultraviolet (UV) protective properties, making it a unique eco-friendly textile material in the 21st century.

[0009] Bamboo is a bast fiber like jute, flax, ramie, etc. The main components of bamboo are rhizomes, roots, culms, branches, leaves and flowers. Bamboo is a lingo-cellulosic bast fiber, and its chemical composition and properties are similar to those of the other bast fibers like jute, and flax. In particular, bamboo contains cellulose (70-74%), hemicellulose (12-14%), lignin (10-12%), and extractives like protein, pectin, and wax (2-3%).

[0010] There are two main types of manufacturing methods for bamboo fibers, namely, chemical process and mechanical process.

[0011] Depending on the type of fabric, bamboo fibers can be produced by two different chemical methods. The majority of bamboo fibers are produced by the viscose rayon processing method, which is economical but has certain environmental downsides. This method is a regenerated or semi-synthetic fiber processing method.

[0012] According to this method, bamboo culms are extracted and crushed. Crushed bamboo is soaked in a solution of 20% NaOH at a temperature of 20° C. for 3 hours to form an alkali solution. Soda cellulose is crushed by a grinder and left to dry for 24 hours. The remaining carbon disulfide (CS2) is removed by evaporation and formation of sodium cellulose xanthate. NaOH is added with sodium cellulose xanthate dissolving it to create a viscous solution consisting of about 5% NaOH and 7% to 15% bamboo fiber cellulose. Then the highly viscous bamboo solution is forced through spinneret nozzles into a large container of a diluted H2SO4 solution. It solidifies into fibers, which are then spun into bamboo yarns.

[0013] Another chemical method, namely, close loop solvent spinning process (also known as Lyocell type of spinning process), is an eco-friendly process. Unlike the above process used for viscose rayon, closed-loop rayon production does not chemically alter the structure of the cellulose used, resulting in a purely organic fabric. While the solvent for making traditional viscose processing is wasted and usually ends up in a biosphere, the solvent (n-methylmorpholine n-oxide) used in closed-loop rayon production can be reused (99.5%) again and again.

[0014] In a mechanical process for forming bamboo fibers, cellulose is not extracted. Instead, a natural enzyme is used on crushed bamboo fibers, and these fibers are then washed and spun into yarn. Such yarns usually have a silky texture, and the fabric made by this process is sometimes called bamboo linen. It is actually true natural bamboo fiber processing. Such a method of making bamboo fabric is not environmentally harmful, and the resulting textile is strong and long-lasting.

[0015] Table 1 shows the general properties of bamboo fibers (Tests done at 20° C. and 65% relative humidity).TABLE 1PropertiesTest DataDry tensile strength (cN / dtex)2.33Wet tensile strength (cN / dtex)1.37Dry elongation at break (%)23.8Linear density (% deviation)1.8Percentage length deviation1.8Overlength staple fibers (%)0.2Whiteness (%)69.6Moisture region13.03Oil content0.17

[0016] Table 2 shows compositions of a first group of exemplary fabrics according to the present invention.TABLE 2Copper-BasedBamboo-ContainingSpandexPolyester Yarns (wt. %)Yarns (wt. %)Yarns (wt. %)A35%55%10%B30%65% 5%C40%48%12%D20%70%10%E55%35%10%F60%32% 8%G70%25% 5%H43%49% 8%

[0017] To form fabrics according to the present invention, copper-based yarns (such as copper-based polyester yarns formed according to known methods, such as those discussed in U.S. Pat. Nos. 10,266,969 B2 and 11,008,675 B1, or copper-based nylon yarns (see Table 3 below)), bamboo-containing yarns (such as yarns containing bamboo fibers as formed according to one of the methods discussed above) and spandex yarns are knitted together. It is envisaged that one or more synthetic yarn (e.g., nylon yarn) and / or natural yarn (e.g., cotton yarn) may also be knitted together to form the fabric.

[0018] A sample of Fabric H in Table 2 was tested under AATCC Test Method 100-Assessment of Antibacterial Finishes on Textile Materials, and was found to demonstrate >99.9% reduction against Methicillin resistant Staphylococcus aures MRSA (ATCC 43300).

[0019] Table 3 shows compositions of a second group of exemplary fabrics according to the present invention.TABLE 3Copper-BasedBamboo-ContainingSpandexNylon Yarns (wt. %)Yarns (wt. %)Yarns (wt. %)170%20%10% 265%30%5%355%40%5%435%55%10% 520%75%5%660%32%8%770%25%5%843%49%8%

[0020] Bamboo fiber can be processed through a regenerated or natural process. As it is 100% cellulosic it is biodegradable in nature without causing pollution. Bamboo can be grown without the use of pesticides, which together with other factors such as fast growing rate and low water consumption makes it a sustainable raw material for textiles.

[0021] Bamboo fiber is finer and softer than cotton. As cross sections of bamboo fibers are filled with micro gaps and micropores, it has better moisture absorption and ventilation capabilities. In summer bamboo fabric can evaporate sweat from the human body very fast just like breathing, thus being both aesthetically pleasant and cool to the human body.

[0022] Researches have shown that bamboo fibers have an inherent natural antibacterial property, and bamboo viscose-made fabric has a significant effect on the odor of body sweat. Furthermore, bamboo-made fabric has ultra-violet (UV) absorption properties, and can protect human skin from UV rays. It may therefore be used as a dress material for children and pregnant women.

[0023] It should be understood that the above only illustrates examples whereby the present invention may be carried out, and that various modifications and / or alterations may be made thereto without departing from the spirit of the invention. It should also be understood that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any appropriate sub-combinations.

Claims

1. A fabric including at least one or more bamboo-containing yarns and one or more copper-based yarns.

2. The fabric of claim 1, including 20-75 wt. % of said bamboo-containing yarn.

3. The fabric of claim 1, including 20-80 wt. % of said copper-based yarn.

4. The fabric of claim 1, further including 5-15 wt. % of one or more spandex yarns.

5. The fabric of claim 1, wherein said bamboo-containing yarn include at least a bamboo fiber.

6. The fabric of claim 1, wherein said copper-based yarn is a copper-based polyester yarn.

7. The fabric of claim 1, wherein said copper-based yarn is a copper-based nylon yarn.

8. The fabric of claim 1, further including a synthetic and / or natural yarn.

9. A method of producing a fabric, including knitting at least one bamboo-containing yarn together with at least one copper-based yarn.

10. The method of claim 9, further including knitting together with at least one spandex yarn.

11. The method of claim 9, wherein said copper-based yarn is a copper-based polyester yarn.

12. The method of claim 9, wherein said copper-based yarn is a copper-based nylon yarn.

13. The method of claim 9, further including knitting together a synthetic and / or natural yarn.