Elastic combination yarns with low temperature finishing including fabrics and garments

Abstract

The present invention relates to elastic combination yams, their method of preparation and their use, particularly in applications requiring retention of mechanical stability subsequent to finishing at temperatures of about 160 °C or less. The elastic combination yarn includes a. bicomponent polyester fiber; and a hard polyolefin fiber.

Description

^^^^^^^^^^^ ^ ^ELASTIC COMBINATION YARNS WITH LOW TEMPERATURE FINISHING INCLUDING FABRICS AND GARMENTS CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of, and priority to U.S. Provisional Patent Application No. 63 / 638,226 filed on April 24, 2024, and U.S. Provisional Patent Application No. 63 / 740,616 filed on December 31, 2024, the contents of which are herein incorporated by reference in their entirety and for all purposes. BACKGROUND Field

[0002] The present invention relates to elastic combination yarns, their method of preparation and their use, particularly in applications requiring retention of mechanical stability subsequent to finishing at temperatures of about 160 °C or less. The elastic combination yarn includes a bicomponent polyester fiber; and a hard polyolefin fiber. Brief Description of Technology

[0003] During the manufacturing process of articles containing elastic yarn, a process of “heat setting” is usually used to finish the product for consumer use. A “dyeing” setting process may also be used. Due to the presence of elastic, heat setting must be used to “set” the elastic yarn. In the absence of a finishing step, the resulting fabric of article may have high shrinkage, excessive fabric weight, and excessive elongation, which may result in a negative experience for the consumer. Excessive shrinkage during the fabric finish process may result in crease marks on the fabric surface during processing and household washing. Creases that develop in this manner are frequently very difficult to remove by ironing.

[0004] Heat setting temperatures for elastic yarns are generally in the range of 175 °C to 200 °C. Heat setting conditions for conventional spandex are for about 45 seconds or more at about 190 °C. Heat setting at high temperature could damage the elastic yarn structure and kill its elasticity and recovery power, which often causes poor garment shape retention during wearing. Moreover, typical elastic yarn heat-setting temperatures can adversely affect sensitive companion yarns, e.g., wool, cotton, polypropylene and silk. After such heat-set, the non-elastic ^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^fabrics become harsh and sometimes possess yellowing. For polyester and Nylon fibers, high temperature heat-set could affect the fabric dye ability. The high heat setting process also introduces additional costs into the manufacture of articles containing elastic yarn.

[0005] Further, non-elastic polyolefin fibers such as polypropylene,^polyethylene, acrylic, wool and any other fibers which cannot be treated in high temperature, have melting points within the heat setting range of conventional elastic fibers. Therefore, said non-elastic fibers are unusable at high heat setting temperatures.

[0006] Elastic cross-linked polyolefin fibers have been used in the manufacture of knit articles wherein the articles have not been subjected to a temperature greater than 160 °C. (See U.S. Patent No. 7,943,536). However, the elastic cross-linked polyolefin fibers require catalyzation to retain elasticity as described in U.S. Patent No. 6,437,014. (requiring at least one amine or nitrogen-containing stabilizer). Moreover, the elastic cross-linked polyolefin fibers require a “radiation crosslinking” step as described in U.S. Patent No. 6,437,014.

[0007] Therefore, there is a need in the industry for a reduced temperature finishing yarn, which retains mechanical stability while preserving the non-elastic fiber properties without the use of catalyzed, cross-linked, elastic polyolefin fibers. SUMMARY

[0008] The present invention solves the problems of the industry by producing a new elastic combination yarn requiring a reduced temperature heat setting step, which may reduce heat damage to certain non-elastic fibers and thus may improve the handle of the finished fabric. As a further benefit, heat sensitive hard yarns can be used, thus increasing the possibilities for different and improved products. In addition, the elastic combination yarns with the ability to be finished at lower finishing temperatures have productivity benefits to the fabric manufacturer.

[0009] One advantageous aspect of the present invention provides an elastic combination yarn including: a bicomponent polyester fiber, the bicomponent comprising glycol terephthalate polyester components having different chain-branched content, and a hard polyolefin fiber, ^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^wherein the elastic combination yarn retains its mechanical stability when finished at a temperature of about 160 C° or less.

[0010] Another advantageous aspect of the present invention provides a fabric comprising an elastic combination yarn including: a bicomponent polyester fiber, the bicomponent comprising glycol terephthalate polyester components having different chain-branched content, and a hard polyolefin fiber, wherein the elastic combination yarn retains its mechanical stability when finished at a temperature of about 160 C° or less.

[0011] Yet another advantageous aspect of the present invention provides a process of preparing an elastic combination yarn including: providing a bicomponent polyester fiber, the bicomponent comprising glycol terephthalate polyester components having different chain-branched content, providing a hard polyolefin fiber, and combining the bicomponent polyester fiber and the hard polyolefin fiber to form the elastic combination yarn, wherein the elastic combination yarn retains its mechanical stability when finished at a temperature of about 160 C° or less. BRIEF DESCRIPTION OF THE FIGURES

[0012] FIG. 1 is a double jersey fabric made using 50 denier / 34 filaments bicomponent polypropylene on one side of the fabric and the 55 denier / 48 filaments T400 bicomponent polyester fiber on both sides of the fabric formed in Construction Type A.

[0013] FIG. 2 is a double jersey fabric made using 50 denier / 34 filaments bicomponent polypropylene on one side of the fabric and the 55 denier / 48 filaments T400 bicomponent polyester fiber on both sides of the fabric formed in Construction Type B. ^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^

[0014] FIG. 3. is a double jersey fabric made using 50 denier / 34 filaments bicomponent polypropylene on one side of the fabric and the 55 denier / 48 filaments T400 bicomponent polyester fiber on both sides of the fabric formed in Construction Type C.

[0015] FIG. 4. is a double jersey fabric made using 50 denier / 34 filaments bicomponent polypropylene on one side of the fabric and the 55 denier / 48 filaments T400 bicomponent polyester fiber on both sides of the fabric formed in Construction Type D. DETAILED DESCRIPTION Definitions

[0016] “Bi-component fiber” means a manufactured fiber made from two different polymer components, which may be composed of different polymer types or variants of the same polymer.

[0017] “Circular knit” means a fabric produced in the form of a tube, the threads running continuously around the fabric.

[0018] “Double knit” means a weft-knit fabric produced on a dial-and-cylinder knitting machine, which is equipped with two sets of latch needles situated at right angles to each other.

[0019] “Fiber” means a unit of matter, either natural or manufactured, that forms the basic element of fabrics and other textile structures. A fiber may be characterized by having a length at least 1000 times its diameter or width.

[0020] “Filament” means a fiber of indefinite or extreme length.

[0021] “Flat knit” means a fabric produced in flat form, the threads alternating back and forth across the fabric.

[0022] “Finish,” “finished,” and “finishing” mean processes that convert the textile into a usable material to improve the look, performance, or “hand” (feel) of the finished textile. Such processes may include, but are not limited to heat setting, dyeing etc.

[0023] “Hard Polyolefin” means polyolefin fiber which has no significant stretch performance after the heat treating / finishing process, such as, but not limited to, polypropylene fiber; ^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^polyethylene fiber; polylactic acid fiber, any other fibers that cannot be treated at high temperature and combinations thereof.

[0024] “Hosiery” means a type of knitting in which one continuous yarn runs crosswise on a cylindrical machine and needs to be cut and sewn.

[0025] “Jersey or jersey knit” means a circular or flat-knit fabric with a plain stitch in which the loops intermesh in only one direction or a tricot fabric made with a simple stitch, characterized by excellent drape and wrinkle recovery properties.

[0026] “Knit or knit fabric” means a structure produced by interlooping one or more ends of yarn or comparable material.

[0027] “Milanese knit” means a type of run-resistant warp knitting with a diagonal rib effect using several sets of yarns.

[0028] “Polyester or polyester fiber” means a manufactured fiber in which the fiber-forming substances is any long-chain synthetic polymer composed of at least 85% by weight of an ester of a substituted aromatic carboxylic acid, including but not limited to substituted terephthalate units and parasubstituted hydroxybenzoate units.

[0029] “Raschel knit” means a type of warp knitting made in plan and jacquard patterns; the latter can be made with intricate eyelet and lacy patterns.

[0030] “Seamless” means a type of knitting, which is conducted on a cylindrical machine and needs little or no cutting and sewing process.

[0031] “Single knit” means a fabric constructed with one needle bed and one set of needles.

[0032] “Warp knit” means a type of knitting in which the yarns generally run lengthwise. The yarns are generally prepared on beams with one or more yarns for each needle. Warp knitting types include tricot, milanese, and raschel.

[0033] “Weft knit” means a type of knitting in which one continuous thread runs crosswise in the fabric making all of the loops in one course. Weft knitting types include circular knit and flat knit. ^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^

[0034] “Yarn” means continuous strands of textile fibers, filaments, or material in a form suitable for knitting, weaving, or otherwise intertwining to form a textile fabric. Bicomponent Polyester Fibers

[0035] The elastic combination yarns of the present invention include bicomponent polyester fibers described in U.S. Patent No. 5,723,215, the subject matter of which is herein incorporated by reference in its entirety.

[0036] In one advantageous aspect of the present invention the bicomponent polyester fibers may include glycol terephthalate polyester components having different chain-branched content. For example, the polyester fibers may be of a helical configuration that has resulted from a difference between chain-branched contents of the glycol terephthalate polyester components of said fibers.

[0037] In another advantageous aspect of the present invention the bicomponent polyester fibers may include at least one glycol terephthalate polyester component which may be copolymerized with up to 3 / 4f(f-2) mole % of chain-branching agent, where f is 3 to 6 and is the number of ester-forming functional groups of the chain-branching agent. In yet another advantageous aspect of the present invention, f is 3. In a further advantageous aspect of the present invention the chain-branched glycol terephthalate polyester component may be copolymerized with at least 0.1 mole % and up to 0.25 mole % of the chain-branching agent.

[0038] In another advantageous aspect of the present invention the glycol terephthalate polyester may be selected from polytrimethylene terephthalate (PTT), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and combinations thereof.

[0039] In yet another advantageous aspect of the present invention the bicomponent chain- branched glycol terephthalate polyester fiber component may be arranged in a configuration selected from helical, side-by-side, sheath core, eccentric, eccentric sheath core, and combinations thereof.

[0040] “Helical” means continuously wound fiber components, wherein at least one component may be wound in the clockwise direction, and at least one component may be wound in the counterclockwise direction. ^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^

[0041] As used herein, the term “side-by-side” means that the two components of the bicomponent fiber are immediately adjacent to one another and that no more than a minor portion of either component is within a concave portion of the other component.

[0042] “Eccentric sheath-core” means that one of the two components completely surrounds the other component but that the two components are not coaxial.

[0043] “Sheath core” means one component forms a core and the other surrounds it as a sheath, and the two components are coaxial.

[0044] Side-by-side fibers can have a “snowman,” oval, or substantially round cross-sectional shape. Eccentric sheath-core fibers can have an oval or substantially round cross-sectional shape. By “substantially round” it is meant that the ratio of the lengths of two axes crossing each other at 90° in the center of the fiber cross-section is no greater than about 1.2:1. By “oval” it is meant that the ratio of the lengths of two axes crossing each other at 90° in the center of the fiber cross- section is greater than about 1.2:1. A “snowman” cross-sectional shape can be described as a side-by-side cross-section having a long axis, a short axis and at least two maxima in the length of the short axis when plotted against the long axis.

[0045] In one advantageous aspect of the present invention the chain-branched glycol terephthalate polyester component may be arranged in a helical configuration. There are two different components in each filament of the bicomponent yarn, which may include but are not limited to polyethylene terephthalate / polyethylene terephthalate, polyethylene terephthalate / polypropylene terephthalate, polyethylene terephthalate / polybutylene terephthalate, which have different shrinkage properties after heat treatment at a certain temperature, resulting in a crimped state of the yarn and at the same time, a certain elasticity.

[0046] In a further advantageous aspect of the present invention the bicomponent polyester fiber forms a “spiral crimp” as described in U.S. Patent No. 5,723,215.

[0047] In yet another advantageous aspect of the present invention, the bicomponent polyester fiber may be present in an amount of about 1% to about 99% by weight of the elastic combination yarn. ^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^

[0048] In yet another advantageous aspect of the present invention, the bicomponent polyester fiber may be present in an amount of about 5% to about 80%; about 10% to about 80%; about 15% to about 80%; about 20% to about 80%; about 25% to about 80%; about 30% to about 80%; about 35% to about 80%; about 40% to about 80%; about 45% to about 80%; about 50% to about 80%; about 55% to about 80%; about 60% to about 80%; about 65% to about 80%; about 70% to about 80%; and about 75% to about 80% percent by weight of the elastic combination yarn.

[0049] In yet another advantageous aspect of the present invention, the bicomponent polyester fiber may be present in an amount of about 20% to about 80%; about 25% to about 80%; about 30% to about 80%; about 35% to about 80%; about 40% to about 80%; about 45% to about 80%; about 50% to about 80%; about 55% to about 80%; about 60% to about 80%; about 65% to about 80%; about 70% to about 80%; and about 75% to about 80% percent by weight of the elastic combination yarn.

[0050] In a further advantageous aspect of the present invention, the bicomponent polyester fiber may be present in an amount of about 20% to about 70%; about 25% to about 70%; about 30% to about 70%; about 35% to about 70%; about 40% to about 70%; about 45% to about 70%; about 50% to about 70%; about 55% to about 70%; about 60% to about 70%; and about 65% to about 70% percent by weight of the elastic combination yarn.

[0051] In yet another advantageous aspect of the present invention, the bicomponent polyester fiber may be present in an amount of about 20% to about 60%; about 25% to about 60%; about 30% to about 60%; about 35% to about 60%; about 40% to about 60%; about 45% to about 60%; about 50% to about 60%; and about 55% to about 60% percent by weight of the elastic combination yarn.

[0052] In another advantageous aspect of the present invention, the bicomponent polyester fiber may be present in an amount of about 20% to about 50%; about 25% to about 50%; about 30% to about 50%; about 35% to about 50%; about 40% to about 50%; and about 45% to about 50% percent by weight of the elastic combination yarn.

[0053] In another advantageous aspect of the present invention, the bicomponent polyester fiber may be present in an amount of about 10% to about 40%; about 15% to about 40%; about 20% ^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^to about 40%; about 25% to about 40%; about 30% to about 40%; and about 35% to about 40%; percent by weight of the elastic combination yarn.

[0054] In another advantageous aspect of the present invention, the bicomponent polyester fiber may be present in an amount of about 5% to about 30%; about 10% to about 30%; about 15% to about 30%; about 20% to about 30%; and about 25% to about 30% percent by weight of the elastic combination yarn. Hard Polyolefin Fibers

[0055] The elastic combination yarn of the present invention includes hard polyolefin fibers.

[0056] One advantageous aspect of the present invention includes the hard polyolefin fibers which may be selected from polypropylene fiber; polyethylene fiber; polylactic acid fiber;^any other fibers that cannot be treated at high temperature and combinations thereof. Fabrics made with polypropylene or polyethylene fibers have good moisture management due to outstanding wicking performance.

[0057] Examples of useful polyolefin resins are commercially available under the brand name VISTAMAXX by ExxonMobil, such as VISTAMAXX® 1100 and VISTAMAXX® 2100 which may be melted and shaped into a film or prepared as a nonwoven.

[0058] In one advantageous aspect of the present invention the hard polyolefin fibers are not crosslinked.

[0059] In one advantageous aspect of the present invention the hard polyolefin fibers do not include a catalyzation step.

[0060] In one advantageous aspect of the present invention the hard polyolefin fibers do not include a stabilizer.

[0061] In one advantageous aspect of the present invention, the hard polyolefin fiber may be present in an amount of about 1% to about 99% by weight of the elastic combination yarn.

[0062] In one advantageous aspect of the present invention, the hard polyolefin fiber may be present in an amount of about 5% to about 70%; about 10% to about 70%; about 15% to about 70%; about 20% to about 70%; about 25% to about 70%; about 30% to about 70%; about 35% to ^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^about 70%; about 40% to about 70%; about 45% to about 70%; about 50% to about 70%; about 55% to about 70%; about 60% to about 70%; and about 65% to about 70% percent by weight of the elastic combination yarn.

[0063] In one advantageous aspect of the present invention, the hard polyolefin fiber may be present in an amount of about 5% to about 60%; about 10% to about 60%; about 15% to about 60%; about 20% to about 60%; about 25% to about 60%; about 30% to about 60%; about 35% to about 60%; about 40% to about 60%; about 45% to about 60%; about 50% to about 60%; and about 55% to about 60% percent by weight of the elastic combination yarn.

[0064] In one advantageous aspect of the present invention, the hard polyolefin fiber may be present in an amount of about 5% to about 50%; about 10% to about 50%; about 15% to about 50%; about 20% to about 50%; about 25% to about 50%; about 30% to about 50%; about 35% to about 50%; about 40% to about 50%; and about 45% to about 50%; percent by weight of the elastic combination yarn.

[0065] In another advantageous aspect of the present invention, the hard polyolefin fiber may be present in an amount of about 5% to about 40%; about 10% to about 40%; about 15% to about 40%; about 20% to about 40%; about 25% to about 40%; about 30% to about 40%; and about 35% to about 40% percent by weight of the elastic combination yarn.

[0066] In yet another advantageous aspect of the present invention, the hard polyolefin fiber may be present in an amount of about 5% to about 30%; about 10% to about 30%; about 15% to about 30%; about 20% to about 30%; and about 25% to about 30% percent by weight of the elastic combination yarn.

[0067] In a further advantageous aspect of the present invention, the hard polyolefin fiber may be present in an amount of about 5% to about 20%; about 10% to about 20%; and about 15% to about 20% percent by weight of the elastic combination yarn.

[0068] In yet a further advantageous aspect of the present invention the hard polyolefin fibers have a fineness of about 5 to about 300 deniers; about 20 to about 300 deniers; about 30 to about 300 deniers; about 40 to about 300 deniers; about 50 to about 300 deniers; about 60 to about 300 deniers; about 70 to about 300 deniers; about 80 to about 300 deniers; about 90 to about 300 deniers; about 100 to about 300 deniers; about 110 to about 300 deniers; about 120 to about 300 ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^deniers; about 130 to about 300 deniers; about 140 to about 300 deniers; about 150 to about 300 deniers; about 160 to about 300 deniers; about 170 to about 300 deniers; about 180 to about 300 deniers; about 190 to about 300 deniers; about 200 to about 300 deniers; about 210 to about 300 deniers; about 220 to about 300 deniers; about 230 to about 300 deniers; about 240 to about 300 deniers; about 250 to about 300 deniers; about 260 to about 300 deniers; about 270 to about 300 deniers; about 280 to about 300 deniers; or about 290 to about 300 deniers.

[0069] In yet a further advantageous aspect of the present invention the hard polyolefin fibers have a fineness of about 10 to about 250 deniers; about 20 to about 250 deniers; about 30 to about 250 deniers; about 40 to about 250 deniers; about 50 to about 250 deniers; about 60 to about 250 deniers; about 70 to about 250 deniers; about 80 to about 250 deniers; about 90 to about 250 deniers; about 100 to about 250 deniers; about 110 to about 250 deniers; about 120 to about 250 deniers; about 130 to about 250 deniers; about 140 to about 250 deniers; about 150 to about 250 deniers; about 160 to about 250 deniers; about 170 to about 250 deniers; about 180 to about 250 deniers; about 190 to about 250 deniers; about 200 to about 250 deniers; about 210 to about 250 deniers; about 220 to about 250 deniers; about 230 to about 250 deniers; or about 240 to about 250 deniers.

[0070] In yet a further advantageous aspect of the present invention the hard polyolefin fibers have a fineness of about 10 to about 200 deniers; about 20 to about 200 deniers; about 30 to about 200 deniers; about 40 to about 200 deniers; about 50 to about 200 deniers; about 60 to about 200 deniers; about 70 to about 200 deniers; about 80 to about 200 deniers; about 90 to about 200 deniers; about 100 to about 200 deniers; about 110 to about 200 deniers; about 120 to about 200 deniers; about 130 to about 200 deniers; about 140 to about 200 deniers; about 150 to about 200 deniers; about 160 to about 200 deniers; about 170 to about 200 deniers; about 180 to about 200 deniers; or about 190 to about 200 deniers.

[0071] In yet a further advantageous aspect of the present invention the hard polyolefin fibers have a fineness of about 10 to about 150 deniers; about 20 to about 150 deniers; about 30 to about 150 deniers; about 40 to about 150 deniers; about 50 to about 150 deniers; about 60 to about 150 deniers; about 70 to about 150 deniers; about 80 to about 150 deniers; about 90 to about 150 deniers; about 100 to about 150 deniers; about 110 to about 150 deniers; about 120 to about 150 deniers; about 130 to about 150 deniers; or about 140 to about 150 deniers. ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^

[0072] In yet a further advantageous aspect of the present invention the hard polyolefin fibers have a fineness of about 10 to about 100 deniers; about 20 to about 100 deniers; about 30 to about 100 deniers; about 40 to about 100 deniers; about 50 to about 100 deniers; about 60 to about 100 deniers; about 70 to about 100 deniers; about 80 to about 100 deniers; or about 90 to about 100 deniers.

[0073] In a further advantageous aspect of the present invention the hard polyolefin fibers have a fineness of about 10 to about 80 deniers; about 20 to about 80 deniers; about 30 to about 80 deniers; about 40 to about 80 deniers; about 50 to about 80 deniers; about 60 to about 80 deniers; or about 70 to about 80 deniers.

[0074] In yet a further advantageous aspect of the present invention the hard polyolefin fibers have a fineness of about 10 to about 60 deniers; about 20 to about 60 deniers; about 30 to about 60 deniers; about 40 to about 60 deniers; or about 50 to about 60 deniers.

[0075] In yet a further advantageous aspect of the present invention the hard polyolefin fibers have a fineness of about 10 to about 40 deniers; about 20 to about 40 deniers; or about 30 to about 40 deniers.

[0076] In yet a further advantageous aspect of the present invention the hard polyolefin fibers have a fineness of about 10 to about 30 deniers; or about 20 to about 30 deniers. Mechanical Stability

[0077] In one advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 160 °C or less; about 150 °C or less; about 140 °C or less; about 130 °C or less; about 120 °C or less; about 110 °C or less; about 100 °C or less; about 90 °C or less; about 80 °C or less; and about 70 °C or less.

[0078] In one advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 160 °C to about 80 °C; about 150 °C to about 80 °C; about 140 °C to about 80 °C; about 130 °C to about 80 °C; about 120 °C to about 80 °C; about 110 °C to about 80 °C; about 100 °C to about 80 °C; and about 90 °C to about 80 °C.

[0079] In one advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 160 °C to about 70 °C; about 150 °C to about ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^70 °C; about 140 °C to about 70 °C; about 130 °C to about 70 °C; about 120 °C to about 70 °C; about 110 °C to about 70 °C; about 100 °C to about 70 °C; about 90 °C to about 70 °C; and about 80 °C to about 70 °C.

[0080] In one advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 160 °C to about 80 °C.

[0081] In one advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 160 °C or less.

[0082] In another advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 150 °C or less.

[0083] In a further advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 140 °C or less.

[0084] In yet a further advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 130 °C or less.

[0085] In yet a further advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 120 °C or less.

[0086] In another advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 110 °C or less.

[0087] In yet another advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 100 °C or less.

[0088] In yet another advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 90 °C or less.

[0089] In yet another advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 80 °C or less.

[0090] In a further advantageous aspect of the present invention, the elastic combination yarns are capable of being finished at a temperature of about 70 °C or less. ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^

[0091] In yet a further advantageous aspect of the present invention, when the hard polyolefin fiber is polypropylene the elastic combination yarns are desirably finished at a temperature of about 130 °C or less.

[0092] In another advantageous aspect of the present invention, the elastic combination yarns exhibit excellent one-way moisture performance, wherein the yarn is able to quickly move any moisture from one side of the respective layer to the other where it evaporates quickly leaving the yarn dry.

[0093] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a breaking elongation of about 5 % to over 200 %.

[0094] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a breaking elongation of about 25 % to about 200 %.

[0095] In another advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a breaking elongation of about 50 % to about 200 %.

[0096] In yet another advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a breaking elongation of about 75 % to about 200 %.

[0097] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a breaking elongation of about 100 % to about 200 %.

[0098] In a further advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a recovery force percentage of about 30 % to about 100 %.

[0099] In yet a further advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a recovery force percentage of about 40 % to about 100 %.

[0100] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a recovery force percentage of about 60 % to about 100 %.

[0101] In another advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a recovery force percentage of about 80 % to about 100 %.

[0102] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a shrinkage of about 10 % to about 40 %. In one advantageous aspect of ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^the present invention, the fabric is treated / finished in a process which generally begins with a greige fabric, followed by a washing step, followed by a heat setting step, followed by a dyeing step, and followed by a finishing step. The term “shrinkage,” refers to the amount of shrinkage (size change) from the fabric width from the start to the end of the treating / finishing process.

[0103] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have an evaporation rate of about 0.1 gram per hour to about 1 gram per hour.

[0104] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have an evaporation rate of about 0.2 gram per hour to about 1 gram per hour.

[0105] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have an evaporation rate of about 0.3 gram per hour to about 1 gram per hour.

[0106] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have an evaporation rate of about 0.4 gram per hour to about 1 gram per hour.

[0107] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have an absorbency of less 1 second to about 10 seconds.

[0108] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a vertical wicking of about 2 inches to over 6 inches.

[0109] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have a planar wicking of about 2 inches to about 6 inches.

[0110] In another advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have an air permeability of about 20 cfm to over 350 cfm.

[0111] In yet another advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have an air permeability of about 100 cfm to about 350 cfm.

[0112] In a further advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have an air permeability of about 150 cfm to about 350 cfm.

[0113] In one advantageous aspect of the present invention, subsequent to finishing, the elastic combination yarns have an air permeability of about 200 cfm to about 350 cfm. ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^Applications

[0114] In one advantageous aspect of the present invention, the elastic combination yarns may be formed according to a technique including, but not limited to, single wrapping of the bicomponent polyester fiber with the hard polyolefin fiber; double wrapping of the bicomponent polyester fiber with the hard polyolefin fiber; continuously covering the bicomponent polyester fiber with the hard polyolefin fiber, followed by twisting during winding; intermingling and entangling the bicomponent polyester fiber with the hard polyolefin fiber with an air jet; twisting the bicomponent polyester fiber and the hard polyolefin fiber together; blending the bicomponent polyester fiber and hard polyolefin fiber together and combinations thereof.

[0115] In one advantageous aspect of the present invention, the elastic combination yarns may be used to form a fabric including, but not limited to, weft knit, warp knit, jersey knit, single knit, double knit, single jersey knit, and combinations thereof.

[0116] In one advantageous aspect of the present invention, the elastic combination yarns may be combined with further fibers may include, but not limited to, polyester, wool, cotton, hemp, silk, lyocell, spandex, nylon, polylactic acid, chlorine fibers.

[0117] In one advantageous aspect of the present invention, an article of manufacture may be made from the elastic combination yarn of the present invention. The article of manufacture may be selected from any number of articles where reduced temperature finishing is useful and / or where retaining the mechanical properties described herein, subsequent to finishing, is useful. For example, the elastic combination yarns of the present invention may be used in the manufacture of garments and fabrics, and combinations thereof.

[0118] In one advantageous aspect of the present invention, the article of manufacture may be made from the elastic combination yarn of the present invention may include, but is not limited to, fibers or yarns or fabrics or clothing, and denim fabrics and clothing made therefrom, wearable clothing, hosiery, leggings, sportswear, underwear, bras, and disposable sanitary articles, including (but not limited to) disposable diapers, training pants, adult incontinence devices and products, menstrual devices, clothing and products, bandages; wound dressings, surgical drapes, surgical gowns, surgical or other sanitary protection covers, sanitary gloves, head coverings, headbands, ostomy bags, mattresses, bed sheets and the like; knitted gloves; ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^upholstery; hair accessories; carpet and carpet backing; conveyor belts; and footwear; undergarments, brassieres, bralettes, panties, lingerie, swimwear, shapers, camisoles, sleepwear, aprons, wetsuits, ties, scrubs, space suits, uniforms, hats, headwear, garters, sweatbands, belts, activewear, outerwear, rainwear, cold-weather jackets, pants (including denim jeans), shirts, dresses, men’s and women’s tops, sweaters, corsets, vests, knickers, socks, knee highs, blouses, tuxedos, bisht, abaya, hijab, jilbab, thoub, burka, cape, costumes, diving suit, kilt, kimono, jerseys, gowns, protective clothing, sari, sarong, skirts, spats, stola, suits, straitjacket, toga, tights, towel, veils, medical compression garments, suit interlinings, waistbands, and all components therein, and combinations thereof. EMBODIMENTS [Clause 1] An elastic combination yarn comprising: a bicomponent polyester fiber, the bicomponent comprising glycol terephthalate polyester components having different chain-branched content, and a hard polyolefin fiber, wherein the elastic combination yarn retains its mechanical stability when finished at a temperature of about 160 C° or less. [Clause 2] The elastic combination yarn of clause 1, wherein at least one glycol terephthalate polyester component is copolymerized with up to 3 / 4f(f-2) mole % of chain-branching agent, where f is 3 to 6 and is the number of ester-forming functional groups of the chain-branching agent. [Clause 3] The elastic combination yarn of any of clauses 1-2, wherein f is 3. [Clause 4] The elastic combination yarn of any of clauses 1-3, wherein the chain-branched glycol terephthalate polyester component is copolymerized with at least 0.1 mole % and up to 0.25 mole % of the chain-branching agent. [Clause 5] The elastic combination yarn of any of clauses 1-4, wherein the hard polyolefin fiber is selected from the group consisting of polypropylene fiber; polyethylene fiber; polylactic acid fiber, and combinations thereof.^ ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^[Clause 6] The elastic combination yarn of any of clauses 1-5, wherein the hard polyolefin fiber is present in an amount of about 1% to about 99% by weight of the elastic combination yarn. [Clause 7] The elastic combination yarn of any of clauses 1-6, wherein the bicomponent polyester fiber is present in an amount of about 1% to about 99% by weight of the elastic combination yarn. [Clause 8] The elastic combination yarn of any of clauses 1-7, wherein the glycol terephthalate polyester is selected from the group consisting of polytrimethylene terephthalate (PTT), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and combinations thereof. [Clause 9] The elastic combination yarn of any of clauses 1-8, wherein the elastic combination yarn has a breaking elongation of about 5 % to over 200 %. [Clause 10] The elastic combination yarn of any of clauses 1-9, wherein the elastic combination yarn has a shrinkage of about 10 % to about 40 %. [Clause 11] The elastic combination yarn of any of clauses 1-10, wherein the elastic combination yarn has a recovery force of about 30 % to about 100 %. [Clause 12] The elastic combination yarn of any of clauses 1-11, wherein the hard polyolefin fiber has a fineness of about 5 denier to about 300 denier. [Clause 13] The elastic combination yarn of any of clauses 1-12, for use in production of an article selected from the group consisting of hosiery, leggings, sportswear, underwear, bras, and disposable sanitary articles, including (but not limited to) disposable diapers, training pants, adult incontinence devices and products, menstrual devices, clothing and products, bandages; wound dressings, surgical drapes, surgical gowns, surgical or other sanitary protection covers, sanitary gloves, head coverings, headbands, ostomy bags, mattresses, bed sheets and the like; knitted gloves; upholstery; hair accessories; carpet and carpet backing; conveyor belts; and footwear; undergarments, brassieres, bralettes, panties, lingerie, swimwear, shapers, camisoles, sleepwear, aprons, wetsuits, ties, scrubs, space suits, uniforms, hats, headwear, garters, sweatbands, belts, activewear, outerwear, rainwear, cold-weather jackets, pants (including denim jeans), shirtings, dresses, mens and womens tops, sweaters, corsets, vests, knickers, socks, knee highs, blouses, tuxedos, bisht, abaya, hijab, jilbab, thoub, burka, cape, costumes, diving suit, kilt, kimono, ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^jerseys, gowns, protective clothing, sari, sarong, skirts, spats, stola, suits, straitjacket, toga, tights, towel, veils, medical compression garments, suit interlinings, waistbands, and all components therein, and combinations thereof. [Clause 14] The elastic combination yarn of any of clauses 1-13, wherein glycol terephthalate polyester components are arranged in a configuration selected from the group consisting of helical, side-by-side, sheath core, eccentric, sheath core eccentric and combinations thereof. [Clause 15] A fabric comprising an elastic combination yarn comprising: a bicomponent polyester fiber, the bicomponent comprising glycol terephthalate polyester components having different chain-branched content, and a hard polyolefin fiber, wherein the elastic combination yarn retains its mechanical stability when finished at a temperature of about 160 C° or less. [Clause 16] A process of preparing an elastic combination yarn comprising: providing a bicomponent polyester fiber, the bicomponent comprising glycol terephthalate polyester components having different chain-branched content, providing a hard polyolefin fiber, and combining the bicomponent polyester fiber and the hard polyolefin fiber to form the elastic combination yarn, wherein the elastic combination yarn retains its mechanical stability when finished at a temperature of about 160 C° or less. [Clause 17] The process of clause 16, wherein the bicomponent polyester fiber and the hard polyolefin fiber are combined according to a technique selected from the group consisting of single wrapping of the bicomponent polyester fiber with the hard polyolefin fiber; double wrapping of the bicomponent polyester fiber with the hard polyolefin fiber; continuously covering the bicomponent polyester fiber with the hard polyolefin fiber, followed by twisting during winding; intermingling and entangling the bicomponent polyester fiber with the hard polyolefin fiber with an air jet; twisting the bicomponent polyester fiber and the hard polyolefin ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^fiber together; blending the bicomponent polyester fiber and hard polyolefin fiber together and combinations thereof. EXAMPLES Fabric Design

[0119] Four fabrics were designed and knitted on a circular knitting machine with two needle beds. The knitting machine that could be used, include but is not limited to knitting machines described herein. Examples A-D and Comparative examples E-G are double jersey fabrics, which refers to fabrics having jersey construction on both sides of the fabric. The composition of Examples A-G is described in Table 1. Table 1 Composition of Fabrics A-G AB C D E F GEXAMPLE A Inventive

[0120] A double jersey fabric was made using 50 denier / 34 filaments bicomponent polyester yarn on both dial and cylinder needles to knit both layers of the fabric and the 55 denier / 48 filaments hard yarn on only cylinder needles to knit the layer. The fabric construction is depicted in Figure 1. ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^EXAMPLE B Inventive

[0121] A double jersey fabric was made using 50 denier / 34 filaments bicomponent polyester yarn on both dial and cylinder needles to knit both layers of the fabric and the 55 denier / 48 filaments hard yarn on only cylinder needles to knit the layer. The fabric construction is depicted in Figure 2. EXAMPLE C Inventive

[0122] A double jersey fabric was made using 50 denier / 34 filaments bicomponent polyester yarn on both dial and cylinder needles to knit both layers of the fabric and the 55 denier / 48 filaments hard yarn on only cylinder needles to knit the layer. The fabric construction is depicted in Figure 3. EXAMPLE D Inventive

[0123] A double jersey fabric was made using 50 denier / 34 filaments bicomponent polyester yarn on both dial and cylinder needles to knit both layers of the fabric and the 55 denier / 48 filaments hard yarn on only cylinder needles to knit the layer. The fabric construction is depicted in Figure 4. EXAMPLE E Comparative

[0124] A double jersey fabric was made using 55 denier / 48 filaments of only hard yarn (i.e. elastic yarn was not used) on both dial and cylinder needles to knit both layers of the fabric. The fabric construction is depicted in Figure 1. EXAMPLE F Comparative

[0125] A double jersey fabric was made using 50 denier / 72 filaments yarn polyester (i.e. elastic yarn was not used) on both dial and cylinder needles to knit both layers of the fabric. The fabric construction is depicted in Figure 1. EXAMPLE G Comparative

[0126] A double jersey fabric was made using 50 denier / 34 filaments of only bicomponent polyester yarn (i.e. hard yarn was not used) on both dial and cylinder needles to knit both layers of the fabric. The fabric construction is depicted in Figure 1. ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^Test Results

[0127] As shown in Table 2 below, four fabrics (Examples A-D and Comparative Examples E- G) were made, tested, and evaluated based on methods referring to standards such AATCC 79, AATCC 197, AATCC 198, ASTM D 737-04 and GB21655.1. Table 2 Results of Fabrics A-G A B C D E F G Ab rb n 0 4 1 .8 0 0. 4. 0

[0128] All fabrics of Examples A-G were made on a circular knitting machine with double needle beds, and then treated under certain conditions. Examples A-G were each treated at about 120 ^ to about 130 ^. As the test results show in Table 2, Examples A and D, which were made with bicomponent fibers as elastic components and polyolefin fibers as hard components, have good performance such as absorbency, vertical wicking performance, and air permeability. It appears that Examples B and C do not possess as good absorbency and vertical wicking ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^performance as A and D, which may be related to fabric construction. It can be seen that each of Examples A-D have good evaporation performance as shown Table 2.

[0129] Comparative fabrics E-G were knitted on the same machine with same construction type as Inventive fabric A. From the results, we see that the Inventive fabric A, which was made with combination of bicomponent fiber and hard polyolefin fibers, has outstanding performance such as absorbency, vertical wicking, planar wicking and so on. Further, Inventive fabric A has a significantly better evaporation performance than Comparative Fabrics E-G.

[0130] Further, Examples A-D have outstanding stretch performance, which may be due to the crimp of the bicomponent polyester fiber after the heat setting process. Even further, the fabric weight is lower than those made with common yarn combination in the industry. The use of lower fabric weight may provide the end user with more freedom and comfort during movement. ^^^^^^^^^^^^^^ ^

Claims

^^^^^^^^^^^ ^ ^CLAIMS:

1. An elastic combination yarn comprising: a bicomponent polyester fiber, the bicomponent comprising glycol terephthalate polyester components having different chain-branched content, and a hard polyolefin fiber, wherein the elastic combination yarn retains its mechanical stability when finished at a temperature of about 160 C° or less.

2. The elastic combination yarn of claim 1, wherein at least one glycol terephthalate polyester component is copolymerized with up to 3 / 4f(f-2) mole % of chain-branching agent, where f is 3 to 6 and is the number of ester-forming functional groups of the chain-branching agent.

3. The elastic combination yarn of claim 1, wherein f is 3.

4. The elastic combination yarn of claim 1, wherein the chain-branched glycol terephthalate polyester component is copolymerized with at least 0.1 mole % and up to 0.25 mole % of the chain-branching agent.

5. The elastic combination yarn of claim 1, wherein the hard polyolefin fiber is selected from the group consisting of polypropylene fiber; polyethylene fiber; polylactic acid fiber, and combinations thereof.^ 6. The elastic combination yarn of claim 1, wherein the hard polyolefin fiber is present in an amount of about 1% to about 99% by weight of the elastic combination yarn.

7. The elastic combination yarn of claim 1, wherein the bicomponent polyester fiber is present in an amount of about 1% to about 99% by weight of the elastic combination yarn.

8. The elastic combination yarn of claim 1, wherein the glycol terephthalate polyester is selected from the group consisting of polytrimethylene terephthalate (PTT), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and combinations thereof.

9. The elastic combination yarn of claim 1, wherein the elastic combination yarn has a breaking elongation of about 5 % to over 200 %. ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^10. The elastic combination yarn of claim 1, wherein the elastic combination yarn has a shrinkage of about 10 % to about 40 %.

11. The elastic combination yarn of claim 1, wherein the elastic combination yarn has a recovery force of about 30 % to about 100 %.

12. The elastic combination yarn of claim 1, wherein the hard polyolefin fiber has a fineness of about 5 denier to about 300 denier.

13. The elastic combination yarn of claim 1, for use in production of an article selected from the group consisting of hosiery, leggings, sportswear, underwear, bras, and disposable sanitary articles, including (but not limited to) disposable diapers, training pants, adult incontinence devices and products, menstrual devices, clothing and products, bandages; wound dressings, surgical drapes, surgical gowns, surgical or other sanitary protection covers, sanitary gloves, head coverings, headbands, ostomy bags, mattresses, bed sheets and the like; knitted gloves; upholstery; hair accessories; carpet and carpet backing; conveyor belts; and footwear; undergarments, brassieres, bralettes, panties, lingerie, swimwear, shapers, camisoles, sleepwear, aprons, wetsuits, ties, scrubs, space suits, uniforms, hats, headwear, garters, sweatbands, belts, activewear, outerwear, rainwear, cold-weather jackets, pants (including denim jeans), shirtings, dresses, mens and womens tops, sweaters, corsets, vests, knickers, socks, knee highs, blouses, tuxedos, bisht, abaya, hijab, jilbab, thoub, burka, cape, costumes, diving suit, kilt, kimono, jerseys, gowns, protective clothing, sari, sarong, skirts, spats, stola, suits, straitjacket, toga, tights, towel, veils, medical compression garments, suit interlinings, waistbands, and all components therein, and combinations thereof.

14. The elastic combination yarn of claim 1, wherein glycol terephthalate polyester components are arranged in a configuration selected from the group consisting of helical, side-by-side, sheath core, eccentric, sheath core eccentric and combinations thereof.

15. A fabric comprising an elastic combination yarn comprising: a bicomponent polyester fiber, the bicomponent comprising glycol terephthalate polyester components having different chain-branched content, and a hard polyolefin fiber, ^^^^^^^^^^^^^^ ^^^^^^^^^^^^ ^ ^wherein the elastic combination yarn retains its mechanical stability when finished at a temperature of about 160 C° or less.

16. A process of preparing an elastic combination yarn comprising: providing a bicomponent polyester fiber, the bicomponent comprising glycol terephthalate polyester components having different chain-branched content, providing a hard polyolefin fiber, and combining the bicomponent polyester fiber and the hard polyolefin fiber to form the elastic combination yarn, wherein the elastic combination yarn retains its mechanical stability when finished at a temperature of about 160 C° or less.

17. The process of claim 16, wherein the bicomponent polyester fiber and the hard polyolefin fiber are combined according to a technique selected from the group consisting of single wrapping of the bicomponent polyester fiber with the hard polyolefin fiber; double wrapping of the bicomponent polyester fiber with the hard polyolefin fiber; continuously covering the bicomponent polyester fiber with the hard polyolefin fiber, followed by twisting during winding; intermingling and entangling the bicomponent polyester fiber with the hard polyolefin fiber with an air jet; twisting the bicomponent polyester fiber and the hard polyolefin fiber together; blending the bicomponent polyester fiber and hard polyolefin fiber together and combinations thereof. ^^^^^^^^^^^^^^ ^

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