Easily settable stretch fabrics including low-melt fiber
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Solution Overview
Problem
Current elastic fiber heat-setting methods for fabrics often damage the elastic fibers, leading to poor dimensional stability, excessive shrinkage, and quality issues such as laddering, curling, and seam slippage, which compromise the comfort and appearance of garments.
Innovation Solution
A stretch fabric comprising rigid, elastic, and low-melt fibers, where the low-melt fibers are fused at a temperature between 60° C. to 200° C., lower than the heat-setting temperature of elastic fibers, to stabilize the fabric without damaging the elastic fibers, allowing for controlled stretch levels and improved anti-slippage and anti-laddering performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high temperature heat-setting is used to stabilize fabric and reduce shrinkage, then dimensional stability is improved, but elastic fiber recovery power is damaged
Solution Approach 1:
A low-melt fiber (melting point 60-200°C) is introduced as an intermediary binding agent between elastic fibers. This low-melt fiber is fused at temperatures below the damage threshold of elastic fibers (using steam at 100°C or dry heat at 150-200°C), creating bonds that stabilize fabric dimensions without exposing elastic fibers to damaging high temperatures. The low-melt fiber acts as a protective mediator that provides dimensional stability while preserving elastic fiber functionality.
Solution Approach 2:
The invention changes the temperature parameter of the heat-setting process from conventional high temperatures (which damage elastic fibers) to lower temperatures (100-200°C) suitable for low-melt fiber fusion. This parameter change enables the fabric setting process to occur at temperatures that activate the low-melt fiber's binding properties while remaining below the damage threshold for elastic fiber recovery power, thus resolving the contradiction between dimensional stability and elastic fiber preservation.
2Reliability
If low temperature heat-setting is used to preserve elastic fiber, then fiber recovery power is maintained, but fabric shrinkage increases
Solution Approach 1:
The low-melt fiber serves as a thermal intermediary that enables fabric stabilization at lower temperatures. By fusing this intermediate-melting-point fiber at 100-200°C, the fabric achieves dimensional stability and reduced shrinkage without requiring the high temperatures that would damage elastic fibers. The low-melt fiber bridges the gap between the low temperature needed for elastic fiber preservation and the high temperature needed for fabric setting.
3Stability of the object's composition
If conventional heat-setting is used to stabilize fabric, then shrinkage is reduced, but fabric quality deteriorates (yellowing, harshness)
Solution Approach 1:
The invention changes the temperature parameter from conventional high-temperature heat-setting to lower temperature processing (100-200°C) appropriate for low-melt fiber fusion. This parameter reduction prevents the thermal degradation, yellowing, and harshness associated with high-temperature processing while still achieving shrinkage reduction and dimensional stability through the low-melt fiber's fusion and binding mechanisms.
4Ease of operation
If elastic fibers are used to provide stretch, then fabric comfort is improved, but laddering and seam slippage problems increase
Solution Approach 1:
The invention merges elastic fibers with low-melt fiber into a composite yarn structure. The low-melt fiber is spun together with elastic fiber (and optionally rigid fiber) to create a combined yarn where the low-melt component provides binding and anti-laddering properties while the elastic component provides stretch and comfort. This merging allows both functionalities to coexist without compromise.
Solution Approach 2:
The low-melt fiber acts as an intermediary binding agent that secures elastic fibers within the fabric structure. By fusing the low-melt fiber during or after knitting/weaving, elastic fibers are anchored in place, preventing them from slipping out at seams or creating ladder defects. This intermediary binding maintains elastic fiber functionality while preventing their harmful movements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a fabric with low shrinkage, excellent shape retention, and enhanced anti-slippage and anti-laddering properties, enabling comfortable and durable garments with adjustable stretch levels for shaping and slimming effects.
Implementation Method 1
the low-melt fiber comprises low-melt polymer which can be fused at lower temperature than heatset temperature of elastic fiber
Implementation Method 2
The low-melt fiber can be fused in the temperature between 60° C. to 200° C., being higher than the temperature used for normal textile process and household laundry, but lower than the temperature used for heat setting elastic fiber
Data Source
AI summary
The present invention provides an easy settable stretch fabric comprising three types of yarns: a rigid fiber, an elastic fiber, and a low-melt fiber, wherein the low-melt fiber comprises low-melt polymer which can be fused in the temperature between 60° C. to 200° C., being higher than the temperature used for normal textile process and household laundry, but lower than the temperature used for heat setting elastic fiber. The low-melt fiber can be selected from a group of fibers made from modified polyester, nylon, and polypropylene and the copolymer from them in the form of staple or filament.