Easily settable stretch fabrics including low-melt fiber
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing elastic fiber-containing fabrics face issues with high shrinkage, damage to elastic fiber recovery power during heat setting, adverse effects on sensitive yarns, and problems like laddering and slippage, which compromise comfort and appearance in shaping garments.
Innovation Solution
A stretch fabric comprising rigid, elastic, and low-melt fibers, where the low-melt fiber is fused at a temperature between 60°C to 200°C to stabilize the fabric without damaging elastic fibers, allowing for controlled stretch levels and reduced shrinkage, and is integrated through methods like fiber spinning, blending, or thermal activating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If heat setting is performed at high temperature to stabilize fabric and reduce shrinkage, then fabric dimensional stability is improved, but elastic fiber recovery power is damaged
Solution Approach 1:
The patent changes the temperature parameter from conventional high-temperature heat setting to low-temperature thermal activation (below elastic fiber heat set temperature). This parameter change allows the low-melt fiber to fuse and stabilize the fabric structure without exposing the elastic fiber to damaging high temperatures, thus preserving its recovery power while achieving dimensional stability
Solution Approach 2:
The low-melt fiber acts as an intermediary substance that performs the stabilizing function at low temperature. It fuses between the rigid fiber and elastic fiber to lock the fabric structure, serving as a mediator that achieves dimensional stability without directly exposing the elastic fiber to high heat that would damage its recovery properties
2Reliability
If heat setting is avoided to preserve elastic fiber properties, then elastic fiber recovery power is maintained, but fabric shrinkage and elongation increase
Solution Approach 1:
The low-melt fiber serves as a mediator that provides the stabilizing function normally achieved through high-temperature heat setting. It fuses at low temperature to lock the fabric structure, preventing shrinkage and excessive elongation while allowing the elastic fiber to retain its recovery power by avoiding high-temperature exposure
3Stability of the object's composition
If high temperature heat set is used to control shrinkage, then fabric stability is improved, but sensitive companion yarns are adversely affected
Solution Approach 1:
The patent changes the processing temperature parameter from high temperature to low temperature (below the heat set temperature of elastic fiber and below the damage threshold of sensitive companion yarns). This parameter change enables fabric stabilization through low-melt fiber fusion without adversely affecting sensitive materials like wool, cotton, polypropylene, or silk
4Adaptability or versatility
If elastic fiber is used to provide stretch, then fabric elasticity is improved, but laddering and slippage problems occur
Solution Approach 1:
The low-melt fiber acts as an intermediary binding agent that fuses between the elastic fiber and rigid fiber, creating a locked structure. This intermediary connection prevents the elastic fiber from slipping out of the fabric structure (anti-slippage) and prevents ladder-like cracks from forming (anti-laddering), while allowing the fabric to maintain its stretchability through the elastic fiber
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, anti-elastane slippage, and anti-laddering properties, maintaining elastic fiber recovery power while allowing for adjustable stretch levels and improved garment shape retention, enhancing comfort and appearance.
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
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
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.