Polyester Staple Fiber Composition for Cotton-Like Athletic Apparel
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Solution Overview
Problem
Athletic apparel made from synthetic yarns lacks the soft hand characteristics of cotton while synthetic yarns do not retain moisture like cotton, leading to discomfort due to trapped sweat and longer drying times.
Innovation Solution
Forming synthetic polyester fibers with controlled dimensions, such as fiber length and denier, to create a textile that mimics cotton's feel and properties, including using irregular cross-sectional shapes like kidney shapes, and varying denier values to achieve a luxurious hand and moisture transfer similar to cotton.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cotton yarn is used to form athletic apparel, then the fabric is softer and provides better wearer comfort upon contact with the skin, but the moisture becomes trapped within the textile, adding weight, increasing dry time and causing wearer discomfort
Solution Approach 1:
The patent applies parameter changes by controlling specific physical properties of synthetic fibers (denier, length, cross-section shape) to transform the fabric's moisture management characteristics. By adjusting these parameters, the synthetic fabric achieves both softness and rapid moisture evaporation, resolving the contradiction between comfort and drying time
Solution Approach 2:
The patent creates a composite fiber structure within the synthetic yarn by combining fibers of different deniers, lengths, and cross-sectional shapes. This composite approach allows the fabric to simultaneously exhibit cotton-like softness and superior moisture-wicking properties, eliminating the trade-off between comfort and drying performance
2Loss of time
If synthetic yarn is used to form athletic apparel, then the apparel transfers moisture away from the skin and dries faster, but it lacks the soft hand characteristics of cotton fabric
Solution Approach 1:
The patent applies local quality by creating regions within the yarn with different fiber characteristics. Specifically, it incorporates fine-denier fibers for softness against the skin and coarser fibers for moisture transport, allowing different parts of the same yarn to fulfill different functional requirements
Solution Approach 2:
The patent transforms the hand characteristics of synthetic fabric by changing key fiber parameters: using irregular cross-sections (kidney, oval shapes) to mimic cotton's natural feel, incorporating a range of fiber lengths for texture depth, and varying denier values for tactile complexity. These parameter changes make synthetic fabric indistinguishable from cotton by touch while retaining moisture-wicking benefits
3Ease of operation
If cotton textile is used, then the fabric provides soft hand characteristics and wearer comfort, but moisture is absorbed and retained leading to added weight and discomfort
Solution Approach 1:
The patent converts the typically harmful effect of moisture retention into a benefit by designing synthetic fibers that actively channel sweat away from the skin and accelerate evaporation. The moisture management system transforms sweat from a comfort-reducing weight into a controlled environmental factor that enhances cooling performance
Data Source
AI summary
A fabric material includes a plurality of synthetic yarns, the yarns including staple fibers having a range of denier values. The polyester staple fibers have deniers ranging from about 0.5 denier per filament to about 2.0 denier per filament. Additionally, more than 50% of the staple fibers present in the fabric possess a length of greater than 1 inch.