Stretch Woven Control Yarn System for Fabric Recovery
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Solution Overview
Problem
Current stretch woven fabrics with staple core spun elastic yarns suffer from poor recovery power, leading to 'bagging and sagging' issues due to over-stretching, as they lack effective control over fabric deformation and visibility of elastic fibers on the fabric surface.
Innovation Solution
Incorporating a separate control yarn system with a corespun elastic base yarn and a control yarn, where the control yarn is selected from single, multiple, or composite yarns, and has a denier greater than zero to 0.8 times that of the corespun elastic base yarn, to restrict over-stretching and enhance recovery power, while being hidden within the fabric to maintain aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If only one set of elastic corespun composite yarn is used to form the main body of the stretch fabric, then the fabric provides elasticity and stretch-recovery function, but the fabric fails to return to its original size after wearing, particularly for fabrics with high stretch level
Solution Approach 1:
The invention divides the elastic yarn system into two separate components: (1) a corespun elastic base yarn that provides the primary stretch and recovery function, and (2) a separate control yarn that prevents over-stretching. This segmentation allows each component to perform its specific function optimally without compromising the other, resolving the contradiction between providing stretch-recovery function and maintaining return to original size.
Solution Approach 2:
The control yarn acts as an intermediary element between the elastic base yarn and the fabric structure. It mediates the stretching process by limiting excessive deformation while allowing controlled elastic recovery, thus preventing the fabric from failing to return to its original size while maintaining the desired stretch-recovery function.
2Ease of operation
If elastic corespun yarn is used to provide elasticity and stretch, then the fabric is easily extended during body movement providing comfort and fit, but when fabrics are over stretched in some parts of the body, they can't quickly recovery to original size and shape
Solution Approach 1:
By segmenting the elastic yarn system into a corespun elastic base yarn and a separate control yarn, the invention allows the base yarn to provide comfort and fit through easy extension, while the control yarn ensures quick recovery by preventing over-stretching in specific areas like knees, buttocks, and waist.
Solution Approach 2:
The control yarn is strategically integrated into the fabric structure to provide localized control over stretching in specific areas. This local quality approach allows different regions of the fabric to have different stretching characteristics, enabling comfort and fit where needed while preventing excessive deformation in areas that require quick recovery.
3Strength
If bare spandex is used in one direction and hard yarns in the other direction, then the fabric achieves stretch in the desired direction, but the spandex must be draw twisted in a separate process and spandex can be exposed on fabric surface
Solution Approach 1:
The invention merges the control function and elastic function into a single integrated yarn construction during the spinning process. The control yarn and corespun elastic base yarn are combined in a way that eliminates the need for separate draw twisting operations, while preventing spandex exposure on the fabric surface through proper yarn arrangement and coverage.
4Strength
If composite yarn with polyurethane yarn wrapped with synthetic multifilament hard yarn is used, then the fabric achieves desired stretch properties, but the elastic yarns have the same size as hard yarn and exposed on the fabric surface
Solution Approach 1:
The invention segments the yarn structure into distinct components with different size characteristics. The corespun elastic base yarn and control yarn are designed with appropriate size relationships that allow the elastic components to be properly covered or positioned, preventing exposure on the fabric surface while maintaining the desired stretch properties.
Solution Approach 2:
The yarn construction employs local quality differentiation where the control yarn and elastic base yarn have specific size relationships optimized for their respective functions. This local quality approach ensures that elastic yarns are not exposed on the fabric surface while still providing the necessary stretch properties in the appropriate directions.
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 control yarn system effectively restricts over-stretching, increases recovery power, and reduces fabric deformation, providing better dimensional stability and preventing 'grin-through' of elastic fibers, resulting in fabrics with improved elongation and shrinkage properties.
Implementation Method 1
Elastic corespun yarn provides elasticity and stretch-recovery function to these fabrics. The elastic fiber core provides stretch and recovery while the staple fiber sheath provides bulk and comfort.
Implementation Method 2
a separate control yarn selected from the group consisting of a single filament yarn, a multiple filament yarn, a composite yarn, and combinations thereof; having a denier greater than zero to about 0.8 times the denier of the corespun elastic base yarn
Data Source
AI summary
An article including a woven fabric comprising warp yarns and weft yarns, wherein at least one of either the warp yarns or the weft yarns includes: (a) a corespun elastic base yarn having a denier and including staple fiber and an elastic fiber core; and (b) a separate control yarn selected from the group consisting of a single filament yarn, a multiple filament yarn, a composite yarn, and combinations thereof; having a denier greater than zero to about 0.8 times the denier of the corespun elastic base yarn; wherein the woven fabric includes (1) a ratio of corespun base yarn ends to control yarn ends of up to about 6:1; or (2) a ratio of corespun base yarn picks to control yarn picks of up to about 6:1; or (3) both a ratio of corespun base yarn ends to control yarn ends of up to about 6:1; and a ratio of corespun base yarn picks to control yarn picks of up to about 6:1.