US20040214494A1 - Stretch fabric - Google Patents
Stretch fabric Download PDFInfo
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- US20040214494A1 US20040214494A1 US10/420,470 US42047003A US2004214494A1 US 20040214494 A1 US20040214494 A1 US 20040214494A1 US 42047003 A US42047003 A US 42047003A US 2004214494 A1 US2004214494 A1 US 2004214494A1
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- Prior art keywords
- fabric
- elastic
- yarns
- knit
- layer
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
- D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
- D04B21/18—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating elastic threads
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
- Y10T442/102—Woven scrim
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
- Y10T442/102—Woven scrim
- Y10T442/109—Metal or metal-coated fiber-containing scrim
- Y10T442/116—Including a woven fabric which is not a scrim
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
- Y10T442/184—Nonwoven scrim
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2738—Coating or impregnation intended to function as an adhesive to solid surfaces subsequently associated therewith
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/40—Knit fabric [i.e., knit strand or strip material]
- Y10T442/45—Knit fabric is characterized by a particular or differential knit pattern other than open knit fabric or a fabric in which the strand denier is specified
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/40—Knit fabric [i.e., knit strand or strip material]
- Y10T442/45—Knit fabric is characterized by a particular or differential knit pattern other than open knit fabric or a fabric in which the strand denier is specified
- Y10T442/456—Including additional strand inserted within knit fabric
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/40—Knit fabric [i.e., knit strand or strip material]
- Y10T442/45—Knit fabric is characterized by a particular or differential knit pattern other than open knit fabric or a fabric in which the strand denier is specified
- Y10T442/456—Including additional strand inserted within knit fabric
- Y10T442/463—Warp knit insert strand
Definitions
- This invention relates to a composite material with controlled elasticity. More particularly, the invention relates to stretch fabrics having an elastic layer laminated to an open carrier layer.
- the stretchable fabric can be made by stretching an elastic or stretchable layer to a selected elongation, placing a nonstretchable layer, such as a nonwoven on the stretched layer, bonding the layers together and allowing the layers to relax so that the nonstretchable layer is gathered.
- the present invention features a stretch fabric including a layer that is elastic in the longitudinally extending direction laminated to one side of a carrier layer.
- the elastic layer/carrier layer laminate is sandwiched between and bonded to top and bottom outer fabric layers that impart the desired properties of appearance, softness and comfort to the elastic fabric.
- the elastic layer is a plurality of longitudinally-extending elastic strands.
- the carrier layer is a warp-knitted fabric, also referred to as a warp knit/weft insertion fabric, oriented with the knit yarns extending longitudinally.
- the warp knit/weft insertion fabric has a weight of less than about 50 grams per square meter (about 1.5 oz. per square yard) and most preferably less than about 25 to 30 grams per square meter (about 0.7 to 0.9 oz. per square yard).
- the top and bottom outer layers can be a lightweight spun-blown synthetic or natural fiber nonwoven, a knitted, or a woven fabric.
- the stretch fabric has a good appearance and is soft and comfortable to the touch, yet has 2 a longitudinal strength and is less expensive than its woven or knitted competitors where the elastic yarns are woven or knitted into the fabric as an integral part of the woven or knitted cloth.
- FIG. 1 is top view, partially broken away, of a stretch fabric according to one or more embodiments of the present invention.
- FIG. 2 is a cross-sectional view, taken at line 2 — 2 of FIG. 1.
- FIG. 3 is a top view of a warp knit/weft insertion layer for use in one or more embodiments of the present invention.
- FIGS. 1 and 2 illustrate a laminated elastic fabric 10 having a top layer 12 and a bottom layer 14 of an outermost woven, knit or nonwoven fabric that imparts the desired properties of appearance, softness and comfort to the fabric.
- a carrier layer 16 Positioned between the top and bottom layers is a carrier layer 16 , shown here as a warp knit/weft insertion fabric, and an elastic layer 18 of longitudinally-extending, transversely spaced (about 12 per inch) elastic strands.
- the four-layer structure is laminated together with a binder 20 that impregnates the inner warp knit/weft insertion fabric, coats the elastic layer, and penetrates into a portion of the top and bottom outer layers.
- the adhesive does not saturate the full thickness of the top and bottom outer layers, so that the outermost surface of the elastic fabric is essentially free of binder.
- the binder can penetrate up to about 95% of the thickness of outer layers, and in some embodiments, the binder penetrates into about 25% to about 75% of the outermost fabric. Typically, the binder penetrates into about 50% of the outermost fabric.
- the outermost fabric contacts the wearer and, as such, is a fabric that is comfortable and provides a pleasing appearance. There is no requirement of a particular weight, weave or thickness for the outer layer.
- the top and bottom layers can be the same or different. In some embodiments, it is breathable and/or capable of gathering.
- the outer fabric is a woven, knit, weft knit/warp insertion or nonwoven fabric prepared from synthetic or natural fibers. For example, they may be selected from the naturally occurring animal and vegetable fibers, including cotton and wool, or synthetic (chemical) fibers such as nylon, cellulosics, rayon, polyesters, polyamides, acrylics, polypropylene, polyethylene and the like, including blends of such fibers.
- the fibers are intimately entangled with each other to form a coherent breathable fibrous nonwoven backing.
- the particular fiber composition that is used as the nonwoven backing substrate is selected from those known in the prior art, according to the web property desired.
- Exemplary nonwovens having a desirable soft or comfortable feel include polypropylene, polyester, polyethylene, and cotton nonwovens.
- the nonwoven fabric is lightweight, and can typically be about 10 grams per square meter (about 0.3 oz. per square yard) or about 17-20 grams per square meter (about 0.5-0.6 oz. per square yard).
- the carrier layer supports the elastic layer and acts as a carrier for the binder.
- the carrier layer can be any lightweight and open woven, knit or nonwoven fabric, or it can be a warp knit/weft insertion fabric.
- the carrier layer is selected to reinforce the assembled structure, while retaining the openness (which is a function of thread count and yarn denier, etc.) of the fabric. It is also selected to provide sufficient adhesive surface area to establish a strong adhesive contact with the outer fabric layers and the elastic layer.
- the fabric can be up to about 95% open, i.e., the fabric makes up about 5% of the surface area, and is typically about 70% open.
- a warp knit/weft insertion fabric 300 is shown on outer fabric 310 .
- the warp-knit/weft insertion fabric 300 includes one or more weft yarns 320 inserted through a knit loop 325 .
- the weft insert yarns may include one or more filaments, the number and size of which are selected to have a desired tensile strength.
- the weft yarns are shown having three filaments; however, the weft yarns may be monofilament or multifilament, for example, the weft yarns can have a number of filaments, for example, 3-15 filaments.
- the knitted warp yarns 325 form rather loose warp yarn “loops” around the fill yarns 320 , and the knitted warp structure also provides that each row of the knitted warp includes three yarns extending in the warp direction.
- This three-yarn warp knit/weft insertion construction results in a lightweight fabric having high tensile strength (about 12.8 lbs/inch) in the warp direction.
- the fully extended warp knit/weft insertion fabric 300 includes spaces 330 between adjacent weft yarns 320 . This spacing, coupled with the loose, non-twisted, filamentary structure of the weft yarns themselves, permits the weft yarns to move towards and away from each other in response to stretch and relaxation of the longitudinal elastic strands 18 , which is of course accompanied by elongation and relaxation of the warp yarns.
- the warp knit/weft insertion fabric has a weight of less than about 50 grams per square meter (about 1.5 oz. per square yard) and most preferably less than about 25 to 30 grams per square meter (about 0.7 to 0.9 oz. per square yard), and may be as low as 5 grams per square meter.
- An exemplary warp knit/weft insertion fabric has a weight ranging from about 25 to about 10 grams per square meter, and a warp/weft thread count ranging from about 18 ⁇ 12 to about 9 ⁇ 9.
- the knitted warp yarns are about 40 denier polyester; the about 150 denier fill or weft yarns are loose, nontwisted, texturized polyester filaments.
- warp knit/weft insertion fabrics are available elsewhere, e.g., warp knit/weft insertion greige fabric available from Milliken & Company of Spartenburg, S.C.
- a lightweight fabric maintains the porosity of the stretch fabric and relaxes to a smooth, comfortable gather.
- the elastic strands 18 used in the present invention for the elastic layer include thermoplastic elastomers, synthetic and natural rubbers.
- An exemplary elastic strand is a 280 denier strand, which is sold under the trademark GLOSPAN by Radici spandex Inc. of Fall River, Mass.
- GLOSPAN trademark of Radici spandex Inc. of Fall River, Mass.
- both the denier and number of elastic strands per inch (measured transversely) of the fabric may vary.
- the denier of the elastic strands may vary from less than 100 to about 1000, and there may be from about 5 to about 15 elastic strands per inch.
- the elastic yarns provide an elastic fabric having a degree of stretch (elongation) ranging from approximately 40% to 275%.
- the elastic fabric 10 is formed by laminating the warp knit/weft insertion fabric 16 when fully extended or taut over stretched elastic strands 18 .
- the binder-impregnated elastic layer/warp knit/weft insertion layer is then contacted, while still fully extended, with the upper and lower outer layers.
- Binder 20 impregnates or coats the inner two layers and penetrates into a portion of the top and bottom outer layers.
- the particular binder 20 used to laminate the four layers together to form the finished product depends, principally, on whether and what kind of adhesive properties are desired.
- the binder can be a thermosetting or thermoplastic adhesive that remains flexible when set or cured.
- the binder is a self-curing laminating adhesive.
- Exemplary binders include carboxylated styrene butadiene (SBR) latexes, acrylic emulsions, copolymer acrylic emulsions, and the like.
- SBR carboxylated styrene buta
- An exemplary fabric includes a lightweight nonwoven polypropylene top and bottom outer fabric having a weight of 10 g/m 2 .
- the carrier layer is a warp knit/weft insertion fabric having a 9 ⁇ 12 warp/weft thread count with a 40 denier monofilament polyester warp yarn and a multifilament warp yarn of 70 denier.
- the elastic layer is 280 denier spandex rubber. All four layers are bonded together using Rovene® 4150 carboxylated SBR emulsion.
- the resultant fabric has a strength in the longitudinal warp direction of about 12 pounds per inch of width, yet it is light and comfortable to wear.
- the laminated elastic fabric of the present invention provides a feel and an appearance that is at least equal and often superior to comparable elastic fabrics.
Abstract
A laminated elastic fabric includes a first carrier layer of non-elastic, open fabric, and a second layer which is elastic in a direction extending longitudinally of the fabric; a first outer fabric layer and a second outer fabric layer on opposing sides of the first carrier and second elastic layers, and a binder bonding the layers together. The carrier layer can be a warp knit/weft insertion fabric having knit yarns and fill yarns and oriented with the knit yarns thereof extending longitudinally of the fabric, the knit yarns being non-elastic, each of the knit yarns extending longitudinally of the fabric including a plurality of longitudinally-spaced knitted loops, and each of the fill yarns extending transversely of the fabric and through loops of the knit yarns.
Description
- This invention relates to a composite material with controlled elasticity. More particularly, the invention relates to stretch fabrics having an elastic layer laminated to an open carrier layer.
- Various kinds of sheet materials having flexibility, elasticity or resiliency have been used for producing the elastic portions of sportswear, clothes for working and surgical operations, working gloves, gathers of caps and hats, diapers, suspenders, belts and the like. In the past, elastic materials have been made elastically extensible using elastic elements disposed, e.g., woven, in the clothes such that the openings are at least partially encircled with elasticized bands. Still other methods include attaching stretchable fabric to the side edges of the main body of the garment. The stretchable fabric can be made by stretching an elastic or stretchable layer to a selected elongation, placing a nonstretchable layer, such as a nonwoven on the stretched layer, bonding the layers together and allowing the layers to relax so that the nonstretchable layer is gathered.
- There remains a need for an inexpensive, elastic fabric that has a good appearance, is soft and comfortable to wear and that, despite its low cost, has a high longitudinal strength.
- The present invention features a stretch fabric including a layer that is elastic in the longitudinally extending direction laminated to one side of a carrier layer. The elastic layer/carrier layer laminate is sandwiched between and bonded to top and bottom outer fabric layers that impart the desired properties of appearance, softness and comfort to the elastic fabric.
- In one or more embodiments, the elastic layer is a plurality of longitudinally-extending elastic strands. In one or more embodiments, the carrier layer is a warp-knitted fabric, also referred to as a warp knit/weft insertion fabric, oriented with the knit yarns extending longitudinally. The warp knit/weft insertion fabric has a weight of less than about 50 grams per square meter (about 1.5 oz. per square yard) and most preferably less than about 25 to 30 grams per square meter (about 0.7 to 0.9 oz. per square yard). The top and bottom outer layers can be a lightweight spun-blown synthetic or natural fiber nonwoven, a knitted, or a woven fabric.
- The stretch fabric has a good appearance and is soft and comfortable to the touch, yet has2 a longitudinal strength and is less expensive than its woven or knitted competitors where the elastic yarns are woven or knitted into the fabric as an integral part of the woven or knitted cloth.
- FIG. 1 is top view, partially broken away, of a stretch fabric according to one or more embodiments of the present invention.
- FIG. 2 is a cross-sectional view, taken at
line 2—2 of FIG. 1. - FIG. 3 is a top view of a warp knit/weft insertion layer for use in one or more embodiments of the present invention.
- FIGS. 1 and 2 illustrate a laminated
elastic fabric 10 having atop layer 12 and abottom layer 14 of an outermost woven, knit or nonwoven fabric that imparts the desired properties of appearance, softness and comfort to the fabric. Positioned between the top and bottom layers is acarrier layer 16, shown here as a warp knit/weft insertion fabric, and anelastic layer 18 of longitudinally-extending, transversely spaced (about 12 per inch) elastic strands. The four-layer structure is laminated together with abinder 20 that impregnates the inner warp knit/weft insertion fabric, coats the elastic layer, and penetrates into a portion of the top and bottom outer layers. - The adhesive does not saturate the full thickness of the top and bottom outer layers, so that the outermost surface of the elastic fabric is essentially free of binder. The binder can penetrate up to about 95% of the thickness of outer layers, and in some embodiments, the binder penetrates into about 25% to about 75% of the outermost fabric. Typically, the binder penetrates into about 50% of the outermost fabric.
- The outermost fabric contacts the wearer and, as such, is a fabric that is comfortable and provides a pleasing appearance. There is no requirement of a particular weight, weave or thickness for the outer layer. The top and bottom layers can be the same or different. In some embodiments, it is breathable and/or capable of gathering. The outer fabric is a woven, knit, weft knit/warp insertion or nonwoven fabric prepared from synthetic or natural fibers. For example, they may be selected from the naturally occurring animal and vegetable fibers, including cotton and wool, or synthetic (chemical) fibers such as nylon, cellulosics, rayon, polyesters, polyamides, acrylics, polypropylene, polyethylene and the like, including blends of such fibers. In a nonwoven substrate backing, the fibers are intimately entangled with each other to form a coherent breathable fibrous nonwoven backing. The particular fiber composition that is used as the nonwoven backing substrate is selected from those known in the prior art, according to the web property desired. Exemplary nonwovens having a desirable soft or comfortable feel include polypropylene, polyester, polyethylene, and cotton nonwovens. In one or more embodiments, the nonwoven fabric is lightweight, and can typically be about 10 grams per square meter (about 0.3 oz. per square yard) or about 17-20 grams per square meter (about 0.5-0.6 oz. per square yard).
- The carrier layer supports the elastic layer and acts as a carrier for the binder. The carrier layer can be any lightweight and open woven, knit or nonwoven fabric, or it can be a warp knit/weft insertion fabric. The carrier layer is selected to reinforce the assembled structure, while retaining the openness (which is a function of thread count and yarn denier, etc.) of the fabric. It is also selected to provide sufficient adhesive surface area to establish a strong adhesive contact with the outer fabric layers and the elastic layer. The fabric can be up to about 95% open, i.e., the fabric makes up about 5% of the surface area, and is typically about 70% open.
- Referring to FIG. 3, a warp knit/
weft insertion fabric 300 is shown onouter fabric 310. The warp-knit/weft insertion fabric 300 includes one ormore weft yarns 320 inserted through aknit loop 325. The weft insert yarns may include one or more filaments, the number and size of which are selected to have a desired tensile strength. By way of example only, the weft yarns are shown having three filaments; however, the weft yarns may be monofilament or multifilament, for example, the weft yarns can have a number of filaments, for example, 3-15 filaments. Because the fabric is warp knit/weft insertion rather than conventionally woven, the knittedwarp yarns 325 form rather loose warp yarn “loops” around thefill yarns 320, and the knitted warp structure also provides that each row of the knitted warp includes three yarns extending in the warp direction. This three-yarn warp knit/weft insertion construction results in a lightweight fabric having high tensile strength (about 12.8 lbs/inch) in the warp direction. - The fully extended warp knit/
weft insertion fabric 300 includesspaces 330 betweenadjacent weft yarns 320. This spacing, coupled with the loose, non-twisted, filamentary structure of the weft yarns themselves, permits the weft yarns to move towards and away from each other in response to stretch and relaxation of the longitudinalelastic strands 18, which is of course accompanied by elongation and relaxation of the warp yarns. - In one or more embodiments, the warp knit/weft insertion fabric has a weight of less than about 50 grams per square meter (about 1.5 oz. per square yard) and most preferably less than about 25 to 30 grams per square meter (about 0.7 to 0.9 oz. per square yard), and may be as low as 5 grams per square meter. An exemplary warp knit/weft insertion fabric has a weight ranging from about 25 to about 10 grams per square meter, and a warp/weft thread count ranging from about 18×12 to about 9×9. The knitted warp yarns are about 40 denier polyester; the about 150 denier fill or weft yarns are loose, nontwisted, texturized polyester filaments. Similar warp knit/weft insertion fabrics are available elsewhere, e.g., warp knit/weft insertion greige fabric available from Milliken & Company of Spartenburg, S.C. A lightweight fabric maintains the porosity of the stretch fabric and relaxes to a smooth, comfortable gather.
- The
elastic strands 18 used in the present invention for the elastic layer include thermoplastic elastomers, synthetic and natural rubbers. An exemplary elastic strand is a 280 denier strand, which is sold under the trademark GLOSPAN by Radici spandex Inc. of Fall River, Mass. Depending on the amount of elasticity desired in theelastic fabric 10, both the denier and number of elastic strands per inch (measured transversely) of the fabric may vary. For example, the denier of the elastic strands may vary from less than 100 to about 1000, and there may be from about 5 to about 15 elastic strands per inch. In some embodiments, the elastic yarns provide an elastic fabric having a degree of stretch (elongation) ranging from approximately 40% to 275%. - Typically, the
elastic fabric 10 is formed by laminating the warp knit/weft insertion fabric 16 when fully extended or taut over stretchedelastic strands 18. The binder-impregnated elastic layer/warp knit/weft insertion layer is then contacted, while still fully extended, with the upper and lower outer layers.Binder 20 impregnates or coats the inner two layers and penetrates into a portion of the top and bottom outer layers. Theparticular binder 20 used to laminate the four layers together to form the finished product depends, principally, on whether and what kind of adhesive properties are desired. The binder can be a thermosetting or thermoplastic adhesive that remains flexible when set or cured. Typically, the binder is a self-curing laminating adhesive. Exemplary binders include carboxylated styrene butadiene (SBR) latexes, acrylic emulsions, copolymer acrylic emulsions, and the like. - An exemplary fabric includes a lightweight nonwoven polypropylene top and bottom outer fabric having a weight of 10 g/m2. The carrier layer is a warp knit/weft insertion fabric having a 9×12 warp/weft thread count with a 40 denier monofilament polyester warp yarn and a multifilament warp yarn of 70 denier. The elastic layer is 280 denier spandex rubber. All four layers are bonded together using Rovene® 4150 carboxylated SBR emulsion. The resultant fabric has a strength in the longitudinal warp direction of about 12 pounds per inch of width, yet it is light and comfortable to wear. As compared to the commercially available elastic fabrics made by weaving or knitting elastic yarns into a woven fabric, the laminated elastic fabric of the present invention provides a feel and an appearance that is at least equal and often superior to comparable elastic fabrics.
- The foregoing detailed description includes many specific details. The inclusion of such detail is for the purpose of illustration only and is non-limiting of the invention. In addition, features in one embodiment may be combined with features in other embodiments of the invention. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims.
Claims (21)
1. A elastic fabric comprising:
a first carrier layer of a non-elastic, open fabric;
a second layer, which is elastic in a direction extending longitudinally of the fabric;
a first outer fabric layer and a second outer fabric layer on opposing sides of the first carrier and second elastic layers; and
a binder bonding the layers together.
2. The elastic fabric of claim 1 , wherein the carrier fabric comprises a warp knit/weft insertion fabric having knit yarns and fill yarns and oriented with the knit yarns thereof extending longitudinally of the fabric, said knit yarns being non-elastic, each of said knit yarns extending longitudinally of the tape and including a plurality of longitudinally-spaced knitted loops, and each of the fill yarns extending transversely of the fabric and through loops of the knit yarns.
3. The elastic fabric of claim 1 , wherein the carrier layer is selected from the group consisting of woven, nonwoven, warp knit/weft insertion and knitted fabrics.
4. The fabric of claim 1 or 2, wherein the binder is in adhesive contact with all layers of the fabric.
5. The fabric of claim 1 or 2, wherein the binder impregnates the first carrier layer and coats the second elastic layer.
6. The fabric of claim 5 , wherein the binder penetrates a partial thickness of the first and second outer layers.
7. The fabric of claim 5 , wherein the binder penetrates up to about 95% of the thickness of the first and second outer layers.
8. The fabric of claim 5 , wherein the binder penetrates in the range of about 25% to about 75% of the thickness of the first and second outer layers.
9. The fabric of claim 5 , wherein the binder penetrates up to 50% of the thickness of the first and second outer layers.
10. The fabric of claim 1 , wherein the top and bottom outer layers are selected from the group consisting of nonwoven materials, woven materials, knitted materials, and warp knit/weft insertion fabrics.
11. The fabric of claim 10 wherein said nonwoven is selected from the group consisting of nylon, rayon, cellulosics, cotton, polyester, polyamide, acrylics, polyethylene, and polypropylene.
12. The fabric of claim 1 , wherein said second layer comprises individual elastic strands spaced transversely of the fabric relative to each other and extending longitudinally of the fabric.
13. The fabric of claim 12 , wherein said elastic strands have a denier less than about 1000.
14. The fabric of claim 12 , wherein said elastic strands are spaced at a density in the range of 5 to 15 per inch measured transversely of the bandage.
15. The fabric of claim 2 , wherein the knit yarns of the warp knit/weft insert fabric comprises polyester.
16. The fabric of claim 2 , wherein the fill yarns of the warp knit/weft insertion fabric comprise a plurality of yarns.
17. The fabric of claim 1 or 2, wherein the carrier fabric has an openness of up to about 95%.
18. The fabric of claim 1 or 2, wherein the carrier fabric has an openness of up to about 70%.
19. The fabric of claim 1 , wherein the binder comprises a self-curing adhesive.
20. The fabric of claim 1 , wherein the binder is a thermosetting adhesive.
21. The fabric of claim 1 , wherein the binder is a thermoplastic adhesive.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/420,470 US20040214494A1 (en) | 2003-04-22 | 2003-04-22 | Stretch fabric |
PCT/US2004/012324 WO2004094709A2 (en) | 2003-04-22 | 2004-04-22 | Stretch fabric |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/420,470 US20040214494A1 (en) | 2003-04-22 | 2003-04-22 | Stretch fabric |
Publications (1)
Publication Number | Publication Date |
---|---|
US20040214494A1 true US20040214494A1 (en) | 2004-10-28 |
Family
ID=33298511
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/420,470 Abandoned US20040214494A1 (en) | 2003-04-22 | 2003-04-22 | Stretch fabric |
Country Status (2)
Country | Link |
---|---|
US (1) | US20040214494A1 (en) |
WO (1) | WO2004094709A2 (en) |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20060242780A1 (en) * | 2005-04-29 | 2006-11-02 | Kimberly-Clark Worldwide, Inc. | Finger wipe with improved seam structure |
US20070267084A1 (en) * | 2006-01-20 | 2007-11-22 | Textile Network Inc. | Stretchable strap with gripper and method of making the same |
US20080031931A1 (en) * | 2006-03-17 | 2008-02-07 | Andover Healthcare, Inc. | Organotellurium and selenium-based antimicrobial formulations and articles |
US7469427B2 (en) * | 2005-06-30 | 2008-12-30 | Kimberly-Clark Worldwide, Inc. | Stretchable and permeable non-woven protective gloves |
US20090252915A1 (en) * | 2008-03-31 | 2009-10-08 | Georg Baldauf | Elastic composite tape |
US20100055157A1 (en) * | 2008-08-28 | 2010-03-04 | Andover Healthcare, Inc. | Silver based antimicrobial compositions and articles |
WO2010048664A1 (en) * | 2008-10-27 | 2010-05-06 | Peerless Industrial Systems Pty Ltd | Polymer fabric, method of manufacture and use thereof |
US20110053449A1 (en) * | 2009-08-25 | 2011-03-03 | Welspun Global Brands Limited | Multipurpose Laminated Stretch Fabric |
EP2709578B1 (en) * | 2011-05-18 | 2017-01-04 | 3M Innovative Properties Company | Tearable elastic composite articles |
CN110528161A (en) * | 2018-09-13 | 2019-12-03 | 刘汉星 | A kind of manufacturing method of natural antibacterial skin care knitting fabric |
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Cited By (20)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7552501B2 (en) | 2005-04-29 | 2009-06-30 | Kimberly-Clark Worldwide, Inc. | Finger wipe with improved seam structure |
US20060242780A1 (en) * | 2005-04-29 | 2006-11-02 | Kimberly-Clark Worldwide, Inc. | Finger wipe with improved seam structure |
US7469427B2 (en) * | 2005-06-30 | 2008-12-30 | Kimberly-Clark Worldwide, Inc. | Stretchable and permeable non-woven protective gloves |
US20070267084A1 (en) * | 2006-01-20 | 2007-11-22 | Textile Network Inc. | Stretchable strap with gripper and method of making the same |
US20090038706A1 (en) * | 2006-01-20 | 2009-02-12 | Textile Network Inc. | Stretchable strap with gripper and method of making the same |
US7490634B2 (en) * | 2006-01-20 | 2009-02-17 | Textile Network, Inc. | Stretchable strap with gripper and method of making the same |
US7600540B2 (en) * | 2006-01-20 | 2009-10-13 | Textile Network, Inc. | Stretchable strap with gripper and method of making the same |
US20080031931A1 (en) * | 2006-03-17 | 2008-02-07 | Andover Healthcare, Inc. | Organotellurium and selenium-based antimicrobial formulations and articles |
US8304355B2 (en) | 2008-03-31 | 2012-11-06 | Nordenia Technologies Gmbh | Elastic composite tape |
US20090252915A1 (en) * | 2008-03-31 | 2009-10-08 | Georg Baldauf | Elastic composite tape |
US20100055157A1 (en) * | 2008-08-28 | 2010-03-04 | Andover Healthcare, Inc. | Silver based antimicrobial compositions and articles |
WO2010048664A1 (en) * | 2008-10-27 | 2010-05-06 | Peerless Industrial Systems Pty Ltd | Polymer fabric, method of manufacture and use thereof |
CN102227310A (en) * | 2008-10-27 | 2011-10-26 | 比尔利斯工业系统有限公司 | Polymer fabric, method of manufacture and use thereof |
US20110272077A1 (en) * | 2008-10-27 | 2011-11-10 | Peerless Industrial Systems Pty Ltd | Polymer fabric, method of manufacture and use thereof |
US8500931B2 (en) * | 2008-10-27 | 2013-08-06 | Peerless Industrial Systems Pty Ltd. | Polymer fabric, method of manufacture and use thereof |
WO2011024075A2 (en) * | 2009-08-25 | 2011-03-03 | Sachin Kulkarni | Multipurpose laminated stretch fabric |
WO2011024075A3 (en) * | 2009-08-25 | 2011-05-05 | Sachin Kulkarni | Multipurpose laminated stretch fabric |
US20110053449A1 (en) * | 2009-08-25 | 2011-03-03 | Welspun Global Brands Limited | Multipurpose Laminated Stretch Fabric |
EP2709578B1 (en) * | 2011-05-18 | 2017-01-04 | 3M Innovative Properties Company | Tearable elastic composite articles |
CN110528161A (en) * | 2018-09-13 | 2019-12-03 | 刘汉星 | A kind of manufacturing method of natural antibacterial skin care knitting fabric |
Also Published As
Publication number | Publication date |
---|---|
WO2004094709A3 (en) | 2005-04-14 |
WO2004094709A2 (en) | 2004-11-04 |
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Legal Events
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Owner name: ANDOVER COATED PRODUCTS, INC., MASSACHUSETTS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:MURPHY, THOMAS S.;PIASECZYNSKI, STANLEY J.;REEL/FRAME:013883/0883;SIGNING DATES FROM 20030730 TO 20030807 |
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STCB | Information on status: application discontinuation |
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Owner name: ANDOVER HEALTHCARE, INC., MASSACHUSETTS Free format text: CHANGE OF NAME;ASSIGNOR:ANDOVER COATED PRODUCTS, INC.;REEL/FRAME:017596/0442 Effective date: 20060217 |