Fabrics Containing Multi-Groove Fibers

Abstract

Fabric having a fabric body defines a first surface and an opposite second surface, with at least one of the first and second surfaces incorporating fibers having an axial core surrounded by a multiplicity of radially extending, axially-elongated whiskers. The whiskers are separated by axially-extending grooves. The fibers have denier of about 0.3 dpf to about 10.0 dpf. Garments formed of such fabric are also described.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a non-provisional of U.S. Application Serial No.: 61/587,299 filed Jan. 17, 2012, the entire content of which is incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates to fabrics consisting, at least in part, of synthetic fibers having an axial core with multiple, axial grooves defined between axially-elongated, axially arranged whiskers.

BACKGROUND

Fine denier fibers, i.e. fibers having relatively reduced weight per length, which can be achieved, e.g., through reduced fiber diameter, are often used in fabrics, e.g. for garments and the like, to provide a soft surface touch, e.g. to the wearer's skin. However, low denier fibers typically generate only very low bulk, i.e. thickness, e.g. when used as a terry knit yarn (in circular knit) and subjected to a raising process, e.g. brushing, napping, etc. Low denier fibers, e.g. less than about 0.3 to 1.0 denier per filament (dpf), incorporated into fabric yarns by direct spinning or by island-in-the-sea construction (i.e. fine denier fibers for the “islands”) introduced in a larger denier fiber of soluble or dissolvable polymer (the “sea” that is subsequently removed leaving the fine denier fibers) tend to flatten out quite readily under pressure, thus causing the fabric to lose its desirable bulk (surface thickness).

High performance and other fabrics are also often designed for enhanced water management performance, i.e. for removal of sweat and other moisture from the fabric inner surface at the wearer's skin by wicking through the fabric to the exposed outer surface, where evaporation can occur. In fabric systems of this nature, it is often desirable to provide a differential of denier between fibers at the inner surface and fibers at the outer surface of the fabric, with the inner surface fibers having relatively higher denier, thereby to encourage enhanced wicking action. This relationship of denier between fibers of the inner surface and fibers of the outer surface thus limits the denier of the inner surface, where enhanced fineness of the fibers would otherwise be desirable, e.g. for increased comfort to the wearer's skin.

Referring to FIGS. 1A and 1B, raised surface fabrics 2, 4, e.g. velour, fleece, shearling, etc., having a single raised surface 5 (FIG. 1A) and two raised surfaces 6, 7 (FIG. 1B), respectively, are also often desirable for their ability to entrap air between raised surfaces fibers, thus to provide theimal insulation. However, the air entrapped amongst the surface fibers of these fabrics is quite easily removed by action of dynamic conditions, i.e. blowing air or movement of the wearer, resulting in rapid loss of insulation.

SUMMARY

In one aspect, the disclosure features a fabric comprising a fabric body defining a first surface and an opposite second surface. At least one of the first surface and the second surface incorporates fibers having an axial core surrounded by a multiplicity of radially extending, axially-elongated whiskers. The whiskers are separated by axially-extending grooves. The fibers have denier of about 0.3 dpf to about 10.0 dpf. In another aspect, the disclosure features a garment formed of such a fabric.

Implementations of the fabric and/or the garment may include one or more of the following features. The first surface is a smooth surface and incorporates said fibers. The first surface is a raised surface and incorporates said fibers. The second surface incorporates fibers other than said fibers. The second surface is a raised surface and incorporates said fibers. The raised surface of the fabric is an inner surface of the garment, facing toward a skin surface of a wearer. The second surface incorporates fibers other said fibers, and the fibers incorporated in the second surface have denier relatively greater than the denier of said fibers incorporated in the first surface. The fibers other than said fibers incorporated in the second surface have denier of about 0.1 dpf to about 3.0 dpf. The fabric has construction selected from among has double needle bar warp knit (raschel), circular terry sinker loop (plaited or reverse plaited), cut loop terry sinker loop, and brushed warp knit construction. The fabric has constructions selected from among plaited single jersey, plaited jersey, double knit, tricot, the jersey side of single face construction, 2-end fleece, and 3-end fleece construction. The raised surface defines pillars separated by intersecting channels, the pillars being defined by discrete regions of relative high pile and the intersecting channels being defined by discrete regions of relatively lower pile or no pile. The raised surface defines pockets, the pockets being defined by discrete regions of relatively low pile or no pile arrayed among relatively higher pile. The first and second surfaces both incorporate said fibers. The fabric body further comprises elastomeric fibers. The fabric body has 4-way stretch. The fabric has construction selected from woven construction, double weave construction, and warp knit construction. The core and the whiskers of said fibers consist of the same polymer or compatible polymers. The polymer of the core and/or of the whiskers comprises polyethylene terephthalate (PET), polypropylene (PP), polyamide 6 (PA 6), PA 66, or any of the combinations. The fibers have about 3 to about 200, e.g., about 10 to about 200, whiskers within a cross-sectional surface of said fibers. The axially-extending grooves are nanogrooves or microgrooves. The whiskers have an average radial length of about 2 nm to about 10 microns, The core has a denier of about 0.3 dpf to about 10.0 dpf. The whiskers may an average length of up to about 200% of the diameter of the core, e.g., for relatively longer whiskers, or may have an average length of down to about 0.01% of a diameter of the core, e.g. for relatively shorter whiskers. The relatively longer whiskers may have an average length in the range of about 20% to about 100% of a diameter of a core, and relatively shorter whiskers may have an average length in the range of about 0.1% to about 1.0% of a diameter of a core, or about 200 nm to about 2 microns.

Implementations of this disclosure may include one or more of the following advantages. For example, fabrics incorporating multi-groove fibers (“MGF”), e.g., multi-groove nano or micro fibers, having a core from which extend, generally radially, multiple axially-elongated whiskers separated by axially-extending grooves can have an ultra-suede touch. The multi-groove fibers can be incorporated into a raised surface, or surfaces, of a fabric forming outer and/or inner surfaces of a garment.

The multi-groove fibers have a relatively fine denier (weight per length), e.g. when compared to standard fibers of similar diameter, but the multi-groove fibers are relatively thicker (i.e. having relatively greater diameter) and provide more bulk, e.g. as compared to fibers of standard cross-section and similar denier. Loop yarn and/or pile surfaces including the multi-groove fibers on the raised surface can have enhanced thickness (bulk).

The multi-groove fibers diffuse light directed onto the surface of a garment, providing the garment with fibers having relatively shorter whiskers with the appearance of a dull or matte finish, e.g. as compared to a reflectively shiny finish.

A raised surface fabric, whether single face or double face, incorporating multi-groove fibers having relatively longer whiskers in the raised surface(s), can provide improved thermal insulation by entrapment and retention of air, and will resist release or displacement of the entrapped air, e.g. as compared to standard raised surface fabric, when exposed to dynamic conditions (movement and/or blowing air). The fabric can have a single raised surface or it can have two, opposite, raised surfaces. Under static conditions, the raised surface of a fabric of the disclosure having a raised surface formed of multi-groove fibers and the raised surface of a fabric having a raised surface formed instead of conventional fibers, without grooves or whiskers, both entrap a similar amount of air to provide similar thermal insulation properties to the fabric. However, air displacement in the raised surface formed of the multi-groove fibers is reduced as compared to a raised surface formed of conventional fibers, e.g., because of the tortuosity effect caused by the multi-groove fibers. In addition, under dynamic conditions, i.e., when the fabrics are in motion, e.g. caused by wind or by movement of the wearer, movement of multi-groove fibers on a raised surface of fabric of the disclosure is more restricted, e.g. as compared to movement of conventional fibers of a raised surface of a conventional fabric, e.g. in particular in the case of relatively longer whiskers. Accordingly, the fabric of the disclosure provides good thermal insulation to the wearer under both static and dynamic conditions.

A fabric incorporating multi-groove fibers can be foamed into a garment having its raised surface facing the skin surface of a wearer. The raised surface can be patterned, e.g., to define grids, pillars, interconnected channels, pockets, or other surface features, including to enhance thermal insulation, air circulation, and water management capabilities.

The multi-groove fibers can also be incorporated into a smooth surface of a fabric, e.g. for use as an outer surface of a garment. The multi-groove fibers having relatively shorter whiskers can be used on the technical face of plaited terry sinker loop, or on the outer side of plaited jersey, double knit and tricot, to provide enhanced water management and improved rate of drying.

In particular, a fabric incorporating the multi-groove fibers having relatively shorter whiskers can have enhanced water management performance. The grooves of the multi-groove fibers can provide enhanced movement of water along or through the fabric by flow of water along the grooves. The whiskers of the multi-groove fibers cause the fibers to have relatively larger surface area, resulting in increased water holding capacity and enhanced water evaporation.

Plaited jersey or double knit with multi-groove fibers having small denier can be used advantageously on the outer-facing surface a garment in order to permit use of relatively coarse denier down to smaller denier fibers on the inner-facing surface of the garment, thereby maintaining the differential of higher to lower denier between the inner-and outer-facing surfaces, as required for effective wicking of fluid towards the outer surface, and also providing enhanced comfort for the wearer with relatively lower denier at the inner facing surface.

Dimensions of the multi-groove fibers, such as length and/or density of the whiskers, can be selected to enhance desired performance features of the fibers, of fabrics made of or containing the fibers, and of garments formed of the fabrics.

All fabrics including the multi-groove fibers can also include elastomeric yarns.

Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIGS. 1A and 1B are schematic edge views of prior art fabrics having a single raised surface and a double raised surface, respectively.

FIG. 2A is a schematic edge cross-sectional view of a fabric of this disclosure incorporating multi-groove fibers (“MGF”) on the technical face (jersey side) of, e.g., a single face or plaited jersey raised fabric, where, in a garment, the raised surface of the technical back would be directed toward a wearer's skin; and

FIG. 2B is a similar schematic edge cross-sectional view of another fabric of this disclosure incorporating multi-groove fibers at one or both surfaces of, e.g., a fabric having a terry sinker loop (reverse plaiting) construction, finished in double face, e.g. velour/velour.

FIGS. 3A and 3B are end section and perspective side views, respectively, of a multi-groove fiber, and

FIG. 3C is an end perspective view of a multi-groove fiber as seen through a scanning electron microscope.

FIGS. 3D and 3E are end section views of other implementations of multi-groove fibers having relative shorter whiskers and having relatively longer whiskers, respectively.

FIG. 4 is a schematic cross-sectional representation of a process for conversion of a precursor into a multi-groove fiber, and

FIG. 4A is an end section view of an intermediate product including a removable sheath during the process of making multi-groove fibers.

FIGS. 5A through 5N are schematic views of other fabric constructions of this disclosure implementing incorporation of multi-groove fibers.

FIG. 6A is a schematic view of a garment segment formed of fabric (e.g. plaited terry sinker loop fabric) of this disclosure having a raised surface containing the multi-groove fibers.

FIG. 6B is s schematic view of another garment segment formed of fabric of this disclosure having two raised surfaces, each containing the multi-groove fibers.

DETAILED DESCRIPTION

Referring to FIG. 2A, in one implementation, a fabric 10 of this disclosure has a fabric body 12 with a raised surface 14 formed of loop yarn or pile (e.g., velour) and an opposite smooth surface 16 that incorporates fine denier multi-groove (nano or micro or other) fibers(“MGF”), which will be described in more detail below. The multi-groove fibers in the smooth surface 16 include relatively shorter whiskers that facilitate water management. As represented in the figure, the fabric 10, when formed into a garment, has its raised surface 14 disposed to face the skin surface, S, of a wearer.

Referring to FIG. 2B, in another implementation, a fabric 10′ has a fabric body 12′ with opposite raised surfaces 14′, 16′ both formed of loop yarn or pile (e.g., velour/velour), with one or both of the raised surfaces incorporating the fine denier multi-groove fibers. The multi-groove fibers in the raised surfaces can have relatively longer whiskers to provide good thermal insulation.

Multi-groove fibers having relatively shorter whiskers, e.g. as developed by Taiwan Textile Researched Institute (“TTRI”), are described in Liu et al. U.S. Patent Publication No. 2010/0159241, published Jun. 24, 2010 (assigned on its face to Taiwan Textile Research Institute), the complete disclosure of which is incorporated herein by reference. As will be described, whisker fibers permit formation of fabrics, including raised surface velour and velour/velour fabrics, with certain advantageous features, including, but not limited to, ultra-suede touch, while still generating appropriate thickness/bulk of the raised surface fabric.

Referring to FIGS. 3A, 3B, and 3C, a multi-groove fiber 20 consists of an axially-elongated core 22 and multiple (e.g., 8-200) grooves 26 defined and spaced apart by whiskers 24 that extend generally radially from the core 22. The whiskers 24, e.g., axially-elongated whiskers, are separated by grooves 26, e.g., axially-elongated grooves, and can have an average radial length, l, in the order of microns or nanometers. The core 22 can have any desired mass density (i.e. denier or mass-per-length), e.g., a coarse denier of about 1.5 dpf to about 10.0 dpf, or a fine denier of about 0.3 dpf to about 1.5 dpf. In some implementations, the total mass density of the fiber 20 is selected to be about 0.3 dpf to about 1.5 dpf.

The core 22 is formed of a synthetic (polymeric) material, e.g., selected from among, e.g. polyester, nylon, polypropylene, and others. The whiskers 24 are formed of the same synthetic material as the core 20. For example, both the core 20 and the whiskers 24 are formed of polyester. Referring to FIGS. 3D and 3E, other implementations of multi-groove fibers 20′, 20″ are shown, e.g. with whiskers of relatively shorter length and relatively longer length, respectively. In some implementations, an average radial length, l, of the whiskers 24′ of multi-groove fibers 20′ is smaller than the diameter of the core 22′. An average radial length, l, of the whiskers 24″ of the multi-groove fibers 20″ is greater than the diameter of the core 22″. The whiskers may an average length of up to about 200% of the diameter of the core, e.g., for relatively longer whiskers, or may have an average length of down to about 0.01% of a diameter of the core, e.g. for relatively shorter whiskers. The relatively longer whiskers may have an average length in the range of about 20% to about 100% of a diameter of a core, and the relatively shorter whiskers can have an average length in the range of about 0.1% to about 1.0% of a diameter of a core, or about 200 nm to about 2 microns.

Referring also to FIG. 4, the multi-groove fibers may be formed according to processes described in Liu et al. U.S. Patent Publication No. 2010/0159241, as referenced above. Multi-groove fibers may also be available commercially from TTRI. Similar fibers may also be available from Hills, Inc. (Florida, USA). As shown in FIG. 4, according to the patent publication of Liu et al., multi-groove fibers are formed initially as a precursor 40′, extruded from a spinneret die, the fiber precursor consisting of a core 32 surrounded by an edge region 46. The edge region 46 is formed of alternating materials 34, 36, e.g., polymeric materials, respectively. The polymer 34 later forms whiskers over the core 32, and the polymer 36 forms a removable, e.g., dissolvable, sheath separating the polymer 34. In some implementations, as shown in FIG. 4A, the sheath 36 extends beyond the whisker material 34 along the radial direction. The surface of the edge region surrounding the core 32 is formed of the sheath material 36. Upon removal of the polymer sheath 36, grooves are formed among the whiskers.

The polymers 34, 36 can be in the form of alternating sheets or webs extending along a longitudinal axis of the core 32. The polymer 34 is the same as the synthetic material forming the core 32. The polymer 36 is different from the materials forming the core 32 and the polymer 34, and is dissolvable or otherwise removable. The polymer 36 and the polymer 34 typically have surface energy that is quite similar. Referring still to FIG. 4, the fiber precursor 40′ is next subjected to processing (arrow, P) for removal of the sheath 36, thereby forming multiple grooves 38 disposed about and extending axially along the core 32 of the multi-groove fiber 40, the grooves 38 being defined by and between intervening “whiskers” 42 formed of the sheets of the first set 34.

Referring again to FIGS. 3A and 3B, and also to FIG. 3C, fibers 20 have a core 22 and whiskers 24 separated by grooves 26 extending from the surface of the core. The fibers 20 can be multi-groove nano fibers having a total (including the core and the whiskers) average mass density of about 0.3 dpf to about 10.0 dpf. The fibers 20 can also be multi-groove micro fibers. The whiskers 24 and grooves 26 cause the fibers 20 to have relatively low mass density as compared to a relatively smaller diameter or thickness for fibers in the indicated range of denier. For example, for purposes of comparison, a conventional fiber without the grooves and whiskers and formed of the same material would have a thickness of about 2% to about 75% of the thickness of the fiber 20, in order to have denier in the range indicated for the multi-groove fiber 20. In contrast, if a conventional fiber had a diameter in the range indicated above for multi-groove fiber 20, and was formed of the same material, such a conventional fiber would have denier in the range of about 1.3 to about 50 times the denier of the fiber 20.

According to the present disclosure, the sizes, thicknesses, and/or mass densities of the multi-groove fibers 20 can be selected based on the desired features of the fibers 20, e.g., denier, and/or other features of the raised surface(s) 14 or 14′, 16′ (FIGS. 2A-2B). The whiskers 24 can have an average radial length, l, of about 2 nm to about 10 microns, e.g., 200 nm to 2 microns, and an average thickness, t, of about 100 rim to 1 micron, e.g., 200 mu to 1 micron, or 250 nm. As mention above, the grooves can be nano-size or micro-size, e.g., having an average width, w, of about 100 nm to 10 microns, e.g., 250 nm. The ratio of the average diameter, D, of the core 22 to the average length, l, of the whiskers 24 and/or the ratio of the average thickness, t, to the average width, w, can be adjusted to obtain desired fiber properties, e.g., by changing the materials for and/or processes of making the multi-groove fibers 20 (discussed further below). In the example shown in FIG. 3E, the ratio of core diameter to the average length of the whiskers is 1:1.

In some implementations, each multi-groove fiber 20 has about 3 to about 200 whiskers, e.g., about 10-200 whiskers, about 40-200 whiskers, or about 60-80 whiskers, extending generally radially from the core. The grooves 26 extend the entire length of the multi-groove fiber 20. In some implementations, the grooves 26 have substantially the same dimensions and/or are substantially evenly distributed about and/or along a cross-sectional surface of the multi-groove fiber 20. In other implementations, the grooves 26 may have different dimensions and/or may be distributed irregularly. Although the core 22 and the multi-groove fibers 20 appearing in the figures are shown as having circular cross-section, it is to be understood that the core 22 and the multi-groove fibers 10 may have other cross-sectional shapes. In some implementations, a fiber can include both relatively longer whiskers and relatively shorter whiskers along its cross section.

In some implementations, the multi-groove fibers 20 are formed or consist of synthetic (polymeric) material. The core 22 and the whiskers 24 are typically formed of the same polymeric material. Suitable polymeric materials for use in the core 22 and the whiskers 24 include, e.g., polyethylene terephthalate (PET), polypropylene (PP), polyamide 6 (PA 6), PA 66, and/or combinations thereof.

Referring again to FIG. 4, multi-groove fibers 40, e.g., that are similar to or the same as the multi-groove fibers 20 of FIGS. 3A and 3B, can be made by forming a polymer extrusion 30 of three or more polymers 32, 34, 36 and removing one of the polymers 36 to form grooves 38 among whiskers 42 formed of the polymer 36. The polymeric extrusion 30 includes a core region 44 formed of the polymer 32 and an edge region 46 formed of polymers 34, 36. The polymer 34 is the same as the polymer 32, and the whiskers are separated by the sheath formed by the removable polymer 36, e.g., dissolvable polyester, polyvinyl alcohol (PVA), polybutylene terephthalate (PBT), poly(lactic acid) or polylactide (PLA), or others. The sheath can be removed by exposing the polymer extrusion 30 to water or caustic soda (NaOH). The polymer 36 can be removed by heating or radiating the polymer extrusion 30 and dissolving the polymer 36. Other removable polymers and removal mechanisms may also be employed. The polymers 32, 34 can be the previously discussed polymers for forming the core 22 and the whiskers 24.

Referring again to FIGS. 3D and 3E, the thickness, t, and the length, l, of the whiskers 42 can be adjusted by modifying the polymers 34, 36 or other related parameters and factors. For example, the spinneret used for extruding the fibers and/or the weight ratio of the whisker polymer 34 and the sheath polymer 36 can be controlled or adjusted to modify parameters of resulting product. The feeding rate of each polymer, the spin head and the spinning plates in the spinneret can also be modified. For example, the weight ratio can be in the range of from 9/1 to 1/9. The dimensional ratio of the core 44 to the edge 42 (FIG. 4) can also be adjusted, e.g., to provide the desired fiber denier and thickness. In some implementations, multi-groove fibers 20′ (FIG. 3D) with relatively shorter and/or thicker edge segments, resulting in relatively shorter and/or thinner whiskers 24′, may be desirable, e.g. to produce fabric having a matte appearance or finish. Conversely, multi-groove fiber 20″ (FIG. 3E) with relatively longer and/or thinner edge segments, resulting in relatively longer and/or thicker whiskers 24″, may also be desirable, e.g. to provide a softer touch to the fibers, and to the fabric containing or made of the fibers, e.g. resembling ultra-suede. The ratio of dissolvable and non-dissolvable segments, as well as the ratio of edge and core dimensions, can also be adjusted.

We refer to now to FIGS. 5A through 5N in describing examples of other implementations of this disclosure.

Referring to FIG. 5A, a velour fabric 60 has a raised surface 62 incorporating multi-groove fibers (or whisker fibers) having a core and whiskers made of the same polymer. The raised surface 62 has an ultra suede touch and still has standard thickness/bulk.

Referring to FIG. 5B, a velour fabric 70 has a raised surface 72 incorporating multi-groove fibers (or whisker fibers) having a core and whiskers, that are relatively thinner and/or longer as compared to FIG. 5A, resulting in relatively softer touch resembling an ultra-suede feeling.

Referring to FIG. 5C, a raised surface and/or pile fabric 80 incorporating multi-groove fibers (or whisker fibers) yarns is formed, e.g., with double needle bar warp knit (raschel), circular terry sinker loop knit, cut terry sinker loop knit, brushed warp knit, etc. construction.

Referring to FIG. 5D, a plaited construction fabric 90, e.g. like plaited single jersey, plaited jersey, double knit, tricot, the jersey side of single face construction, 2-end fleece, 3-end fleece, etc., has multi-groove fibers (or whisker fibers) incorporated on the smooth outer side 92 of a garment funned of the fabric.

Referring to FIG. 5E, in a fabric 100 of a plaited construction, employed, e.g., in a garment 102 (FIG. 5F) for improved water management, i.e. moving liquid sweat from the inner (skin surface) side 104 to the outer side 106, relatively coarser denier fibers are used on inner side 104 (next to skin) and relatively finer denier fibers are used on outer side 106 (away from skin). Use of the multi-groove fibers (or whisker fibers) as the relatively finer denier fiber on the outer side 106 permits use of very fine fibers on inner side 104 (0.1 to 1.0 dpf), while still maintaining, or improving, water management. Referring also to FIGS. 3A-3E and 4, the configuration of the fibers 20, 20′, 20′, and 40′ can enhance the soft touch and water management capability of the fabric 100. In some implementations, the whiskers having a relatively longer radial length, l, e.g., longer than the diameter of the core, provides a still further enhancement of the soft touch to a surface of the fabric 100 and to the garment 102. Whiskers having a relatively shorter length, l, e.g., 200 nm to 10 microns, can provide good water management by allowing water to move along the grooves 26, 38 among the whiskers. The whiskers 24, 42 and the grooves 26, 38 also increase the total surface area of the fibers 20, 40, so that the fibers 20, 40 have a relatively larger capacity to hold liquid and water evaporation can be enhanced. In some implementations, the fibers 20, 40 can have any size core (i.e., any denier) with a desired length of whiskers selected to provide a desired fiber property, e.g., denier and/or water management.

Referring to FIG. 5G, a single faced raised fabric 110 formed into a garment (not shown) has multi-groove fibers (or whisker fibers) incorporated on technical face (jersey (smooth) side) 112, while the raised surface on technical back 114 is facing the wearer's skin to enhance further water management. As shown in the figure, the single face fabric 110 can have surface construction with raised pillars 116 separated by intersecting channels 118. This single face fabric 110 can also include elastomeric yams, e.g., for enhancement of stretch/recovery. The fabric 110 can also include elastomeric yarn, e.g., yarn containing or made of spandex, to provide stretch. In some implementations, the fabric body 110 can have 2-way stretch or 4-way stretch, which can facilitate, e.g., thermal insulation and water management.

Referring to FIG. 5H, a fabric 120 with terry sinker loop construction (reverse plaited knit construction) has multi-groove fibers (or whisker fibers) used in different proportions. For example, the multi-groove fibers (or whisker fibers) may be used at every end, or at every second end, or at every third end, or . . . at every X end (where “X” is any integer). Multi-groove fibers (or whisker fibers) can also be used in different proportions (e.g. at every X end) of the jersey side (technical face, outer side of terry sinker loop in single face plaited construction), or in single jersey or double knit constructions. The fabric 120 can also include elastomeric yarn.

Referring to FIGS. 5I and 5J, a terry sinker loop fabric 130 in single face 132 (FIG. 5I) or a terry sinker loop fabric 140 in double face 142, 144 (FIG. 5J) can have a patterned design (e.g., grid, pile out, jacquard, etc.) with multi-groove fibers (or whisker fibers) incorporated therein. For example, referring to FIG. 5I, the raised surface 132 can include plaited terry sinker loop pile and can be on the technical back of the fabric 130. The raised surface 132 is patterned to enhance wearer comfort with the raised loops or pile forming discrete pillars 134 separated by channels, e.g., intersecting channels 136, formed by region of relatively low pile or no pile. During wearer activity, the intersected channels 136 allow air to flow between the wearer's skin and the fabric 130 to facilitate evaporation of the sweat from the wearer's skin. In contrast, during wearer inactivity, the intersecting channels 136 entrap the air between the wearer's skin and the fabric to provide enhanced thermal insulation. The pillars 134 and the channels 136 can be arranged in any desired pattern or at random. The pillars 134 can have any desired cross-sectional sizes and/or shapes, e.g., such as square, circular, triangular, or others. Referring next to FIG. 5J, the fabric 140 defines pockets 148 formed in the raised surface 142. The raised surface 142 can be plaited terry sinker loop pile on the technical back of the fabric 140. The pockets 148 do not extend the entire thickness of the fabric 140 and are formed by regions of relatively low pile or no pile. Similar to the intersecting channels 136 of FIG. 5I, the pockets 148 can entrap air during wearer inactivity, to provide enhanced thermal insulation. The pockets 148 can be arranged in any pattern or at randomly upon the raised surface 142, and the pockets can have any desired sizes and/or cross-sectional shapes, e.g., square, triangular, circular, or others.

Referring to FIG. 5K, a fabric 150 of other constructions, e.g. woven construction, double weave construction, or warp knit construction, can have multi-groove fibers (or whisker fibers) incorporated therein.

Referring to FIGS. 5L and 5M, a single face fabric 160 (FIG. 5L) and a plaited jersey fabric 170 (FIG. 5M) have multi-groove fibers (or whisker fibers) incorporated on the outer surface 162, 172, respectively (away from skin when formed into a garment).

Referring to FIG. 5N, a terry sinker loop (reverse plaiting) fabric 180, finished in double face (velour/velour) 182, 184 has multi-groove fibers (or whisker fibers) incorporated on both sides.

The multi-groove fibers 20, 40 can be used in one or more raised surfaces of a fabric to provide thermal insulation, particularly in dynamic conditions. Referring to FIGS. 6A, a segment of a garment 200 formed of single-faced fabric has a raised surface 204, e.g., in the form of pile and a smooth surface 208 on a fabric body 202. The raised surface 204 contains, or is formed of, multi-groove fibers 206, e.g., the same as or similar to the fibers 20, 40, having relatively longer whiskers. When the fabric is incorporated into garment 200, the raised surface 204 can be an outer surface facing an environment or an inner surface facing towards skin of a wearer. Under static conditions, the raised surface 204 of a fabric 202 (FIG. 6A) of the disclosure, fainted of multi-groove fibers 206, and the raised surface 5 of a fabric 2 (FIG. 1A), formed instead of conventional fibers, without grooves or whiskers, both entrap similar volumes of air to provide similar thermal insulation properties to the respective fabrics. However, air displacement in the raised surface formed of the multi-groove fibers is reduced as compared to a raised surface formed of conventional fibers, e.g., because of the tortuosity effect caused by the multi-groove fibers. In addition, under dynamic conditions, i.e., when the fabrics 2, 202 are in motion relative to surrounding air, e.g. caused by wind movement or by wearer motion, movement of multi-groove fibers 206 on a raised surface 204 of fabric 202 of the disclosure is more restricted, e.g. as compared to movement of conventional fibers of a raised surface 5 of a conventional fabric 2, e.g. in particular, in the case of relatively longer whiskers. Accordingly, the fabric 202 of the disclosure provides thermal insulation, or enhanced thermal insulation, to the wearer under both static conditions and dynamic conditions. Referring to FIG. 6B, a segment of a garment 210 formed of a double-faced fabric has two opposite, raised surfaces 214, 218 on a fabric body 212, each raised surface containing or formed of multi-groove fibers 218, 220, e.g., similar to or the same as fibers 20, 40. The multi-groove fibers 218, 220 on different surfaces can be the same or can be different, e.g., having different denier. Similar to the surface 204 of FIG. 6A, the surfaces 214, 216 can also provide good thermal insulation to the garment 210 under static and/or dynamic conditions. In some implementations, fabric of this disclosure can form an entire garment or it can form selected portions of a garment.

In some implementations, the fabrics and garment segments discussed above, e.g., in FIGS. 2A-2B, 5A-5N and 6A-6B, particularly the fabric 130 of FIG. 5I and the fabric 140 of FIG. 5J, can be used as a component of a fabric laminate, with the fabric of the disclosure on the inner side, the outer side, or on both the inner side and the outer side of the fabric laminate. The fabric laminate can include a breathable membrane.

Other embodiments are within the scope of the following claims.

Claims

1. A fabric comprising a fabric body defining a first surface and an opposite second surface, and at least one of the first surface and the second surface incorporating fibers having an axial core surrounded by a multiplicity of radially extending, axially-elongated whiskers, separated by axially-extending grooves, said fibers having denier of about 0.3 dpf to about 10.0 dpf.

2. The fabric of claim 1, wherein the first surface is a smooth surface and incorporates said fibers.

3. The fabric of claim 1, wherein the first surface is a raised surface and incorporates said fibers.

4. The fabric of claim 2 or claim 3, wherein the second surface incorporates fibers other than said fibers.

5. The fabric of claim 3, wherein the second surface is a raised surface and incorporates said fibers.

6. The fabric of claim 2 or claim 3, wherein the second surface incorporates fibers other said fibers, and the fibers incorporated in the second surface have denier relatively greater than the denier of said fibers incorporated in the first surface.

7. The fabric of claim 3, wherein the fibers other than said fibers incorporated in the second surface have denier of about 0.1 dpf to about 3.0 dpf.

8. The fabric of claim 3, wherein the fabric has construction selected from among has double needle bar warp knit (raschel), circular terry sinker loop, cut loop terry sinker loop, and brushed warp knit construction.

9. The fabric of claim 2, wherein the fabric has constructions selected from among plaited single jersey, plaited jersey, double knit, tricot, the jersey side of single face construction, 2-end fleece, and 3-end fleece construction.

10. The fabric of claim 6, wherein the raised surface defines pillars separated by intersecting channels, the pillars being defined by discrete regions of relative high pile and the intersecting channels being defined by discrete regions of relatively lower pile or no pile.

11. The fabric of claim 6, wherein the raised surface defines pockets, the pockets being defined by discrete regions of relatively low pile or no pile arrayed among relatively higher pile.

12. The fabric of claim 1, wherein the first and second surfaces both incorporate said fibers.

13. The fabric of claim 1, wherein the fabric body further comprises elastomeric fibers.

14. The fabric of claim 13, wherein the fabric body has 4-way stretch.

15. The fabric of claim 1, wherein said fabric has construction selected from woven construction, double weave construction, and warp knit construction.

16. The fabric of claim 1, wherein the core and the whiskers of said fibers consist of the same polymer or compatible polymers.

17. The fabric of claim 1, wherein the polymer of the core and/or of the whiskers comprises polyethylene terephthalate (PET), polypropylene (PP), polyamide 6 (PA 6), PA 66, or any of the combinations.

18. The fabric of claim 1, wherein said fibers have about 3 to about 200 whiskers within a cross-sectional surface of said fibers.

19. The fabric of claim 1, wherein said axially-extending grooves are nanogrooves or microgrooves.

20. The fabric of claim 1, wherein said whiskers have an average radial length of about 2 nm to about 10 microns.

21. The fabric of claim 1, wherein the core has a denier of about 0.3 dpf to about 10.0 dpf.

22. The fabric of claim 1, wherein the whiskers have an average length up to about 200% of a diameter of the core.

23. The fabric of claim 1, wherein the whiskers have an average length down to about 0.01% of a diameter of the core.

24. The fabric of claim 1, wherein the whiskers have an average length in the range of about 20% and to about 100% of a diameter of the core, or about 0.1% to about 1.0% of a diameter of the core.

25. A garment formed of the fabric of claim 1, claim 2, or claim 3, wherein a raised surface of the fabric is an outer surface of the garment, facing away from skin of a wearer.

26. A garment formed of the fabric of claim 1, claim 2, or claim 3, wherein a raised surface of the fabric is an inner surface of the garment, facing toward a skin surface of a wearer.