Fabric with Moisture Management Function

Abstract

A knitted or woven fabric with moisture management function is described that includes an inner layer having a first yarn that is semi-hydrophilic with a first moisture regain, and an outer layer having a second yarn that is hydrophilic with a second moisture regain greater than the first moisture regain of the first yarn. The fabric has a moisture regain gradient between the inner layer and the outer layer that acts to pull moisture through the inner layer in contact with the wearer’s skin and out through the outer layer. In one embodiment, the second yarn is a combination of a core bi-component yarn and at least one outer sheath yarn surrounding the core bi-component yarn.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of and claims priority to PCT/CA2021/051872, titled “Fabric with Moisture management Function”, filed on Dec. 22, 2021 and which application claims benefit of U.S. Provisional Application No. 63/129,705 filed Dec. 23, 2020, the contents of which applications are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

It is provided a knitted and a woven fabric with moisture management function comprising a hydrophilic gradient.

BACKGROUND

Fabrics used in apparel designed for athletic activities are conceived with the objective of maximizing the body performance by notably controlling the body temperature and keeping the moisture away from the individual in order to reduce the quantity of perspiration that accumulates adjacent to the skin, which causes discomfort with wet cling and increases friction with skin causing chafing The challenge is to manufacture such apparel which generally exhibit characteristics that enhance the performance without compromising the appearance and/or comfort of an individual.

The nature of the textiles that are incorporated into an apparel are generally selected based upon the targeted property for which the apparel is conceived, such as for example wind resistance, reduction of perspiration that accumulates adjacent to the skin, and enhancing comfort of individuals engaged in specific athletic activities.

Textiles normally incorporated in such fabrics may be cotton, wool, silk, synthetic materials such as rayon, nylon, polyester, and polyacrylic for example.

There is always a challenge to provide athletes when competing or training, with improved apparel which will allow to cope with heat/cold from the external environment, but also with heat generated within the body of the athlete as a result of physical exertion and associated sweat and lack of heat dissipation.

It is thus highly desired to be provided with improved fabrics.

SUMMARY

It is provided a knitted or woven fabric with moisture management function comprising a first fabric layer comprising a first yarn to form the first layer being semi-hydrophilic with lower moisture regain and a second fabric layer comprising a second yarn, the second fabric layer being hydrophilic with higher moisture regain, wherein the first fabric layer has a moisture regain lower than the moisture regain of the second fabric layer providing a hydrophilic gradient between the first fabric layer and the second fabric layer of the knitted / or woven fabric pulling moisture through the first fabric layer and pushing it out through the second fabric layer.

The proposed combination of yarns and total moisture regain of the fabric provides optimum comfort to the wearer by making sure that excess sweat does not accumulate next to skin while still provide moisture in the fabric that would help in cooling and breathability.

In an embodiment, the fabric is a weft or warp knitted fabric or a woven fabric.

In an embodiment, the moisture regain of the first fabric layer is in the range of 0.2% - 6% and the moisture regain of the second fabric layer is in the range of 4% - 16%, and the moisture regain gradient is greater than 3%.

In a further embodiment, the first yarn is selected from a group consisting of a nylon, a polyester, a polypropylene, an acrylic, cotton, wool, silk, regenerated cellulosic fibers and any blend combination thereof.

In an embodiment, the first fabric layer further comprises a third yarn joined together with the first yarn and the second fabric layer further comprises a fourth yarn joined together with the second yarn.

In a supplemental embodiment, the third yarn is a synthetic polymer.

In another embodiment, the first fabric layer is a composite blend of a synthetic polymer plaited with an elastane.

In an embodiment, the second yarn comprises a natural or a regenerated cellulosic fiber or a blend of natural or regenerated cellulosic fibers with synthetic fibers such as nylon, a polyester, a polypropylene, an acrylic.

In another embodiment, the second yarn is selected from the group consisting of a cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose, cupro, artificial silk, nylon, a polyester, a polypropylene, an acrylic and any combination thereof.

In a further embodiment, the fourth yarn is a synthetic polymer.

In an embodiment, the fourth yarn is an elastane.

In another embodiment, the second fabric layer is a composite blend of a natural fiber plaited with an elastane or a blend of natural fiber and synthetic fiber such as nylon, a polyester, a polypropylene, or an acrylic.

In an embodiment, the second yarn is a synthetic polymer.

In another embodiment, the second yarn is selected from a group consisting of a nylon, a polyester, a polypropylene, an acrylic or blended with cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose, cupro, artificial silk and a combination thereof.

In a further embodiment, the second fabric layer is pitched to increase its surface area.

In a supplemental embodiment, the fabric is knitted and further comprises a connecting yarn binding together the first and the second fabric layers.

In an embodiment, the connecting yarn is at least a single strand.

In an embodiment, the connecting yarn is an elastane.

In a further embodiment, the connecting yarn is a synthetic polymer.

In another embodiment, the connecting yarn is a natural fiber.

In an embodiment, the connecting yarn is a zig-zag structure between the first fabric layer and the second fabric layer. It is understood that the zig-zag structure means mainly a lapping back and forth between first and second layer fabrics in order to connect them.

In a supplemental embodiment, the fabric is knitted from a single jersey plaited construction, a double jersey plaited construction, a tricot or warp knit construction.

In an embodiment, at least one of the first yarn, the second yarn, the third yarn and the fourth yarn is produced by compact spinning.

In an embodiment, the first fabric layer and the second fabric layer are woven with a number of yarn cross overs desired.

In a further embodiment, the yarn cross over is of 3 up and 3 down, 3 up and one down, 3 up and 2 down, or 4 up and 1 down.

It is further provided an article of apparel comprising the fabric as defined herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the accompanying drawings.

FIG. 1 illustrates a schematic representation of a double jersey plaited construction fabric as encompassed herein in accordance to an embodiment.

FIG. 2 illustrates a schematic representation of a single jersey plaited construction fabric in accordance to another embodiment.

FIG. 3 illustrates a compact spinning technique used for the fabrication of the yarns as encompassed herein.

FIG. 4A illustrates the outer layer of a fabric in accordance to an embodiment.

FIG. 4B illustrates the inner layer of the fabric shown in FIG. 4A in accordance to an embodiment.

FIG. 5 illustrates a schematic representation of a double woven construction fabric as encompassed herein in accordance to an embodiment.

FIG. 6 illustrates a schematic representation of a plaited tricot (warp) knitted construction fabric as encompassed herein in accordance to an embodiment.

FIG. 7 illustrates a schematic representation of a core bi-component yarn with an outer sheath yarn surrounding the core bi-component yarn.

FIG. 8A illustrates a schematic representation of a core bi-component yarn with an outer sheath yarn surrounding the core bi-component yarn.

FIG. 8B illustrates a schematic representation of a core bi-component yarn with two outer sheath yarns surrounding the core bi-component yarn.

FIG. 9 illustrates a schematic representation of a plaited jersey knit construction fabric as encompassed herein in accordance to an embodiment.

FIG. 10 illustrates a schematic representation of a plaited twill knit construction fabric plaited jersey knit construction fabric as encompassed herein in accordance to an embodiment.

FIG. 11 illustrates a schematic representation of a circular knit double knit construction fabric as encompassed herein in accordance to an embodiment.

FIG. 12 illustrates a schematic representation of a warp knit construction fabric as encompassed herein in accordance to an embodiment.

DETAILED DESCRIPTION

In accordance with the present disclosure, it is provided a knitted or woven fabric with moisture management function comprising a first fabric layer comprising a first yarn and forming a next to skin back fabric layer, the first fabric layer having a first moisture regain and being a semi-hydrophilic or hydrophobic layer and a second fabric layer comprising a second yarn forming a face fabric layer facing towards outside, the second fabric layer having a second moisture regain and being a hydrophilic layer. In case of a knitted fabric, it can further comprise a connecting yarn binding together the first fabric layer and the second fabric layer.

As described herein, the moisture from a wearer’s skin is pushed through the first fabric layer and pulled out through the second fabric layer due to the presence of a moisture regain gradient between the first fabric layer and the second fabric layer of the knitted fabric.

In an embodiment, the moisture regain of the first fabric layer is in the range of 0.2% - 6% while the moisture regain of the second fabric layer is in a range of 4% - 16% and the moisture regain gradient between the two fabric layers is greater than 3%. For example, the moisture regain gradient between the two fabric layers is greater than 3%, such as e.g. between 3% - 15%.

As seen in FIG. 1, the fabric 10 comprises a first layer 12 which is the layer next to the skin A (inner layer) and a second layer 14 which correspond to the layer of the fabric 10 facing the exterior B (outer layer) and away from the skin A. As illustrated in FIG. 1, in an embodiment, a connecting yarn 16 binds together the first fabric layer 12 and the second fabric layer 14 tightening the fabric 10 together. The moisture from a wearer’s skin is pushed through the first fabric layer 12 towards the second fabric layer 14. The presence of a hydrophilic (moisture regain) gradient between the first fabric layer 12, being a semi-hydrophilic layer, and the second fabric layer 14, representing a hydrophilic layer, of the fabric 10 allows the moisture to be pushed as indicated from the direction of the arrow between region A of the skin towards exterior region B.

The first fabric layer 12 in an embodiment comprises a first yarn 18 and the second fabric layer 14 comprises a second yarn 23. In the illustrated embodiment of FIG. 1, the first fabric layer 12 further comprises a third yarn 20 knitted or woven together to form the next to skin A inner fabric layer 12, the first fabric layer 12 being a semi-hydrophilic or hydrophobic layer as mentioned. It is encompassed that the first yarn 18 and the third yarn 20 are a synthetic polymer, such as for example but not limited to, a polyester, a polypropylene, an acrylic, a polyacrylic or any combination thereof. As illustrated herein, the third yarn 20 is an elastane, resulting in a first fabric layer 12 being a composite blend of a synthetic polymer plaited with an elastane. In one embodiment, the first yarn 18 can be a composite of synthetic polymer and natural fiber such as for example, cotton, wool, silk or regenerated cellulosic fibers and can be configured as semi-hydrophilic with a first moisture regain. For example the first yarn 18 can be a blend of 70 - 95% synthetic polymer (e.g., polyester) and 5 - 30% natural fibers (e.g., cotton).

The second fabric layer 14 further comprises a fourth yarn 24 knitted or woven together to form a face (outer) fabric layer 14 facing towards outside B, the second fabric layer 14 being a hydrophilic layer. As encompassed, the second yarn 23 comprises a natural fiber, such as for example and not limited to, a cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose or a combination thereof. The second yarn 23 can alternatively be a composite blend of a modal and a cotton. Alternatively, the second yarn can also be a synthetic polymer such as for example a nylon, a polyester, a polypropylene, an acrylic, a polyacrylic or a combination thereof. The fourth yarn 24 can be a synthetic polymer, such as elastane. As a further embodiment, it is encompassed a second fabric layer 14 comprising a composite blend of a natural fiber plaited with an elastane. In one embodiment, the second yarn 23 is a composite blend of natural or regenerated cellulosic fiber and synthetic fiber such as nylon, a polyester, a polypropylene, an acrylic. One means to increase the hydrophilic nature of the second layer 14 is to increase its surface area. Accordingly, it is encompassed that the second fabric layer 14 can be pitched to increase its surface area.

The connecting yarn 16 binding together the first fabric layer 12 and the second fabric layer 14 is at least a single strand. As encompassed herein, the connecting yarn 16 is an elastane. It is also encompassed that the connecting yarn 16 is a synthetic polymer such as for example a nylon, a polyester, a polypropylene, an acrylic, a polyacrylic or a combination thereof. Alternatively, the connecting yarn 16 as described herein can comprise preferably a natural fiber such as for example a cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose or a combination thereof. The connecting yarn is preferably a zig-zag structure (an overlap) between the first fabric layer 12 and the second fabric layer 14. It is encompassed that the zig-zag structure consist of a lapping back and forth between first and second layer fabrics in order to connect them (FIG. 6). The connecting yarn 16 can be single strand or multiple strands. Each strand of the plurality of strands of the connecting yarn 16 can have independent zig-zag (underlap and overlap) structure.

It is thus described a fabric construction comprising an hydrophilic side and a semi hydrophilic or hydrophobic side allowing maximum moisture control. The fabric describe herein has the characteristic to push the moisture by a hydrophilic gradient using semi-hydrophilic and fully-hydrophilic layers next to each other. The combination of potentially 4 different types of fibers and the semi-hydrophilic or hydrophobic and fully-hydrophilic surfaces next to each other allows for efficient moisture management and quick drying.

As described herein, in some embodiments, the described fabric is made with a knitting construction which can be a weft knitted or wrap knitted structure. For example, the fabric can be a single jersey plaited construction (see FIG. 2) or a double jersey plaited construction for example (see FIG. 1) or Tricot warp knit plaited structure. As illustrated in FIG. 2, the fabric 100 has a single jersey plaited construction with a first layer 112 that comprises a first yarn 118 having the first moisture regain and a second layer 114 that comprises a second yarn 123 with the second moisture regain. The first moisture regain is lower than the second moisture regain providing a hydrophilic gradient between the first fabric layer 112 and the second fabric layer 114 of the fabric 100 thus pushing the moisture through the first fabric layer 112 and out through the second fabric layer 114. The fabric 100 further comprising a plaited yarn 125. The plaited yarn 125 can be elastane to increase the elasticity of the fabric 100.

In an embodiment, the moisture regain of the first fabric layer is in the range of 0.2% - 6% and the moisture regain of the second fabric layer is in the range of 4% - 16% and the moisture regain gradient between the two fabric layers is greater than 3%.

In an embodiment, at least one of the first, second, third or fourth yarn are fabricated using a compact spinning technique to spin the cotton/micromodal yarn for example that helps reducing pilling and better handfeel.

As seen in FIG. 3, in traditional spinning machines, such as ring spinner 31, the fiber stream is twisted without first being brought close together by compressing it (compacting) and the resulting yarn may pill or feel rough due to the broad twisting triangle 32 formed before the fibers are twisted. Compact spinning 30 involves narrowing and decreasing the width of the band of fibers (b_comp) so that it is much narrower than the width of the fibers band (b_ring) in the ring spinning 31 (see FIG. 3). Such compacted fibers band is then twisted into a yarn, and the x twisting triangle is eliminated. Compacting the fiber stream first causes the fiber stream in the form of the flat band of fibers to be condensed into a compact fiber stream with increased frictional contact points between the fibers. Compact spinning allows to produce compact yarns. Thus, compact spinning is a process where fiber strand drawn by drafting system is condensed before twisting it.

In some embodiment, at least one of the first, second, third or fourth yarn are fabricated using a ring spinning technique, such as Sirospun™, core spun, compact spun where one yarn can be a natural fiber and the other yarn can be a synthetic fiber. Any other spinning technique (e.g. air jet spinning, ring spinning, mule spinning) can be used without departing from the scope of the invention.

FIGS. 4 provides a picture of a fabric comprising 26% cotton and 26% modal forming the outer layer with higher moisture regain fibers in A), and 25% elastane and 23% nylon forming an inner layer with lower moisture regain allowing and moisture management as described herein.

FIG. 5 illustrates an example of fabric construction that is double weave 150. The first 152 and the second layers 154 are woven in order to keep one fabric to one side in a way that the number of yarn cross overs is reduced. For example, in the illustrated example of fabric construction in FIG. 5, the cross over is 3 up C and 3 down D but it can be a sequence of 3 up and one down, 3 up and 2 down, or 4 up and 1 down etc.

In some embodiments, the fabric with moisture management function described herein may include at least one yarn formed by a combination of a core bi-component yarn and at least one outer sheath yarn surrounding the core bi-component yarn. For example, as shown in FIG. 1, fabric 10 comprises first layer 12 (inner layer) which is the layer next to the skin A and a second layer 14 (outer layer) which corresponds to the layer of fabric 10 facing the exterior B and away from the skin A. In another example, as shown in FIG. 2, fabric 100 comprises first layer 112 (inner layer) which is the layer next to the skin A and second layer 114 (outer layer) which corresponds to the layer of fabric 100 facing the exterior B and away from the skin A.

In one embodiment, outer layer 14 of fabric 10 and/or outer layer 114 of fabric 100 may include at least one yarn formed by a combination of a core bi-component yarn and at least one outer sheath yarn surrounding the core bi-component yarn. Referring now to FIG. 7, an example embodiment of a combination yarn 200 is shown. In this embodiment, combination yarn 200 includes a core bicomponent yarn 202 that is surrounded by an outer sheath yarn 204 that extends along a length of core bi-component yarn 202.

In some embodiments, the at least one outer sheath yarn may be spun, wrapped, or twisted around the core bi-component yarn and extend along a length of the core bi-component yarn. Referring now to FIG. 8A, an example embodiment of combination yarn 200 formed by core bi-component yarn 202 and outer sheath yarn 204 surrounding core bi-component yarn 202 is shown. In one embodiment, outer sheath yarn 204 may be spun, wrapped, or twisted around core bi-component yarn 202 using any one of a single or double spinning process or a vortex spinning process to produce combination yarn 200.

In an example embodiment, bi-component yarn 202 may be formed by a synthetic material that includes acrylic, nylon, polyester, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and/or any blend combination thereof, and outer sheath yarn 204 may be formed by a natural staple or a combination of two or more natural staples. In embodiments, the outer sheath yarn 204 can comprise a synthetic filament combined with the natural staple. For example, outer sheath yarn 204 may comprise a similar synthetic material as bi-component yarn 202, including acrylic, nylon, polyester, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and/or any blend combination thereof. Natural staple material in outer sheath yarn 204 may include cotton, modal, acetate, silk, wool, lyocell, protein fibers, regenerated cellulosic fibers, and/or any blend combination thereof.

In another embodiment, a combination yarn 210 may be made from core bi-component yarn 202 that has two outer sheath yarns surrounding core bi-component yarn 202. Referring now to FIG. 8B, in this embodiment, combination yarn 210 has first outer sheath yarn 204 spun, wrapped, or twisted along a length of core bi-component yarn 202 and also a second outer sheath yarn 206 that is spun, wrapped, or twisted to surround core bi-component yarn 202 along a length of core bi-component yarn 202. In some cases, first outer sheath yarn 204 and second outer sheath yarn 206 may be made of the same materials. In other cases, first outer sheath yarn 204 and second outer sheath yarn 206 may be made from different materials, including different blends or combinations of similar materials.

For example, in one embodiment, both first outer sheath yarn 204 and second outer sheath yarn 206 may be made of a natural material, combination of natural materials or a combination of a natural and synthetic materials. In another embodiment, one of first outer sheath yarn 204 or second outer sheath yarn 206 may be made from a synthetic material that includes acrylic, nylon, polyester, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and/or any blend combination thereof, and the other may be made from a natural staple material that includes cotton, modal, acetate, silk, wool, lyocell, protein fibers, regenerated cellulosic fibers, and/or any blend combination thereof. In still another embodiment, both first outer sheath yarn 204 and second outer sheath yarn 206 may be made of a natural staple material.

In some embodiments, combination yarn 200 including core-bi-component yarn 202 and one outer sheath yarn 204 and/or combination yarn 210 including core-bi-component yarn 202 and two outer sheath yarns (e.g., first outer sheath yarn 204 and second outer sheath yarn 206) may be incorporated into a face layer or outer layer of a fabric. For example, outer layer 14 (second layer) of fabric 10 and/or outer layer 114 (second layer) of fabric 100 may include at least one combination yarn 200 and/or combination yarn 210 made of core-bi-component yarn 202 surrounded by first outer sheath yarn 204 and/or second outer sheath yarn 206 along a length of core-bi-component yarn 202.

In some cases, combination yarn 200 or combination yarn 210 may form an entirety of outer layer 14 and/or outer layer 114. In other cases, combination yarn 200 or combination yarn 210 may be combined with at least one additional yarn forming outer layer 14 and/or outer layer 114. For example, in one embodiment, combination yarn 200 or combination yarn 210 may be joined with second yarn 23 forming outer layer 14 of fabric 10 and/or may be joined with second yarn 123 forming outer layer 114 of fabric 100. In some cases, combination yarn 200 or combination yarn 210 may be plaited with one of second yarn 23 or second yarn 123. In some embodiments, combination yarn 200 or combination yarn 210 may be plaited with one of fourth yarn 24, the fourth yarn 24 being an elastane.

In some embodiments, fabric 10 and/or fabric 100 may have a wash or finish applied to the completed fabric and/or to the individual yarns forming fabric 10 and/or fabric 100. In an example embodiment, fabric 10 and/or fabric 100 may be dyed with indigo. In another embodiment, outer layer 14 of fabric 10 and/or outer layer 114 of fabric 100 may be dyed with indigo. In another embodiment, combination yarn 200 and/or combination yarn 210 included in fabric 10 or fabric 100 may be dyed with indigo. In still another embodiment, at least one outer sheath yarn (e.g., one or both of first outer sheath yarn 204 and second outer sheath yarn 206) may be pre-dyed with indigo before being spun, wrapped, or twisted around core bi-component yarn 202.

As described above, in various embodiments, fabrics with moisture management function described herein may be knit or woven, including fabric 10 and/or fabric 100. In one embodiment, a plaited jersey knit construction fabric with moisture management function may be formed according to the knit diagram shown in FIG. 9. For example, FIG. 9 shows an example embodiment of a plaited jersey knit construction 900 that uses a 100% modal or modal cotton blended (50%+50%) yarn with an elastane, 32/2 micro modal cotton (60%+40%) yarn with an elastane, or a core spun 30D/32F bicomponent polyester yarn for feeds 1 and 3 and a 80D/68F Nylon 6 yarn for feeds 2 and 4.

In another embodiment, a plaited twill knit construction fabric with moisture management function may be formed according to the knit diagram shown in FIG. 10. For example, FIG. 10 shows an example embodiment of a plaited twill knit construction 1000 that uses a 80D/68F Nylon 6 yarn with an elastane for feeds 1, 3, and 5 and a 100% modal or modal cotton blended (50%+50%) yarn with an elastane, 32/2 micro modal cotton (60%+40%) yarn with an elastane, or a core spun 30D/32F bicomponent polyester yarn for feeds 2, 4, and 6. As shown in FIG. 10, the technical back of the plaited twill knit construction 1000 is used as the face of the fabric.

Referring now to FIG. 11, a circular knit double knit construction fabric 1100 is shown. In an example embodiment, circular double knit fabric 1100 may be formed from four yarns, including a first yarn 1112, a second yarn 1114, a third yarn 1116, and a fourth yarn 1118. At least one of first yarn 1112, second yarn 1114, third yarn 1116, and fourth yarn 1118 may include a combination yarn, as described above. Additionally, in some embodiments, one of first yarn 1112, second yarn 1114, third yarn 1116, and fourth yarn 1118 may be an elastane. Knit diagram 1120 illustrates an example embodiment of a schematic for forming circular double knit fabric 1100 using a circular knitting machine.

In different embodiments, circular double knit fabric 1100 may be knitted in any gauge or machine diameter with jacquard or engineer designs. Multiple yarn options may be used in combination on technical face or back of circular double knit fabric 1100. Yarns (e.g., first yarn 1112, second yarn 1114, third yarn 1116, and fourth yarn 1118 ) may be of counts 10′s to 120′s or higher and denier may be 10D to 300D in any ply and combinations of spun, filaments or monofilament.

FIG. 12 illustrates a schematic representation of a warp knit construction fabric 1200. In an example embodiment, warp knit fabric 1200 may be formed from three yarns, including a first yarn 1212, a second yarn 1214, and a third yarn 1216. Knit diagram 1212 illustrates an example embodiment of a schematic for forming warp knit fabric 1200 using a warp knitting machine. In this embodiment, warp knit fabric 1200 is shown in reference to knit diagram 1220 for a 3 bar warp knit machine. In other embodiments, the warp knitting machine may be a 2 bar, 3 bar, or 4 bar warp knitting machine and may include tricot, raschel, or jacquard knitting machines. Multiple yarn options may be used randomly in any of the bars in combinations. Yarns (e.g., first yarn 1212, second yarn 1214, and third yarn 1216) may be of counts 10′s to 120′s or higher and denier may be 10D to 300D in any ply and combinations of spun, filaments or monofilament.

As encompassed herein, the knitted fabric described herein with moisture management can be any type of articles of apparel including shirts, headwear, coats, jackets, pants, underwear, gloves, socks, and footwear.

While the disclosure has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations including such departures from the present disclosure as come within known or customary practice within the art and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims.

Claims

1. A fabric with moisture management function comprising:

an inner layer comprising a first yarn forming the inner layer, the first yarn being semi-hydrophilic with a first moisture regain;

an outer layer comprising a second yarn forming the outer layer, the second yarn being hydrophilic with a second moisture regain;

the second moisture regain of the second yarn is greater than the first moisture regain of the first yarn so as to generate a moisture regain gradient between the inner layer and the outer layer;

wherein the moisture regain gradient between the inner layer and the outer layer acts to pull moisture through the inner layer and push the moisture out through the outer layer; and

wherein the second yarn is a combination of a core bi-component yarn and at least one outer sheath yarn surrounding the core bi-component yarn.

2. The fabric according to claim 1, wherein the at least one outer sheath yarn is spun, wrapped, or twisted around the core bi-component yarn and extends along a length of the core bi-component yarn.

3. The fabric according to claim 1, wherein the core bi-component yarn comprises a synthetic filament and the at least one outer sheath yarn comprises a natural staple yarn.

4. The fabric according to claim 3, wherein the synthetic filament is made of a material that includes acrylic, nylon, polyester, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and/or any blend combination thereof; and

wherein the natural staple yarn is made of a material that includes cotton, modal, acetate, silk, wool, lyocell, protein fibers, regenerated cellulosic fibers, and/or any blend combination thereof.

5. The fabric according to claim 1, wherein the at least one outer sheath yarn comprises a synthetic filament or staple.

6. The fabric according to claim 5, wherein the synthetic filament is made of a material that includes acrylic, nylon, polyester, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and/or any blend combination thereof.

7. The fabric according to claim 1, wherein the at least one outer sheath yarn comprises two natural staple yarns.

8. The fabric according to claim 1, wherein the fabric is dyed with indigo.

9. The fabric according to claim 1, wherein the second yarn is dyed with indigo.

10. The fabric according to claim 1, wherein the at least one outer sheath yarn is pre-dyed with indigo.

11. The fabric according to claim 1, wherein the first moisture regain of the inner layer is in the range of 0.2% - 6%, the second moisture regain of the outer layer is in the range of 4% - 16%, and the moisture regain gradient is greater than 3%.

12. The fabric according to claim 8, wherein the moisture regain gradient is between 3% to 15%.

13. A fabric with moisture management function comprising:

an inner layer comprising at least a first yarn forming the inner layer, the first yarn being semi-hydrophilic with a first moisture regain;

an outer layer comprising at least a second yarn forming the outer layer, the second yarn being hydrophilic with a second moisture regain;

the second moisture regain of the second yarn is greater than the first moisture regain of the first yarn so as to generate a moisture regain gradient between the inner layer and the outer layer;

wherein the moisture regain gradient between the inner layer and the outer layer acts to pull moisture through the inner layer and push the moisture out through the outer layer; and

wherein the outer layer includes a combination of a core bi-component yarn and at least one outer sheath yarn surrounding the core bi-component yarn.

14. The fabric according to claim 13, wherein the combined core bi-component with at least one outer sheath yarn is joined with the second yarn forming the outer layer.

15. The fabric according to claim 13, wherein the fabric is a weft or warp knitted fabric or a woven fabric.

16. The fabric according to claim 15, wherein the fabric is knitted from a single jersey plaited construction, a double jersey plaited construction, a tricot or warp knit construction.

17. The fabric according to claim 13, wherein the combined core bi-component with at least one outer sheath yarn is formed by a single or double spinning process or a vortex spinning process.

18. The fabric according to claim 13, wherein at least one of the inner layer or the outer layer has a fabric wash or mechanical finish applied.

19. The fabric according to claim 13, wherein the inner layer further comprises a third yarn joined together with the first yarn and the outer layer further comprises a fourth yarn joined together with the second yarn; and

wherein the combined core bi-component with at least one outer sheath yarn comprises the fourth yarn.

20. The fabric according to claim 19, wherein the inner layer is a composite blend of a synthetic polymer plaited with an elastane.

21. The fabric according to claim 19, wherein the outer fabric layer is a composite blend of a natural fiber plaited with an elastane or a blend of natural fiber and synthetic fiber.

22. An article of apparel comprising a fabric with moisture management function, the fabric including:

an inner layer of the article of apparel comprising at least a first yarn forming the inner layer, the first yarn being semi-hydrophilic with a first moisture regain;

an outer layer of the article of apparel comprising at least a second yarn forming the outer layer, the second yarn being hydrophilic with a second moisture regain;

the second moisture regain of the second yarn is greater than the first moisture regain of the first yarn so as to generate a moisture regain gradient between the inner layer and the outer layer;

wherein the moisture regain gradient between the inner layer and the outer layer acts to pull moisture through the inner layer and push the moisture out through the outer layer; and

wherein the outer layer includes a combination of a core bi-component yarn and at least one outer sheath yarn surrounding the core bi-component yarn.