Patent Description:
Various fabrics are described in documents <CIT>, <CIT>, <CIT>, <CIT> and <CIT>.

Any discussion of the prior art throughout this specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field.

Fast-drying clothing is becoming increasingly popular in areas such as sport, recreation and outdoor occupations where wearers of the clothing produce large volumes of perspiration. Fabrics used in fast-drying clothing work by wicking perspiration from the skin to the outer surface of the fabric where evaporation takes place.

The present inventor has developed improved fabrics suitable for use in fast-drying clothing applications which are able to rapidly absorb and efficiently transport perspiration to the outer surface of the clothing.

In a first aspect the present invention provides a fabric comprising:.

The first yarn may consist of a fiber blend of modal and polyester.

The spun yarn may be a spun yarn of between <NUM> and <NUM> single counts.

The spun yarn may be a spun yarn of <NUM> or <NUM> single counts.

The polyester may be present in the fiber blend in an amount between about <NUM>% and about <NUM>% by weight and the modal may be present in the fiber blend in an amount between about <NUM>% and about <NUM>% by weight.

The polyester may be present in the fiber blend in an amount of about <NUM>% by weight and the modal may be present in the fiber blend in an amount of about <NUM>% by weight.

The polyester in the fiber blend may have a cross-section that is X-shaped, M-shaped I-shaped, honeycomb-shaped, Y-shaped, U-shaped or O-shaped, thereby creating a plurality of spaces along the length of the first yarn that facilitate a capillary action.

The polyester in the fiber blend may have a cross-section that is X-shaped thereby creating a plurality of spaces along the length of the first yarn that facilitate a capillary action.

The modal in the fiber blend may have a cross-section that is substantially rectangular.

The polyester and modal in the fiber blend may be of staple length.

The first yarn may comprise between about <NUM>% and about <NUM>% by weight of the fabric.

The first yarn may comprise about <NUM>% to <NUM>% by weight of the fabric.

The second yarn may comprise or consist of <NUM>% spandex.

The spandex of the second yarn may be between about <NUM>-denier and about <NUM>-denier.

The spandex of the second yarn may be about <NUM>-denier or about <NUM>-denier.

The second yarn may comprise between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>% by weight of the fabric.

The second yarn may comprise about <NUM>% by weight of the fabric.

The third yarn may comprise or consist of <NUM>% polyester.

The polyester of the third yarn may be between about <NUM>-denier and about <NUM>-denier.

The polyester of the third yarn may be <NUM>-denier.

The third yarn may comprise between about <NUM>% and about <NUM>% by weight of the fabric.

The third yarn may comprise about <NUM>% to <NUM>% by weight of the fabric.

The second yarn may be inter-knitted between the first yarn and the third yarn.

The fabric may be a single jersey, pique, pointelle, double knit, jacquard or terry.

In an embodiment of the first aspect the present invention provides a fabric comprising or consisting of:.

and wherein the polyester in the fiber blend has a cross-section that is X-shaped, M-shaped, I-shaped, honeycomb-shaped, Y-shaped, U-shaped or O-shaped, thereby creating a plurality of spaces along the length of the bottom yarn that facilitates a capillary action.

In this embodiment the third yarn may comprise about <NUM>% by weight of the fabric, the second yarn may comprise about <NUM>% by weight of the fabric, and the first yarn may comprise about <NUM>% by weight of the fabric.

In this embodiment the fabric may be a single jersey.

In another embodiment of the first aspect the present invention provides a fabric comprising or consisting of:.

In this embodiment the fabric may be a pique.

In this embodiment the fabric may be a pointelle.

In yet another embodiment of the first aspect the present invention provides a fabric comprising or consisting of:.

In this embodiment the fabric may be a jersey.

In a second aspect the present invention provides an article of clothing or a home textile when produced from the fabric of the first aspect.

The clothing may be a shirt, singlet, jersey, pyjamas, maillot, fleece, shorts, pants, hood, running hat, skull cap, helmet liner, mask, headband or socks.

The home textile may be towels, bedding, cushions, sofa or furniture.

Throughout this specification, unless the context requires otherwise, the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. Thus, in the context of this specification, the term "comprising" means "including principally, but not necessarily solely".

In the context of this specification the terms "a" and "an" are used herein to refer to one or to more than one (i. e to at least one) of the grammatical object of the article.

The term "about" is understood to refer to a range of numbers that a person of skill in the art would consider equivalent to the recited value in the context of achieving the same function or result.

In the context of this specification the term "yarn" is understood to mean a continuous length of interlocked fibers that can be made into a textile material.

In the context of this specification the term "filament yarn" is understood to mean a yarn made of one or more continuous fibers in the form of filaments in which each filament runs the entire length of the yarn.

In the context of this specification the term "spun yarn" is understood to mean staple-length fibers twisted or spun together to form a continuous strand.

In the context of this specification the term "staple length" refers to the average length of a group of fibers and is dependent on the origin of the fibers. Natural fibers such as cotton or wool have a range of lengths in each staple and therefore the staple length is an average. In the case of synthetic fibers which are cut to a certain length, the staple length is the same for every fiber.

In the context of this specification the term "denier" refers to a unit of measurement for the linear mass density of fibers defined as mass (in grams) per <NUM> meters of the fiber.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which:.

In one aspect the present invention provides a fabric comprising or consisting of:.

In some embodiments the first yarn may be a spun yarn. The spun yarn may have between about <NUM> and about <NUM> single counts, or between about <NUM> and about <NUM> single counts, or between about <NUM> and about <NUM> single counts, or between about <NUM> and about <NUM> single counts, or between about <NUM> and about <NUM> single counts, or between about <NUM> and about <NUM> single counts, or about <NUM> single counts.

The modal may be present in the fiber blend in an amount between about <NUM>% and about <NUM> %, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or about <NUM>% by weight.

The polyester may be present in the fiber blend in an amount between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or about <NUM>% by weight. The polyester in the fiber blend may be recycled polyester.

In one embodiment the polyester may be present in the fiber blend in an amount between about <NUM>% and about <NUM>% by weight and the modal may be present in the fiber blend in an amount between about <NUM>% and about <NUM>% by weight.

The first yarn may comprise between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or about <NUM>% by weight of the fabric.

In some embodiments the second yarn is a filament yarn, and comprises, or may consist of <NUM>% spandex. Spandex provides elasticity to the fabric. The spandex of the second yarn may be between about <NUM>-denier and about <NUM>-denier, or between about <NUM>-denier and about <NUM>-denier, or between about <NUM>-denier and about <NUM>-denier, or between about <NUM>-denier and about <NUM>-denier, or between about <NUM>-denier and about <NUM>-denier.

The second yarn may comprise between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or between about <NUM>% and about <NUM>%, or about <NUM>% by weight of the fabric.

The third yarn may be a filament yarn, and comprises or may consist of <NUM>% polyester. In some embodiments the polyester of the third yarn may be between about <NUM>-denier and about <NUM>-denier, or between about <NUM>-denier and about <NUM>-denier, or between about <NUM>-denier and about <NUM>-denier, or between about <NUM>-denier and about <NUM>-denier, or between about <NUM>-denier and about <NUM>-denier, or about <NUM>-denier. The polyester may be recycled polyester.

The third yarn may comprise between about <NUM>% and about <NUM>% by weight, or between about <NUM>% and about <NUM>% by weight, or about <NUM>% by weight of the fabric.

The first, second and third yarns are present as layers. The first yarn forms a bottom layer, the second yarn forms a middle layer and the third yarn forms a top layer. When part of an article of clothing, the bottom layer is intended to be in contact with the skin of a wearer. In some embodiments the polyester of the fiber blend may have a cross-section that is X-shaped, M-shaped, I-shaped, honeycombed-shaped, Y-shaped, U-shaped or O-shaped. These cross-sectional configurations create a plurality of spaces along the length of the first yarn (see <FIG>). The plurality of spaces facilitates a capillary action that is capable of drawing liquid, such as perspiration, from the skin of a wearer along the length of the fibers to the top of the bottom layer. The cross-sectional areas may also maximise the surface area of the fibers thereby lowering the drying time of the fabric. In addition, the air permeability of the fibers may also assist in releasing hot air so as to assist in keeping the wearer fresh and cool. Once the perspiration is moved to the top of the bottom layer it moves through the middle layer and then to the top layer where it is radiated to the environment. In these embodiments, the ordinarily hydrophobic polyester fibers are rendered hydrophilic by altering their cross-sectional structure.

Perspiration present in the space created amongst the polyester fibers may also act as a good heat conductor. As a result, an improved rate of heat extraction is created thereby preventing or minimizing additional perspiration resulting from trapped heat.

Modal is hydrophilic and therefore assists in drawing perspiration from the skin. The presence of modal may also assist entry of perspiration into the spaces created amongst the polyester fibers. The hydrophilic properties of modal may also cause perspiration to be absorbed and dispersed radially outward, thereby wetting a large area of the bottom layer for an increased rate of transportation of perspiration to the top layer. Because modal is highly hydrophilic, only a relatively small amount (about <NUM>% to <NUM>% for example) may be required in the bottom layer to dramatically increase the rate of perspiration removal from skin. Further advantages associated with inclusion of modal are that it can offset the generally sticky feel of polyester so as to provide a soft/silky feel to the wearer and its dull appearance minimizes unwanted heat reflection to the wearer's skin.

When the third yarn is present as the top layer the polyester forms a large outer surface thereby allowing perspiration reaching the outer surface to evaporate efficiently, either by moving air or general evaporation. Another advantage of using polyester as the top layer is that it may be easily decorated by a clothing manufacturer.

In some embodiments the second yarn may be inter-knitted between the first yarn and the third yarn (see <FIG>).

Fabrics may be prepared by a three-thread knitting method. In some embodiments, the fabric may be prepared by a method comprising the following steps:.

A three layer, tri-knit pique fabric having the following composition was prepared:.

The method used to prepare the fabric was as per that described above in paragraph [<NUM>].

The structure of the fabric is illustrated in <FIG> and <FIG>.

The water vapour resistance (ISO <NUM>:<NUM>) of the fabric was tested according to the particulars shown below in Table <NUM>:.

The results are presented below in Table <NUM>:.

The drying time of the fabric was determined using American Association of Textile Chemists (AATCC) <NUM>-<NUM> and the results are shown below in Table <NUM>:.

The vertical wicking capability of the fabric was determined using AATCC <NUM>, Option B and the results are shown below in Table <NUM>:.

The absorbency of the fabric was determined using AATCC <NUM>-<NUM> and the results are shown below in Table <NUM>:.

A three layer, tri-knit single jersey fabric having the following composition was prepared:.

The water vapour resistance (ISO <NUM>:<NUM>) of the fabric was tested according to the parameters shown above in Table <NUM>. The results are presented below in Table <NUM>:.

The drying time of the fabric was determined using AATCC <NUM>-<NUM> and the results are shown below in Table <NUM>:.

The absorbency, drying time, vertical wicking and water vapour resistance of the fabric was compared to a commonly used <NUM>% polyester knitted quick-dry jersey manufactured by Nike. The results of each test are summarised in Table <NUM>.

The water-vapour resistance test was conducted as set out in Table <NUM>.

It will be seen from the results in Table <NUM> that the fabric of the present invention is quicker drying, provides better wicking and less vapour resistance compared to the Nike jersey.

The absorbency and the wicking of the fabric was also compared to the commonly used CLIMACHILL fabric manufactured by Adidas. The results are summarised in Table <NUM>. It will be seen that the fabric of the present invention provides excellent absorbency and wicking, including after multiple washes.

A three layer, tri-knit pointelle fabric having the following composition was prepared:.

A three-layer, tri-knit jersey fabric having the following composition was prepared:.

The method used to prepare the fabric was as per that described above in paragraph [<NUM>]. The structure of the fabric is illustrated in <FIG> and <FIG>.

Water vapour resistance was tested in accordance with ISO <NUM>:<NUM> as set out in Table <NUM>. The mean water vapour resistance (Ret) of the fabric was measured to be <NUM> (m<NUM>·Pa)/W.

The drying time of the fabric was determined in accordance with AATCC TM <NUM>-<NUM> (Drying temperature <NUM>° C. End point: to the original dry weight of a specimen; measured at <NUM>° C, <NUM>% RH). The results are set out in Table <NUM>.

The vertical wicking capability of the fabric was determined in accordance with AATCC <NUM>-<NUM>, Option B. The face side of the fabric was tested, and the results are set out in Table <NUM>.

The absorbency of the fabric was determined in accordance with AATCC TM <NUM>-<NUM> and, on average, the water drop disappeared almost immediately.

It will be understood that the tri-knit fabric may comprise different compositions and sizes, including those set out in Table <NUM>.

Claim 1:
A knitted fabric comprising:
a first yarn forming a bottom layer;
a second yarn forming a middle layer; and
a third yarn forming a top layer and comprising polyester,
characterised in that the first yarn comprises a fiber blend of modal and polyester, the second yarn comprises spandex and the polyester in the fiber blend has a cross-section that creates a plurality of spaces along the length of the first yarn that facilitate a capillary action.