Methods for improving the dyeability and puncture resistance of fabrics comprising high tenacity fibers and fabrics produced by such methods

Abstract

A variety of methods of improving the dyeability and printability of fabrics comprising or consisting essentially of high tenacity fibers having a tensile breaking strength of at least about 10 g/Denier are disclosed. Such methods can result in fabrics, yarns, and/or fiber bundles having an improved ability to be dyed and/or printed with a printed pattern (e.g., a camouflage pattern), when compared to typical high tenacity fiber-based fabrics known in the prior art. The fabrics can have dyeability characteristics enabling them to be dyed with a variety of commercially relevant fabric dyes, such that the fabrics, after exposure to the dyes, are characterized by an essentially visually uniform dyed color density. In one embodiment, a dyeable fiber bundle, which can be utilized to form dyeable yarns and fabrics, which comprises at least about 5% of high tenacity fibers having a tensile breaking strength of at least about 10 g/Denier is disclosed. Also disclosed is a method for pre-washing roll stock of fabrics comprising or consisting essentially of high tenacity fibers in order to improve the level of cut, puncture, or tear resistance of the fabrics subsequent to the pre-wash and before assembly of the fabrics into articles of apparel. A variety of fabrics including high tenacity fibers having a tensile breaking strengths of at least about 10 g/Denier, as produced by or treated by such methods are also disclosed.

What is claimed:  
     
         1 . An article comprising: 
 a fiber bundle formed of a plurality of fibers, at least about 5% of the plurality of fibers comprising fibers having a tensile breaking strength of at least about 10 g/Denier, the fiber bundle being constructed such that upon exposure to a fabric dye, the fiber bundle is dyed to an essentially visually uniform color density.    
     
     
         2 . The article as in  claim 1 , wherein at least about 10% of the plurality of fibers comprise fibers having a tensile breaking strength of at least about 10 g/Denier.  
     
     
         3 . The article as in  claim 2 , wherein at least about 20% of the plurality of fibers comprise fibers having a tensile breaking strength of at least about 10 g/Denier.  
     
     
         4 . The article as in  claim 3 , wherein at least about 50% of the plurality of fibers comprise fibers having a tensile breaking strength of at least about 10 g/Denier.  
     
     
         5 . The article as in  claim 4 , wherein at least about 65% of the plurality of fibers comprise fibers having a tensile breaking strength of at least about 10 g/Denier.  
     
     
         6 . The article as in  claim 5 , wherein at least about 75% of the plurality of fibers comprise fibers having a tensile breaking strength of at least about 10 g/Denier.  
     
     
         7 . The article as in  claim 6 , wherein at least about 85% of the plurality of fibers comprise fibers having a tensile breaking strength of at least about 10 g/Denier.  
     
     
         8 . The article as in  claim 1 , wherein the at least about 5% of the plurality of fibers comprising fibers having a tensile breaking strength of at least about 10 g/Denier are formed of a material selected from the group consisting of: para-aramids; liquid crystal polyesters; ultra-high molecular weight polyethylenes; and poly(p-phenylene-2,6-benzobisoxazole) (PBO).  
     
     
         9 . The article as in  claim 1 , wherein at least about 5% of the plurality of fibers comprise fibers having a tensile breaking strength of at least about 15 g/Denier.  
     
     
         10 . The article as in  claim 9 , wherein at least about 5% of the plurality of fibers comprise fibers having a tensile breaking strength of at least about 20 g/Denier.  
     
     
         11 . The article as in  claim 10 , wherein at least about 10% of the plurality of fibers comprise fibers having a tensile breaking strength of at least about 10 g/Denier.  
     
     
         12 . The article as in  claim 11 , wherein at least about 5% of the plurality of fibers comprise fibers having a tensile breaking strength of at least about 30 g/Denier.  
     
     
         13 . The article as in  claim 1 , wherein at least one fiber of the plurality has a tensile breaking strength of less than about 10 g/Denier.  
     
     
         14 . The article as in  claim 13 , wherein at least one fiber of the plurality has a tensile breaking strength of less than about 8 g/Denier.  
     
     
         15 . The article as in  claim 14 , wherein at least one fiber of the plurality has a tensile breaking strength of less than about 5 g/Denier.  
     
     
         16 . The article as in  claim 15 , wherein at least one fiber of the plurality has a tensile breaking strength of less than about 3 g/Denier.  
     
     
         17 . The article as in  claim 13 , wherein the at least one fiber of the plurality having a tensile breaking strength of less than about 10 g/Denier is formed of a material selected from the group consisting of: polyamides; cellulosic materials; polyesters; acrylic polymers; and polyolefins.  
     
     
         18 . The article as in  claim 1 , wherein the fabric dye is selected from the group consisting of: cationic dyes; anionic dyes; and polyester dyes.  
     
     
         19 . The article as in  claim 1 , wherein the fiber bundle is formed of a plurality of spun staple fibers.  
     
     
         20 . The article as in  claim 19 , wherein the fiber bundle is formed by a Cotton System spinning process and the length of the staple fibers does not exceed about 2 inches.  
     
     
         21 . The article as in  claim 19 , wherein the fiber bundle is formed by a Worsted System spinning process and the length of the staple fibers exceeds about 2 inches.  
     
     
         22 . The article as in  claim 19 , wherein the fiber bundle has a primary twist multiplier of at least about 2.7.  
     
     
         23 . The article as in  claim 22 , wherein the fiber bundle has a primary twist multiplier of at least about 3.  
     
     
         24 . The article as in  claim 23 , wherein the fiber bundle has a primary twist multiplier of at least about 3.5.  
     
     
         25 . The article as in  claim 24 , wherein the fiber bundle has a primary twist multiplier of at least about 4.  
     
     
         26 . The article as in  claim 25 , wherein the fiber bundle has a primary twist multiplier of at least about 4.5.  
     
     
         27 . The article as in  claim 26 , wherein the fiber bundle has a primary twist multiplier of at least about 5.  
     
     
         28 . The article as in  claim 19 , wherein any given cross-section of the fiber bundle along its length includes therein between about 60 and about 100 fibers.  
     
     
         29 . The article as in  claim 1 , wherein the fabric dye and essentially visually uniform color density of the dyed fiber bundle are lighter in color than the undyed color of at least one fiber of the plurality of fibers comprising fibers having a tensile breaking strength of at least about 10 g/Denier.  
     
     
         30 . A plied yarn comprising: 
 a first fiber bundle comprising the fiber bundle as recited in  claim 1;  and    at least a second fiber bundle plied together with the first fiber bundle.    
     
     
         31 . The plied yarn as in  claim 30 , wherein the second fiber bundle is substantially similar in composition and construction to the first fiber bundle.  
     
     
         32 . The plied yarn as in  claim 30 , wherein the plied yarn is characterized by a secondary ply twist of at least about ¼ that of a primary twist of the first fiber bundle and the second fiber bundle.  
     
     
         33 . The plied yarn as in  claim 32 , wherein the plied yarn is characterized by a secondary ply twist of at least about ½ that of a primary twist of the first fiber bundle and the second fiber bundle.  
     
     
         34 . The plied yarn as in  claim 33 , wherein the plied yarn is characterized by a secondary ply twist of at least about equal to that of a primary twist of the first fiber bundle and the second fiber bundle.  
     
     
         35 . A woven fabric at least partly formed of the fiber bundle as recited in  claim 1 .  
     
     
         36 . An article of apparel at least partly formed of the woven fabric as recited in  claim 35 .  
     
     
         37 . The article of apparel as in  claim 36 , wherein the article of apparel is selected from the group consisting of: gloves; aprons; chaps; pants; boots; gators; shirts; jackets; coats; socks; shoes; undergarments; vests; waders; hats; and gauntlets.  
     
     
         38 . A method comprising the step of: 
 dying a fiber bundle formed of a plurality of fibers, at least about 5% of the plurality of fibers comprising high tenacity fibers having a tensile breaking strength of at least about 10 g/Denier, with a fabric dye to form a dyed fiber bundle having an essentially visually uniform dye color density.    
     
     
         39 . A method comprising the steps of: 
 pre-washing roll stock of a fabric that includes at least one fiber of a first type having a tensile breaking strength of at least about 10 g/Denier; and    increasing the puncture resistance of the fabric in comparison to the puncture resistance of the fabric prior to the pre-washing step.    
     
     
         40 . The method as in  claim 39 , wherein the fiber of the first type has a tensile breaking strength of at least about 15 g/Denier.  
     
     
         41 . The method as in  claim 40 , wherein the fiber of the first type has a tensile breaking strength of at least about 20 g/Denier.  
     
     
         42 . The method as in  claim 41 , wherein the fiber of the first type has a tensile breaking strength of at least about 25 g/Denier.  
     
     
         43 . The method as in  claim 42 , wherein the fiber of the first type has a tensile breaking strength of at least about 30 g/Denier.  
     
     
         44 . The method as in  claim 39 , wherein the fiber of the first type is formed of a material selected from the group consisting of: para-aramids; liquid crystal polyesters; ultra-high molecular weight polyethylenes; and poly(p-phenylene-2,6-benzobisoxazole) (PBO).  
     
     
         45 . The method as in  claim 39 , wherein the fabric consists essentially of fibers having a tensile breaking strength of at least about 10 g/Denier.  
     
     
         46 . The method as in  claim 39 , wherein the fabric is a woven fabric formed of a plurality of fill yarns and a plurality of warp yarns.  
     
     
         47 . The method as in  claim 46 , wherein the woven fabric has a fill yarn cover factor of at least about 75% and a warp yarn cover factor of at least about 100%.  
     
     
         48 . The method as in  claim 47 , wherein the woven fabric has a fill yarn cover factor of at least about 80%.  
     
     
         49 . The method as in  claim 48 , wherein the woven fabric has a fill yarn cover factor of at least about 85%.  
     
     
         50 . The method as in  claim 49 , wherein the woven fabric has a fill yarn cover factor of at least about 88%.  
     
     
         51 . The method as in  claim 50 , wherein the woven fabric has a warp yarn cover factor of at least about 110%.  
     
     
         52 . The method as in  claim 51 , wherein the woven fabric has a warp yarn cover factor of at least about 120%.  
     
     
         53 . The method as in  claim 52 , wherein the woven fabric has a warp yarn cover factor of at least about 130%.  
     
     
         54 . The method as in  claim 53 , wherein the woven fabric has a warp yarn cover factor of at least about 140%.  
     
     
         55 . The method as in  claim 54 , wherein the woven fabric has a warp yarn cover factor of at least about 145%.  
     
     
         56 . The method as in  claim 55 , wherein the woven fabric has a warp yarn cover factor of at least about 150%.  
     
     
         57 . The method as in  claim 39 , wherein the pre-washing step increases the puncture resistance of the fabric by at least about 5%.  
     
     
         58 . The method as in  claim 57 , wherein the pre-washing step increases the puncture resistance of the fabric by at least about 10%.  
     
     
         59 . The method as in  claim 58 , wherein the pre-washing step increases the puncture resistance of the fabric by at least about 15%.  
     
     
         60 . The method as in  claim 59 , wherein the pre-washing step increases the puncture resistance of the fabric by at least about 20%.  
     
     
         61 . The method as in  claim 60 , wherein the pre-washing step increases the puncture resistance of the fabric by at least about 25%.  
     
     
         62 . The method as in  claim 39 , wherein the pre-washing step decreases the bending stiffness of the fabric by at least about 5%.  
     
     
         63 . The method as in  claim 62 , wherein the pre-washing step decreases the bending stiffness of the fabric by at least about 10%.  
     
     
         64 . The method as in  claim 63 , wherein the pre-washing step decreases the bending stiffness of the fabric by at least about 15%.  
     
     
         65 . The method as in  claim 64 , wherein the pre-washing step decreases the bending stiffness of the fabric by at least about 20%.  
     
     
         66 . The method as in  claim 65 , wherein the pre-washing step decreases the bending stiffness of the fabric by at least about 25%.  
     
     
         67 . The method as in  claim 39 , wherein the pre-washing step comprises the steps of: 
 saturating the fabric with an aqueous solution of a surfactant; and    subjecting the fabric to mechanical flexing and agitation.    
     
     
         68 . The method as in  claim 67 , wherein the subjecting step has a duration of between about 1 and about 5 hours.  
     
     
         69 . The method as in  claim 67 , wherein the subjecting step is performed with a drum washing machine.  
     
     
         70 . The method as in  claim 39 , further comprising the step of: 
 dying the fabric to an essentially visually uniform dye color density.    
     
     
         71 . The method as in  claim 39 , further comprising after the pre-wash step, the step of: 
 drying the fabric.    
     
     
         72 . The method as in claim  71 , further comprising after the pre-wash step, the step of: 
 assembling the fabric into an article of apparel.    
     
     
         73 . The method as in claim  72 , wherein the article of apparel is selected from the group consisting of: gloves; aprons; chaps; pants; boots; gators; shirts; jackets; coats; socks; shoes; undergarments; vests; waders; hats; and gauntlets.