Woven stretch fabrics and methods of making same

Abstract

Woven fabrics made from non-stretch yarns yet having high levels of stretch and recovery are described. The fabrics include at least about 50% of a synthetic fiber component, and are woven such that the warp and filling are approximately balanced by weight before warp contraction, with about 50% warp density or less. The fabrics are exposed to a cumulative dynamic tension in the warp direction of at least about 250 min-lb/linear ft, and are then finished to about 70-80% of their reed width at a temperature greater than or equal to the heat set temperature for the synthetic fiber component. The fabrics may also be exposed to a face finishing process and/or a fluid treatment process.

1 . A method of making a woven stretch fabric comprising the steps of: 
 weaving a fabric from substantially all non-stretch yarns such that the warp and filling yarn densities are within ±10% of each other before warp contraction, and wherein said fabric has at least about 50% of a synthetic fiber component, and    exposing the fabric to at least about 250 min-lb/linear ft of dynamic tension in the warp direction and setting the fabric at a width less than its reed width, to thereby provide a fabric having at least about 15% stretch and at least about 80% recovery in the filling direction when tested according to Test Methods TTM 074 and TTM 077.    
   
   
       2 . The method according to  claim 1 , wherein the fabric is woven in a construction selected from the group consisting of plain weave, twill weave, satin weave.  
   
   
       3 . A fabric made by the method of  claim 1 .  
   
   
       4 . A woven stretch fabric comprising: 
 a plurality of interwoven warp and filling yarns, wherein said warp and filling yarns consist essentially of non-stretch yarns, wherein said fabric comprises at least about 50% of a synthetic fiber component, and said fabric has about 15% or greater of stretch when tested according to TTM 074 Test Method and at least about 80% recovery when tested according to TTM 077.    
   
   
       5 . The fabric according to  claim 2 , wherein said synthetic fiber component is selected from the group consisting of polyester, nylon, and aramids.  
   
   
       6 . The fabric according to  claim 2 , wherein said fabric has a warp density of about 50% or less.  
   
   
       7 . A woven fabric consisting essentially of non-stretch yarns, said fabric having warp and filling directions, wherein said fabric has a stretch in filling direction of at least about 15% when tested according to TTM-074, and at least about 80% recovery when tested according to TTM-077.  
   
   
       8 . The fabric according to  claim 3 , wherein said fabric comprises about 50% or greater of a synthetic fiber component.  
   
   
       9 . A method of making a stretch woven fabric from non-stretch yarns comprising the steps of: 
 weaving a fabric having about 50% or less warp yarn density and at least about 50% of a synthetic fiber component,    exposing the fabric to a cumulative dynamic tension of at least about 250 min-lb/linear foot, and    heat setting the fabric at a width of less than its reed width of the fabric.    
   
   
       10 . The method according to  claim 4 , further comprising the step of exposing the fabric to dynamic tension comprises exposing the fabric to a cumulative dynamic tension of about 250 min-lb/linear foot to about 700 min-lb/linear foot.  
   
   
       11 . The method according to  claim 4 , wherein said step of heat setting comprises heat setting the fabric at a width of about 70 to about 80% of its reed width.  
   
   
       12 . The method according to  claim 4 , wherein said step of exposing the fabric to a cumulative dynamic tension comprises exposing the fabric to a face finishing process.  
   
   
       13 . The method according to  claim 4 , wherein said step of exposing the fabric to a cumulative dynamic tension comprises exposing the fabric to a high energy fluid treatment process.