Fabric and a method of making the fabric

Abstract

The present invention is based on the realization that improved wicking of liquid from an inner face to an outer face of a fabric can be achieved by a fabric structure where the inner face of the fabric has a substantially uniform hydrophobicity and where the inner face is formed by hydrophobic yarn that is assembled in a manner that allows the liquid to penetrate between hydrophobic yarn and make contact with hydrophilic yarn that forms at least part of the outer face of the fabric. When liquid penetrates the inner face and makes contact with the hydrophilic yarn, liquid is able to be drawn through the inner face to the outer face of the fabric. Although the hydrophobic and hydrophilic yarns and may be made from any one or a blend of man-made or synthetic fibers, and natural fibers, it is preferred that the yarns and the fully formed fabric be made entirely of cotton fibers. The fabric is suitable for use in a wide range of applications including underwear. Another application involves laminating the fabric to a functional film such as a waterproof and/or windproof breathable membrane to produce functional outerwear garments.

1 . A fabric including: 
 a) an inner face that is formed entirely from one or more than one hydrophobic yarn that has been treated to render it hydrophobic and said yarn or yarns are assembled over the inner face so that the inner face has a hydrophobicity that is substantially the same over the inner face; and    b) an outer face that in comparison to the inner face is hydrophilic and is formed at least in part by one or more than one hydrophilic yarn, 
 wherein the hydrophobic yarn or yarns are assembled so that liquid can penetrate the inner face and make contact with the hydrophilic yarn or yarns that form at least part of the outer face of the fabric and that, in turn, can draw liquid to the outer face of the fabric.  
   
   
   
       2 . The fabric according to  claim 1 , wherein the hydrophobic yarn or yarns are assembled so that some sections of hydrophobic yarn in the inner face are separated by spaces through which liquid can penetrate.  
   
   
       3 . The fabric according to  claim 1 , wherein hydrophobic yarn or yarns are assembled over the inner face of the fabric so as to form loops or floats on the inner face and thereby form said sections of hydrophobic yarn separated by spaces.  
   
   
       4 . The fabric according to  claim 1 , wherein the spacing of the sections of hydrophobic yarn on the inner face of the fabric ranges from 0.01 to 25 mm in the wale or warp direction and ranges from 0.01 to 25 mm in the course or weft direction.  
   
   
       5 . The fabric according to  claim 1 , wherein the spacing of the sections of hydrophobic yarn on the inner face of the fabric ranges from 0.1 to 2.5 mm in the wale or warp direction and ranges from 0.1 to 2.5 mm in the course or weft direction.  
   
   
       6 . The fabric according to  claim 1 , wherein when worn against skin or located against an object, the hydrophobic yarn directly contacts the skin or object without hydrophilic yarn directly contacting the skin or object.  
   
   
       7 . The fabric according to  claim 1 , wherein the hydrophilic and hydrophobic yarns include any one or a blend of the following types of fibers: a) man-made or synthetic fibers including, but not restricted to, polyester, polyurethane, polypropylene, polyamide, polyacrylonitrite, polyvinylchloride and regenerated cellulose; and b) natural fibers including proteinaceous fibers such as wool and hair and cellulosic fibers such as cotton.  
   
   
       8 . The fabric according to  claim 1 , wherein the hydrophobic yarn or yarns are pre-treated with a hydrophobic agent prior to formation of the fabric.  
   
   
       9 . The fabric according to  claim 8 , wherein fibers of the hydrophobic yarn or yarns are pre-treated with a hydrophobic agent when in the form of a yarn.  
   
   
       10 . The fabric according to  claim 1 , wherein the outer face of the fabric is made from at least 50 percent hydrophilic yarn.  
   
   
       11 . The fabric according to  claim 1 , wherein the outer face of the fabric is formed from at least 80 percent hydrophilic yarn.  
   
   
       12 . The fabric according to  claim 1 , wherein the outer face of the fabric is formed from 100 percent hydrophilic yarn.  
   
   
       13 . The fabric according to  claim 1 , wherein the hydrophobic yarn is pre-treated using an exhaust process.  
   
   
       14 . The fabric according to  claim 1 , wherein at least one of the hydrophobic or hydrophilic yarns include cotton fibers and/or other types of cellulosic fibers.  
   
   
       15 . The fabric according to  claim 1 , wherein at least one of the hydrophobic or hydrophilic yarns contains at least 50 percent cotton and/or other types of cellulosic fibers.  
   
   
       16 . The fabric according to  claim 1 , wherein at least one of the hydrophobic or hydrophilic yarns contain at least 80 percent cotton and/or other types of cellulosic fibers.  
   
   
       17 . The fabric according to  claim 1 , wherein both of said yarns are made entirely of cotton and/or other types of cellulosic fibers.  
   
   
       18 . The fabric according to  claim 1 , wherein the ratio of hydrophilic to hydrophobic yarns on a mass basis ranges from 95:5 to 10:90 respectively.  
   
   
       19 . The fabric according to  claim 1 , wherein the ratio of hydrophilic to hydrophobic yarns on a mass basis ranges from 60:40 to 80:20 respectively.  
   
   
       20 . The fabric according to  claim 1 , wherein the hydrophobic and hydrophilic yarns are intermeshed in a manner whereby the hydrophilic yarns from part of a core or central region of the fabric and the outer face of the fabric.  
   
   
       21 . The fabric according to  claim 1 , wherein the hydrophobic yarn is located at a distance ranging from 0.01 to 2.0 mm from an outer plane of the inner face of the fabric.  
   
   
       22 . The fabric according to  claim 1 , wherein the hydrophobic yarn is located at a distance ranging from 0.1 to 1.0 mm from an outer plane of the inner face of the fabric.  
   
   
       23 . The fabric according to  claim 1 , wherein the fabric has a buffering capacity against liquid water K f , which, when measured in accordance with a Hohenstein Institute standard test, ranges from 0.1 to 1.  
   
   
       24 . The fabric according to  claim 1 , wherein the fabric has a buffering capacity against liquid water K f , which, when measured in accordance with a Hohenstein Institute standard test, ranges from 0.9 to 1.  
   
   
       25 . The fabric according to  claim 1 , wherein the fabric has a drop sorption index i B , which, when measured in accordance with a Hohenstein Institute standard test, ranges from 0 to 250.  
   
   
       26 . The fabric according to  claim 1 , wherein the fabric has a drop sorption index i B , which, when measured in accordance with a Hohenstein Institute standard test, ranges from 0 to 5.  
   
   
       27 . A fabric including: 
 a) an inner face that is formed entirely from one or more than one hydrophobic yarn and said yarns are assembled over the inner face so that the inner face has a hydrophobicity that is substantially the same over the inner surface and is suitable for making the inside of a garment, wherein said yarns include cotton and/or other types of cellulosic fibers and have been pre-treated with a hydrophobic agent prior to formation of the fabric; and    b) an outer face that in comparison to the inner face is relatively hydrophilic such that liquid can be wicked through the inner face to the outer face, and wherein the outer face is made of yarns that include cotton and/or other types of cellulosic fibers.    
   
   
       28 . The fabric according to  claim 27 , wherein the hydrophobic yarn is pre-treated with a hydrophobic agent prior to formation of the fabric.  
   
   
       29 . The fabric according to  claim 28 , wherein fibers forming the hydrophobic yarn are pre-treated with a hydrophobic agent when in the form of a yarn.  
   
   
       30 . The fabric according to  claim 28 , wherein the hydrophobic yarns be pre-treated using an exhaust process.  
   
   
       31 . The fabric according to  claim 27 , wherein the outer face of the fabric is made from at least 50 percent hydrophilic yarns.  
   
   
       32 . The fabric according to  claim 27 , wherein the outer face of the fabric is formed from at least 80 percent hydrophilic yarn.  
   
   
       33 . The fabric according to  claim 27 , wherein the outer face of the fabric is formed from 100 percent hydrophilic yarn.  
   
   
       34 . The fabric according to  claim 27 , wherein at least one of the hydrophobic or hydrophilic yarns contains 50 percent cotton and/or other types of cellulosic fibers.  
   
   
       35 . The fabric according to  claim 27 , wherein at least one of the hydrophobic or hydrophilic yarns contains at least 80 percent cotton and/or other types of cellulosic fibers.  
   
   
       36 . The fabric according to  claim 27 , wherein both of said yarns are made entirely of cotton and/or other types of cellulosic fibers.  
   
   
       37 . The fabric according to  claim 27 , wherein the fabric has a ratio of hydrophilic to hydrophobic yarns on a mass basis ranges from 95:5 to 10:90 respectively.  
   
   
       38 . The fabric according to  claim 27 , wherein the fabric has a ratio of hydrophilic to hydrophobic yarns on a mass basis ranges from 60:40 to 80:20 respectively.  
   
   
       39 . The fabric according to  claim 27 , wherein the hydrophobic yarn or yarns are assembled so that sections of hydrophobic yarn in the inner face are separated by spaces through which liquid can penetrate and make contact with the hydrophilic yarn or yarns that form at least part of the outer face of the fabric and that, in turn, can draw liquid to the outer face of the fabric.  
   
   
       40 . The fabric according to  claim 39 , wherein the hydrophobic yarns form loops or floats on the inner face and form said sections of hydrophobic yarn separated by spaces through which liquid can penetrate.  
   
   
       41 . The fabric according to  claim 39 , wherein the spacing of said sections of hydrophobic yarn on the inner face of the fabric ranges from 0.01 to 25 mm in the wale or warp direction and ranges from 0.01 to 25 mm in the course or weft direction.  
   
   
       42 . The fabric according to  claim 39 , wherein the spacing of said sections of hydrophobic yarn on the inner face of the fabric ranges from 0.1 to 2.5 mm in the wale or warp direction and ranges from 0.1 to 2.5 mm in the course or weft direction.  
   
   
       43 . The fabric according to  claim 27 , wherein the hydrophobic and hydrophilic yarns are intermeshed in a manner whereby the hydrophilic yarns from part of a core or central region of the fabric and the outer face of the fabric.  
   
   
       44 . The fabric according to  claim 27 , wherein the hydrophilic yarn is located at a distance ranging from 0.01 to 2.0 mm from an outer plane of the inner face of the fabric.  
   
   
       45 . The fabric according to  claim 27 , wherein the hydrophilic yarn is located at a distance ranging from 0.01 to 1.0 mm from an outer plane of the inner face of the fabric.  
   
   
       46 . The fabric according to  claim 27 , wherein when worn against skin or located against an object, hydrophilic yarn directly contacts the skin or object without hydrophilic yarn directly contacting the skin or object.  
   
   
       47 . The fabric according to  claim 27 , wherein the fabric has a buffering capacity against liquid water K f , which, when measured in accordance with a Hohenstein Institute standard test, ranges from 0.1 to 1.  
   
   
       48 . The fabric according to  claim 27 , wherein the fabric has a buffering capacity against liquid water K f , which, when measured in accordance with a Hohenstein Institute standard test, ranges from 0.9 to 1.  
   
   
       49 . The fabric according to  claim 28 , wherein the fabric has a drop sorption index i B , which, when measured in accordance with a Hohenstein Institute standard test, ranges from 0 to 250.  
   
   
       50 . The fabric according to  claim 28 , wherein the fabric has a drop sorption index i B , which, when measured in accordance with a Hohenstein Institute standard test, ranges from 0 to 5.  
   
   
       51 . A method of making a fabric that is capable of wicking liquid through an inner face to an outer face of the fabric, the method includes the steps of: 
 a) providing a hydrophilic yarn;    b) providing a hydrophobic yarn that has been pre-treated to render it hydrophobic; and    c) forming a fabric using said hydrophilic and hydrophobic yarns, wherein the yarns are assembled relative to each other such that the inner face of the fabric is made entirely from the hydrophobic yarn and liquid can penetrate the inner face and make contact with hydrophilic yarn that forms at least part of the outer face of the fabric and that, in turn, can draw liquid through the inner face to the outer face of the fabric.    
   
   
       52 . The method according to  claim 51 , wherein some sections of hydrophobic yarn in the inner face are separated by spaces through which liquid can penetrate.  
   
   
       53 . The method according to  claim 51 , wherein the hydrophilic and hydrophobic yarns include any one or a blend of the following types of fibers: 
 a) man-made or synthetic fibers including, but not restricted to, polyester, polyamide, polyurethane, polypropylene, polyacrylonitrile polyvinylchloride and regenerated cellulose; and    b) natural fibers including proteinaceous fibers such as wool and hair and cellulosic fibers such as cotton.    
   
   
       54 . The method according to  claim 51 , wherein at least one of the hydrophobic or hydrophilic yarns include cotton fibers and/or other types of cellulosic fibers.  
   
   
       55 . The method according to  claim 51 , wherein at least one of the hydrophobic or hydrophilic yarns contains at least 50 percent cotton and/or other types of cellulosic fibers.  
   
   
       56 . The method according to  claim 51 , wherein at least one of the hydrophobic or hydrophilic yarns contains at least 80 percent of cotton fibers and/or other types of cellulosic fibers.  
   
   
       57 . The method according to  claim 51 , wherein both of said yarns are made entirely of cotton and/or other types of cellulosic fibers.  
   
   
       58 . The method according to  claim 54 , wherein step b) includes pre-treating the fibers with a liquor containing a hydrophobic agent and results in the hydrophobic agent being fixed to the fibers.  
   
   
       59 . The method according to  claim 58 , wherein the pre-treatment involves contacting the fibers with the liquor using an exhaust process.  
   
   
       60 . The method according to  claim 58 , wherein the pre-treatment is carried out at a temperature ranging from 10 to 110° C.  
   
   
       61 . The method according to  claim 58 , wherein the pre-treatment is carried out at a temperature ranging from 20 to 70° C.  
   
   
       62 . The method according to  claim 58 , wherein the pre-treatment is carried out at a starting temperature of 10° C. increasing at a rate ranging from 0.1 to 5.0 degrees per minute to a maximum of 110° C.  
   
   
       63 . The method according to  claim 58 , wherein the pre-treatment is carried out at a starting temperature of 20° C. increasing at a rate ranging from 0.5 to 1.5 degrees per minute to a maximum of 70° C.  
   
   
       64 . The method according to  claim 58 , wherein the hydrophobic agent used in the pre-treatment is any one or a combination of silicones, fluorochemicals, oils, latexes and hydrocarbons.  
   
   
       65 . The method according to  claim 58 , wherein the hydrophobic agent included in the liquor is a fluoroacrylate polymer.  
   
   
       66 . The method according to  claim 58 , wherein the liquor contains a concentration of electrolyte that minimises undesired deposition of hydrophobic agent or flocculation of hydrophobic agent and assists in achieving uniformity of the deposition of the hydrophobic agent throughout the yarns packages.  
   
   
       67 . The method according to  claim 58 , wherein the liquid includes an electrolyte in the form of sodium sulphate or magnesium chloride.  
   
   
       68 . The method according to  claim 66 , wherein the electrolyte concentration in the liquor ranges from 0 to 20 g/l.  
   
   
       69 . The method according to  claim 66 , wherein the electrolyte concentration in the liquor ranges from 5 to 10 g/l.  
   
   
       70 . The method according to  claim 51 , wherein the liquor includes a cross-linking agent for forming bonds between the hydrophobic agent and the cotton or other cellulosic fibers.  
   
   
       71 . The method according to  claim 70 , wherein the cross-linking agent is heat activated and the method also includes a heat curing step in which the pre-treated yarn is heated to a temperature ranging from 50 to 230° C.  
   
   
       72 . The method according to  claim 70 , wherein the curing step involves heating the pre-treated yarn to a temperature ranging from 110 to 190° C.  
   
   
       73 . The method according to  claim 71 , wherein the heat curing step is carried out for a period ranging from 1 second to 40 minutes.  
   
   
       74 . A method of making a fabric that is capable of wicking liquid through an inner face to an outer face of the fabric and the fabric includes two or more than two yarns that include cotton fibers and/or other types of cellulosic fibers, the method includes the steps of: 
 a) pre-treating cotton fibers and/or other types of cellulosic fibers of at least one of the yarns with a liquor containing a hydrophobic agent so as to impart hydrophobic properties to the fibers; and    b) forming a fabric from two or more yarns of which at least one yarn includes the cotton fibers and/or other types of cellulosic fibers pre-treated according to step a) and, wherein the yarns are assembled relative to each other such that the inner face of the fabric is made entirely from said yarn containing fibers pre-treated according to step a)and that the inner face of the fabric is hydrophobic compared to the outer face and has a hydrophobicity that is substantially the same over the inner face.    
   
   
       75 . The method according to  claim 74 , wherein the step of pre-treating the cotton fibers and/or other cellulosic fibers with the liquor containing a hydrophobic agent results in the hydrophobic agent being fixed to the fibers.  
   
   
       76 . The method according to  claim 74 , wherein step a) is carried out either before, during or after the cotton fibers and/or other types of cellulosic fibers are spun into a yarn.  
   
   
       77 . The method according to  claim 74 , wherein at least one of the yarns contains at least 50 percent cotton and/or other types of cellulosic fibers.  
   
   
       78 . The method according to  claim 74 , wherein at least one of the yarns contains at least 80 percent cotton and/or other cellulosic fibers on a weight basis.  
   
   
       79 . The method according to  claim 74 , wherein the yarns include cotton fibers and/or other types of cellulosic fibers consist entirely of cotton fibers.  
   
   
       80 . The method according to  claim 74 , wherein step a) involves submerging the cotton fibers in the liquor so that the hydrophobic agent is preferentially adsorbed onto the cotton fibers from the liquor.  
   
   
       81 . The method according to  claim 74 , wherein step a) involves contacting the fibers with the liquor using an exhaust process.  
   
   
       82 . The method according to  claim 74 , wherein step a) is carried out at a temperature ranging from 10 to 110° C.  
   
   
       83 . The method according to  claim 74 , wherein step a) is carried out at a temperature ranging from 20 to 70° C.  
   
   
       84 . The method according to  claim 74 , wherein step a) is carried out at a starting temperature of 10° C. increasing at a rate ranging from 0.1 to 5.0 degrees per minute to a maximum of 110° C.  
   
   
       85 . The method according to  claim 74 , wherein step a) is carried out at a starting temperature of 20° C. increasing at a rate ranging from 0.5 to 1.5 degrees per minute to a maximum of 70° C.  
   
   
       86 . The method according to  claim 74 , wherein the liquor includes any one or a combination of silicones, fluorochemicals, oils, latexes and hydrocarbons.  
   
   
       87 . The method according to  claim 74 , wherein the hydrophobic agent included in the liquor is a fluoroacrylate polymer.  
   
   
       88 . The method according to  claim 74 , wherein the hydrophobic agent is capable of forming covalent bonds to the surface of cotton and/or other types of cellulosic fibers treated according to step a).  
   
   
       89 . The method according to  claim 74 , wherein the liquor contains a concentration of electrolyte that assists in achieving uniformity of the deposition of the hydrophobic agent throughout the yarn packages and minimises undesired deposition of polymer onto the treatment vessel or flocculation of hydrophobic agent.  
   
   
       90 . The method according to  claim 89 , wherein the electrolyte is one or a combination of sodium sulphate or magnesium chloride.  
   
   
       91 . The method according to  claim 89 , wherein the electrolyte concentration ranges from 0 to 20 g/l.  
   
   
       92 . The method according to  claim 89 , wherein the electrolyte concentration ranges from 5 to 10 g/l.  
   
   
       93 . The method according to  claim 74 , wherein liquor includes a cross-linking agent for forming bonds between the hydrophobic agent and the cotton or other cellulosic fibers.  
   
   
       94 . The method according to  claim 93 , wherein the cross-linking agent is heat activated.  
   
   
       95 . The method according to  claim 93 , wherein the method includes a heat curing step in which the pre-treated yarn is heated to a temperature ranging from 50 to 230° C.  
   
   
       96 . The method according to  claim 95 , wherein the curing step involves heating the pre-treated yarn to a temperature ranging from 110 to 190° C.  
   
   
       97 . The method according to  claim 94 , wherein the heat curing step is carried out for a period ranging from 1 second to 40 minutes.  
   
   
       98 . The method according to  claim 94 , wherein the heat curing step is carried out over a time period that can range from 30 seconds to 20 minutes.  
   
   
       99 . The fabric according to  claim 1 , wherein the outer face is laminated or joined to a waterproof and/or a windproof breathable membrane.