Composite fabric and a method and apparatus for manufacturing the same

Abstract

This invention relates generally to a composite fabric and a method and apparatus for manufacturing a composite fabric, especially suitable for apparel application, upholstery, bed and bath applications. In an embodiment, a composite fabric comprises a base fabric made by weaving or knitting. A plurality of gaps is disposed in-between the fibers of the yarns of the base fabric. A plurality of functional fibers is entangled in the gaps followed by swelling of the fibers, with predetermined retention to the yarns of the base fabric.

1 . A composite fabric, comprising:
 (i) a base fabric made by weaving or knitting;   (ii) a plurality of gaps disposed in-between the fibers of the yarns of the base fabric wherein a plurality of functional fibers are entangled in the gap with predetermined retention to the yarns of the base fabric.   
   
   
       2 . A composite fabric according to  claim 1  further comprising a plurality of functional fibers locked in-between the yarns of the base fabric. 
   
   
       3 . A composite fabric according to  claim 2  further comprising a plurality of functional fibers in mutually entangled configuration. 
   
   
       4 . A composite fabric according to  claim 1  wherein the entangled functional fibers and the fibers of the yarns of the base fabric are permanently swollen. 
   
   
       5 . A composite fabric according to  claim 1  wherein the base fabric comprises at least one of a natural or a synthetic fiber. 
   
   
       6 . A composite fabric according to  claim 1  wherein the functional fiber is selected based on required properties and application of the composite fabric product. 
   
   
       7 . A composite fabric according to  claim 6  wherein the functional fiber includes at least one among the group consisting of phase change fiber, anti-microbial fiber, eco-friendly fiber, regenerated fiber, cotton, bamboo, nylon, silk, polyester and wool. 
   
   
       8 . A composite fabric according to  claim 6  wherein the fabric product is at least one among an apparel, upholstery, bed and bath fabric product. 
   
   
       9 . A composite fabric manufacturing apparatus, comprising:
 (i) at least one first entanglement unit for stabilizing a base fabric;   (ii) at least one second entanglement unit for entangling a plurality of functional fibers into the yarns of the base fabric, wherein the entanglement units are configured having a plurality of injectors and perforated drums operating at predetermined operating parameters so as to lock the functional fibers into the yarns of the base fabric.   
   
   
       10 . An apparatus according to  claim 9  wherein the drums are covered with sleeves having openness in the range of about 20% to 80%. 
   
   
       11 . An apparatus according to  claim 9  further comprises a means for maintaining the dimensional stability of the stabilized base fabric. 
   
   
       12 . An apparatus according to  claim 9  further comprises a means for squeezing the composite fabric. 
   
   
       13 . An apparatus according to  claim 9  further comprises a unwinding unit configured having a means for continuous monitoring and control of the original dimensions of the base fabric. 
   
   
       14 . A composite fabric manufacturing method, comprising:
 (i) stabilizing and forming gaps in-between fibers in the yarns of a base fabric, using a fluid jet of predetermined first pressure;   (ii) entangling a plurality of functional fibers in the gaps using fluid jet of predetermined second pressure wherein the functional fibers are coupled to the yarns of the base fabric with predetermined retention.   
   
   
       15 . A method according to  claim 14  wherein the fluid jet comprises water. 
   
   
       16 . A method according to  claim 14  wherein the first pressure is in the range of about 20 bar to 250 bar. 
   
   
       17 . A method according to  claim 14  wherein the second pressure is in the range of about 60 bar to 400 bar. 
   
   
       18 . A method according to  claim 14  wherein the length of the fluid jet is in the range of about 6 mm to 12 mm. 
   
   
       19 . A method according to  claim 14  wherein the jet size is in the range of about 0.07 mm to 0.3 mm. 
   
   
       20 . A method according to  claim 14  wherein the yarns are spun with substantially low twist levels and/or with substantially shorter and coarser fibers.