Synthetic-Rich Fabrics

Abstract

A synthetic-rich fabric (e.g., polyester, polypropylene, nylon, acrylic and elastane fibers—including lycra, spandex, etc.) useful in the manufacture of commercially launderable items is described. The fabric has many of the properties that make cotton fabrics desirable including hand feel, and wicking, but retains the best properties of synthetic fabrics, in addition, the soil release properties, pilling resistance and UV protection offered by the present items make the fabric ideal in manufacturing apparel and non-apparel (e.g., pillow cases, bed sheets, aprons, tablecloths, napkins, etc.) items.

1 . A process for making a fabric comprising the steps of:
 a. selecting a synthetic-rich yarn;   b. making said yarn into a sheet of tightly constructed fabric so as not to disturb the face of the fabric; and   c. chemically, physically and thermally treating said fabric.   
     
     
         2 . The process of  claim 1  wherein said synthetic-rich yarn is chosen from a group consisting of polyester, polypropylene, nylon, acrylic and elastane fibers (including lycra, spandex, etc.). 
     
     
         3 . The process of  claim 2  wherein the yarn is 65% polyester and 35% cotton. 
     
     
         4 . The process of  claim 2  wherein the yarn is 85% polyester and 15% cotton. 
     
     
         5 . The process of  claim 2  wherein the yarn is 100% polyester. 
     
     
         6 . The process of  claim 5  wherein said polyester yarn is ring spun yarn. 
     
     
         7 . The process of  claim 5  wherein said polyester yarn is open ended. 
     
     
         8 . The process of  claim 5  wherein said polyester is air jet spun. 
     
     
         9 . The process of  claim 5  wherein the step of making the yarn into a fabric includes knitting. 
     
     
         10 . The process of  claim 9  wherein said fabric is a single-knit jersey fabric in which yarn is 20/1 and has a finished weight of between approximately 5.4 and 7.5 oz. per square yard. 
     
     
         11 . The process of  claim 10  wherein the finished weight is exactly 7.4 and the jersey fabric has a UPF label rating of 50 after 25 industrial washings. 
     
     
         12 . The process of  claim 10  wherein the tighter the knit (and consequently the greater the finished weight) increases the UV protection. 
     
     
         13 . The process of  claim 5  wherein the step of making the yarn into a fabric includes weaving. 
     
     
         14 . The process of  claim 13  wherein fabric is a woven fabric in which the yarn is 16/1 and has a denier of approximately 1.2. 
     
     
         15 . The process of  claim 8  wherein the fabric is a fleece in which the yarn is an air jet 16/1. 
     
     
         16 . The process of  claim 7  wherein the fabric is a fleece in which the yarn is an open ended 10/1. 
     
     
         17 . The process of  claim 5  wherein said step of chemically, physically and thermally treating said fabric includes the steps of:
 a) scouring said fabric to remove lubricants and the like which remained from the yarn production and knitting processes; and 
 b). jet dying said fabric (such as in a Colorstar or a Thies jet dye machine). 
 
     
     
         18 . The process of  claim 17  wherein said scouring step comprises the steps of:
 i) filling said jet dye machine to load volume with water heated to approximately 100° F.; 
 ii) adding approximately 0.5% defoamer MC-1 to said 100° F. water; 
 iii) loading the fabric into said water/defoamer mixture in said jet dye machine; 
 iv) adding 1.0% J-Scour WPE to water/defoamer mixture; 
 v) circulating said water/defoamer mixture for about four minutes; 
 vi) adding 5.0% Polymeric/Surfactant blend to water/defoamer mixture; 
 vii) running said jet dye machine for about 2 minutes; 
 viii) increasing the temperature of said mixture by about 3° F. per minute until the temperature of said mixture reaches approximately 180° F.; 
 ix) circulating said mixture for about 5 minutes at approximately 180° F.; 
 x) raising the temperature of said mixture by about 2° F. per minute until the mixture reaches a temperature of approximately 265° F.; 
 xi) holding the temperature of said mixture at approximately 265° F. for about thirty minutes; 
 
       xii) reducing the temperature of said mixture at an approximate rate of 2° F. per minute until it reaches approximately 140° F.;
 xiii) using an overflow wash of 100° F. water, reducing the temperature of the mixture to approximately 100° F. over about 10 minutes; 
 xiv) draining said mixture from the jet; 
 xv) filling said jet to volume with water heated to about 100° F.; 
 xvi) overflow washing with said jet for about 10 minutes using approximately 100° F. water; 
 xvii) checking the pH of the water bath to make sure it is within specified range for fabric type; 
 xviii) unloading fabric; and 
 xix) draining the jet. 
 
     
     
         19 . The process of  claim 17  wherein said dyeing step comprises the steps of:
 i) filling said jet dye machine to load volume with water heated to approximately 100° F.; 
 ii) adding approximately 0.5% defoamer MC-1 to said 100° F. water; 
 iii) loading the fabric into said water/defoamer mixture in said jet dye machine; 
 iv) adding 1.5% Acetic Acid, 1% Chem Assist T and any dye combination necessary to achieve desired color to water/defoamer mixture; 
 v) circulating said water/defoamer mixture for about five minutes; 
 vi) adding 5.0% Polymeric/Surfactant blend to water/defoamer mixture; 
 vii) running said jet dye machine for about two minutes; 
 viii) increasing the temperature of said mixture by about 4° F. per minute until the temperature of said mixture reaches approximately 265° F.; 
 ix) holding the temperature of said mixture at approximately 265° F. for about thirty minutes; 
 x) reducing the temperature of said mixture at an approximate rate of 2° F. per minute until it reaches approximately 170° F.; 
 xi) checking shade of fabric to ensure it matches standard; 
 xii) adding 3% Pressclear AW to the mixture; 
 xiii) draining said mixture from the jet; 
 xiv) filling said jet to volume with water heated to about 120° F.; 
 xv) overflow washing with said jet for about ten minutes using approximately 100° F. water; 
 xvi) draining said mixture from the jet; 
 xvii) filling said jet to volume with water heated to about 80° F.; 
 xviii) running the jet for approximately five minutes; 
 xix) checking the pH of the water bath to make sure it is within specified range for fabric type; 
 xx) checking shade of fabric a second time to ensure it matches standard; 
 xxi) unloading fabric; and 
 xxii) draining the jet. 
 
     
     
         20 . A fabric particularly suitable for use in the production of industrially-launderable items, said fabric being comprised of:
 substantially all polyester yarns;   having a wicking absorbency rating of less than 0.5 inches when tested according to AATCC Test Method 79-2000;   having a ultraviolet factor rating of 50 when tested according to AATCC Test Method 183-2000 after 50 industrial washes;   having a soil release rating of about 4.5 or greater after 100 industrial washes;   having a finished weight of about 7 oz/sq yard;   having a color fastness to laundering of about 5 or greater when tested according to AATCC Test Method 61; and   having a crocking resistance rating of class 5 about 4.0 when tested according to AATCC Test Method 8.   
     
     
         21 . A garment made from the fabric of  claim 20 . 
     
     
         22 . A non-apparel item (e.g., pillowcase, bed sheets, table cloths, napkins, etc.) made from the fabric of  claim 20 .