Stretchable fabric

Abstract

First warp yarns and second warp yarns are each interwoven with weft yarns to produce a one-layer, lightweight, stretchable fabric. The first warp yarns include stretchable yarns that are activatable to achieve a contracted state, and the second warp yarns include non-stretchable yarns. The first warp yarns may include a stretchable core yarn with non-stretchable wrap yarn wrapped around the stretchable core yarn. The first warp yarns may be in an alternating arrangement with the second warp yarns. When the yarns are woven together, the first warp yarns are in an extended state and the second warp yarns are in an unbunched state. The fabric then undergoes a finishing procedure during which the first warp yarns are activated to achieve a contracted state. The second warp yarns thus achieve a bunched state, and the resulting fabric is stretchable in the warp direction.

1 . A fabric comprising:
 a plurality of weft yarns;   a plurality of first warp yarns interwoven with the weft yarns, wherein the first warp yarns comprise stretchable yarns and are activatable to achieve a contracted state; and   a plurality of second warp yarns interwoven with the weft yarns, wherein the second warp yarns comprise non-stretchable yarns;   wherein the fabric is stretchable in a warp direction upon activation of at least some of the plurality of first warp yarns.   
     
     
         2 . The fabric of  claim 1 , wherein at least some of the plurality of second warp yarns achieve a bunched state upon activation of the first warp yarns. 
     
     
         3 . The fabric of  claim 1 , wherein at least some of the first warp yarns comprise a stretchable core yarn and a non-stretchable wrap yarn wrapped around the stretchable core yarn. 
     
     
         4 . The fabric of  claim 3 , wherein the stretchable core yarn comprises Lycra and the non-stretchable wrap yarn comprises nylon. 
     
     
         5 . The fabric of  claim 3 , wherein the stretchable core yarn is stretchable to a length between approximately 2 and 7 times the respective yarn's original length under tension and is capable of returning to approximately the respective yarn's original length when no longer under tension, and wherein the non-stretchable wrap yarn is incapable of being stretched to a length greater than approximately 2 times the respective yarn's original length under tension or is plastically deformed when stretched to a length greater than approximately 2 times the respective yarn's original length. 
     
     
         6 . The fabric of  claim 1 , wherein the first warp yarns comprise Lycra and the second warp yarns comprise nylon. 
     
     
         7 . The fabric of  claim 1 , wherein the first warp yarns float at least two of the plurality of weft yarns. 
     
     
         8 . The fabric of  claim 1 , wherein the second warp yarns float at least two of the plurality of weft yarns. 
     
     
         9 . The fabric of  claim 1 , wherein the weft yarns are fire-resistant. 
     
     
         10 . The fabric of  claim 1 , wherein at least some of the first warp yarns comprise stretchable yarns that are stretchable to a length between approximately 2 and 7 times the respective yarn's original length under tension and are capable of returning to approximately the respective yarn's original length when no longer under tension, and wherein at least some of the second warp yarns comprise non-stretchable yarns that are incapable of being stretched to a length greater than approximately 2 times the respective yarn's original length under tension or are plastically deformed when stretched to a length greater than approximately 2 times the respective yarn's original length. 
     
     
         11 . A fabric comprising:
 a plurality of weft yarns;   a plurality of first warp yarns interwoven with the weft yarns, wherein the first warp yarns are activatable to achieve a contracted state; and   a plurality of second warp yarns interwoven with the weft yarns;   wherein at least some of the plurality of second warp yarns achieve a bunched state upon activation of the first warp yarns.   
     
     
         12 . The fabric of  claim 11 , wherein the plurality of first warp yarns are in an alternating arrangement with the plurality of second warp yarns. 
     
     
         13 . The fabric of  claim 11 , wherein at least some of the plurality of second warp yarns comprise non-stretchable yarns. 
     
     
         14 . The fabric of  claim 11 , wherein at least some of the first warp yarns comprise a stretchable core yarn and a non-stretchable wrap yarn wrapped around the stretchable core yarn. 
     
     
         15 . The fabric of  claim 14 , wherein the stretchable core yarn comprises Lycra and the non-stretchable wrap yarn comprises nylon. 
     
     
         16 . The fabric of  claim 14 , wherein the non-stretchable wrap yarn is a first non-stretchable wrap yarn, and wherein at least some of the first warp yarns further comprise a second non-stretchable wrap yarn, wherein the first non-stretchable wrap yarn is wrapped about the stretchable core yarn in a first direction and the second non-stretchable wrap yarn is wrapped about the stretchable core yarn in a second direction. 
     
     
         17 . The fabric of  claim 11 , wherein the fabric comprises at least one of an anti-microbial and a water-resistant coating. 
     
     
         18 . The fabric of  claim 11 , wherein the first warp yarns comprise Lycra and the second warp yarns comprise nylon. 
     
     
         19 . The fabric of  claim 11 , wherein the weft yarns are fire-resistant. 
     
     
         20 . A method of weaving a fabric comprising:
 providing a plurality of weft yarns;   providing a plurality of first warp yarns in an extended state;   providing a plurality of second warp yarns;   interweaving the first warp yarns with the weft yarns;   interweaving the second warp yarns with the weft yarns; and   activating the first warp yarns to achieve a contracted state of at least some of the first warp yarns,   wherein the fabric is stretchable in a warp direction upon activation of at least some of the plurality of the first warp yarns.   
     
     
         21 . The method of  claim 20 , wherein providing the plurality of second warp yarns comprises providing the second warp yarns in an unbunched state, and wherein activating the first warp yarns causes at least some of the second warp yarns to move from the unbunched state to a bunched state. 
     
     
         22 . The method of  claim 20 , wherein at least some of the first warp yarns comprise a stretchable core yarn and a non-stretchable wrap yarn wrapped around the stretchable core yarn. 
     
     
         23 . The method of  claim 20 , wherein interweaving the first and second warp yarns with the weft yarns comprises alternately weaving the first and second warp yarns. 
     
     
         24 . The method of  claim 20  further comprising chemically treating the fabric to impart anti-microbial or water-resistant characteristics to the fabric. 
     
     
         25 . The method of  claim 20 , wherein interweaving the first warp yarns with the weft yarns comprises floating at least two of the plurality of weft yarns, and wherein interweaving the second warp yarns with the weft yarns comprises floating at least two of the plurality of weft yarns. 
     
     
         26 . The method of  claim 20 , wherein providing a plurality of first warp yarns in an extended state comprises applying tension to the first warp yarns. 
     
     
         27 . A fabric comprising:
 a plurality of weft yarns;   a plurality of first warp yarns interwoven with the weft yarns, wherein the first warp yarns are in a contracted state, the first warp yarns being stretchable between the contracted state and an extended state; and   a plurality of second warp yarns interwoven with the weft yarns, wherein the second warp yarns are in a bunched state,   wherein, when the fabric is stretched in the warp direction, the plurality of first warp yarns is moved from the contracted state to the extended state and the plurality of second warp yarns is moved from the bunched state to an unbunched state.   
     
     
         28 . The fabric of  claim 27 , wherein the amount of stretch of the fabric is limited by a length of the second warp yarns in their respective unbunched states. 
     
     
         29 . The fabric of  claim 27 , wherein at least some of the first warp yarns comprise a stretchable core yarn and a non-stretchable wrap yarn wrapped around the stretchable core yarn. 
     
     
         30 . The fabric of  claim 29 , wherein the stretchable core yarn comprises Lycra and the non-stretchable wrap yarn comprises nylon. 
     
     
         31 . The fabric of  claim 29 , wherein the non-stretchable wrap yarn is a first non-stretchable wrap yarn, and wherein at least some of the first warp yarns further comprise a second non-stretchable wrap yarn, wherein the first non-stretchable wrap yarn is wrapped about the stretchable core yarn in a first direction and the second non-stretchable wrap yarn is wrapped about the stretchable core yarn in a second direction. 
     
     
         32 . A garment, at least a portion of the garment comprising a fabric, wherein the fabric comprises:
 a plurality of weft yarns;   a plurality of first warp yarns interwoven with the weft yarns, wherein the first warp yarns are in a contracted state and are stretchable between the contracted state and an extended state; and   a plurality of second warp yarns interwoven with the weft yarns, wherein the second warp yarns are in a bunched state,   wherein, when the fabric is stretched in the warp direction, the first warp yarns are moved from the contracted state to the extended state and the second warp yarns are moved from the bunched state to an unbunched state.   
     
     
         33 . The garment of  claim 32 , wherein at least some of the first warp yarns comprise a stretchable core yarn and a non-stretchable wrap yarn wrapped around the stretchable core yarn. 
     
     
         34 . The garment of  claim 33 , wherein the stretchable core yarn comprises Lycra and the non-stretchable wrap yarn comprises nylon. 
     
     
         35 . The garment of  claim 33 , wherein the non-stretchable wrap yarn is a first non-stretchable wrap yarn, and wherein at least some of the first warp yarns further comprise a second non-stretchable wrap yarn, wherein the first non-stretchable wrap yarn is wrapped about the stretchable core yarn in a first direction and the second non-stretchable wrap yarn is wrapped about the stretchable core yarn in a second direction.