Woven fabric comprising elastic on both warp and weft and method of making same

Abstract

A woven fabric comprising warp yarns and weft yarns is provided, wherein the warp yarns and weft yarns comprise an elastane core covered by cellulose fibers or short staple polyester fibers. The woven fabric comprises an elastane content of 2% to 15% by weight based on total woven fabric weight. The woven fabric has an elasticity on warp ranging from about 110% to about 150% and an elongation on weft from about 110% to about 170%. According to the AATCC 135 Test Method, the shrinkage on warp is 0% to −8%, and the shrinkage on weft is 0% to −20%. Methods of making the woven fabrics are also provided.

That which is claimed: 
     
         1 . A woven fabric comprising warp yarns and weft yarns, wherein:
 a. The warp yarns comprise an elastane core covered by cellulose fibers or short staple polyester fibers;   b. The weft yarns comprise an elastane core covered by cellulose fibers or short staple polyester fibers; and   c. The woven fabric comprises an elastane content of 2% to 15% by weight based on total woven fabric weight.   
     
     
         2 . The woven fabric of  claim 1 , wherein the woven fabric has an elasticity on warp ranging from about 110% to about 150%. 
     
     
         3 . The woven fabric of  claim 1 , wherein the woven fabric has an elongation on weft from about 110% to about 170%. 
     
     
         4 . The woven fabric of  claim 1 , wherein the shrinkage on warp according to the AATCC 135 Test Method is 0% to −8%. 
     
     
         5 . The woven fabric of  claim 1 , wherein the shrinkage on weft according to the AATCC 135 Test Method is 0% to −20%. 
     
     
         6 . The woven fabric of  claim 1 , wherein the warp yarn is at least 40% of the weft yarn. 
     
     
         7 . The woven fabric of  claim 1 , wherein the cellulose fibers are cotton fibers. 
     
     
         8 . The woven fabric of  claim 1 , wherein the woven fabric does not comprise a separate control yarn. 
     
     
         9 . A method of making the woven fabric of  claim 1 , comprising the steps of:
 i. Obtaining the warp yarns of  1 ( a );   ii. Obtaining the weft yarns of  1 ( b ); and   Weaving together the warp yarns of  1 ( a ) with the weft yarns of  1 ( b ).   
     
     
         10 . The method of  claim 9 , wherein step  9 ( c ) is a weave selected from the group consisting of 1/1, 2/1, 3/1, 4/1, 5/1, 2/2, 3/3, 1/2, 1/3, 1/4, and 1/5. 
     
     
         11 . The method of  claim 9 , wherein the steps of  9 ( a ) and  9 ( b ) comprise spinning of the elastane core at 0.5 to 5 times the speed of spinning the cellulose fibers or the short staple polyester fibers. 
     
     
         12 . A woven fabric comprising warp yarns and weft yarns, wherein:
 a. The warp yarns comprise an elastane core covered by cellulose fibers or short staple polyester fibers;   b. The weft yarns comprise a combination of:
 i. A pick of yarn comprising an elastane core covered by cellulose fibers; and 
 ii. A pick of yarn that does not comprise elastane; and 
   c. The woven fabric comprises an elastane content of 2% to 15% by weight based on total woven fabric weight.   
     
     
         13 . The woven fabric of  claim 12 , wherein the woven fabric has an elasticity on warp ranging from about 110% to about 150%. 
     
     
         14 . The woven fabric of  claim 12 , wherein the woven fabric has an elongation on weft from about 110% to about 170%. 
     
     
         15 . The woven fabric of  claim 12 , wherein the shrinkage on warp according to the AATCC 135 Test Method is 0% to −8%. 
     
     
         16 . The woven fabric of  claim 12 , wherein the shrinkage on weft according to the AATCC 135 Test Method is 0% to −20%. 
     
     
         17 . The woven fabric of  claim 12 , wherein the warp yarn is at least 40% of the weft yarn. 
     
     
         18 . The woven fabric of  claim 12 , wherein the cellulose fibers are cotton fibers. 
     
     
         19 . The woven fabric of  claim 12 , wherein the woven fabric does not comprise a separate control yarn. 
     
     
         20 . A method of making the woven fabric of  claim 12 , comprising the steps of:
 i. Obtaining the warp yarns of  12 ( a );   ii. Obtaining the weft yarns of  12 ( b ); and   iii. Weaving together the warp yarns of  12 ( a ) with the weft yarns of  12 ( b ).   
     
     
         21 . The method of  claim 20 , wherein step  20 ( c ) is a weave selected from the group consisting of 1/1, 2/1, 3/1, 4/1, 5/1, 2/2, 3/3, 1/2, 1/3, 1/4, and 1/5. 
     
     
         22 . The method of  claim 20 , wherein the steps of  20 ( a ) and  20 ( b ) comprise spinning of the elastane core at 0.5 to 5 times the speed of spinning the cellulose fibers or the short staple polyester fibers.