Lyocell-Polyester Fabric and Methods of Manufacture

Abstract

A fabric is disclosed and includes warp yarns of only lyocell fiber, and weft yarns of multifilament polyester only, where the fabric has a warp yarn count from Ne40 to Ne120, a weft yarn count from 15 D (denier) to 100 D, a thread count (TC) between 200 and 2000, with ends per inch in warp between 100 and 250, and picks per inch in weft being between 100 to 1800. In one embodiment, the lyocell fiber is lyocell fiber resulting from being spun in an environment where the relative humidity is maintained at between 40% and 50%, or between 44% and 46%. The resulting fabric has low shrinkage, good durability, a desirable softness, a cool feel due to its moisture-wicking properties, and an excellent uniformity in color when dyed.

What is claimed is: 
     
         1 . A fabric, comprising:
 warp yarns consisting of lyocell fiber; and   weft yarns consisting of multifilament polyester, wherein   said fabric has a warp yarn count from Ne40 to Ne120, a weft yarn count from 15 D (denier) to 100 D, a thread count (TC) between 200 and 2000 with ends per inch in warp between 100 and 250 and picks per inch in weft being between 100 to 1800.   
     
     
         2 . A fabric according to  claim 1 , wherein:
 said lyocell fiber is lyocell fiber resulting from being spun in an environment where the relative humidity is maintained at between 40% and 50%.   
     
     
         3 . A fabric according to  claim 2 , wherein:
 said relative humidity is maintained at between 44% and 46% during spinning.   
     
     
         4 . A fabric according to  claim 2 , wherein:
 said fabric has a warp tensile strength between 4 lbs and 15 lbs and said fabric has a weft tensile strength of between 4 lbs and 20 lbs.   
     
     
         5 . A fabric, comprising:
 warp yarns consisting of lyocell fiber, said lyocell fiber resulting from being spun in an environment where the relative humidity is maintained at between 40% and 50%; and   weft yarns consisting of multifilament polyester, wherein   said fabric has a warp yarn count from Ne40 to Ne120, a weft yarn count from 15 D (denier) to 100 D, a thread count (TC) between 200 and 2000.   
     
     
         6 . A fabric according to  claim 5 , wherein:
 said fabric has a warp tensile strength between 4 lbs and 15 lbs and said fabric has a weft tensile strength of between 4 lbs and 20 lbs.   
     
     
         7 . A method of making a fabric, comprising:
 obtaining lyocell fibers;   carding the fibers to form slivers and processing the slivers in a draw frame;   spinning the processed slivers in a spinning machine;   twisting the spun fibers into a lyocell yarn;   obtaining a multifilament polyester yarn; and   weaving said lyocell yarn in warp and said polyester yarn in weft into said fabric where said fabric has a warp yarn count from Ne40 to Ne120, a weft yarn count from 15 D (denier) to 100 D, a thread count (TC) between 200 and 2000.   
     
     
         8 . A method according to  claim 7 , wherein:
 said spinning is conducted in a controlled environment at between 40% and 50% relative humidity.   
     
     
         9 . A method according to  claim 8 , wherein:
 said weaving is conducted with lyocell yarn ends per inch in warp between 100 and 250 and polyester yarn picks per inch in weft being between 100 to 1800.