Apparel fabric manufacturing process; system and product thereof

Abstract

A process and system for forming an apparel fabric having a predetermined requisite optical colour and pattern effect and predetermined physical fabric properties are disclosed. The process comprises the steps of: (1) providing a first plurality of n yarn; (ii) providing at least one further plurality of m yarn; and (iii) knitting the first plurality of n yarn with the at least one further plurality of m yarn by way of a knitting process to form a multi-ply apparel fabric; wherein each yarn is formed from a plurality of fibers formed from a polymeric material, wherein the fibers are formed from a dope dyeing process and wherein the fibers are colored during the dope dyeing process; wherein upon knitting the first plurality of n yarn with the at least one further plurality of m yarn to form the multi-ply apparel fabric, the apparel fabric is formed having the predetermined requisite optical colour and pattern effect devoid of optically detectable variants in the requisite optical colour and pattern effect; and wherein the first plurality of n yarn and the at least one further plurality of m yarn are selected to provide the predetermined requisite optical colour and pattern effect and the predetermined physical fabric properties.

1 . A process of forming an apparel fabric having a predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties, said process comprising the steps of:
 providing a first plurality of n yarn, wherein the total denier of n yarn is equal to a first denier (D 1 );   (ii) providing at least one further plurality of m yarn, wherein the total denier of m yarn is equal to a further Denier (D 2 );   (iii) forming a plurality of multi-ply yarn each formed from two or more yarn, wherein each multi-ply yarn is formed one of the first plurality of n yarn and the yarn of one of the further plurality of m yarn, whereby the denier of each yarn of the multi-ply yarn collectively provide the requisite yarn denier for a knitting process; and   (iv) knitting the multi-ply yarn formed from the first plurality of yarn with the at least one further plurality of yarn by way of a knitting process so as to form a multi-ply apparel fabric   wherein each yarn is formed from a plurality of fibers formed from a polymeric material, wherein the fibers are formed from a dope dyeing process and wherein said fibers are colored during said dope dyeing process;   wherein upon knitting of the multi-ply yarn formed from said first plurality of n yarn with said at least one further plurality of m yarn to form said multi-ply apparel fabric, said apparel fabric is formed having said predetermined requisite optical colour and pattern effect devoid of optically detectable variants in said requisite optical colour and pattern effect; and   wherein the first plurality of n yarn and the at least one further plurality of m yarn are selected so as to provide said predetermined optical colour and pattern effect and said predetermined physical fabric properties.   
     
     
         2 . A process according to  claim 1 , wherein the first denier (D 1 ) and the further denier (D 2 ) are in the range of from 45 denier to 200 denier. 
     
     
         3 . A process according to  claim 1 , wherein each yarn of the first plurality of n yarn and each yarn of the at least further plurality of m yarn consists of p number of fibers whereby p is in the range of from 40 to 300, and wherein each fiber has a largest cross sectional diameter in the range of from 0.2 μm to 1.1 μm. 
     
     
         4 . A process according to  claim 1 , wherein the polymeric material each yarn of the first plurality of n yarn and each yarn of the at least further plurality of m yarn is formed selected from the group including Polyethylene Terephthalate, Polyester, Acrylic, Polyolefin, Nylon 6 and Nylon 66 and blends thereof. 
     
     
         5 . A process according to  claim 1 , wherein the polymeric material utilised in the dope dyeing process is of irregular form having a maximum dimension in the range of from 1.5 to 4 mm. 
     
     
         6 . A process according to  claim 5 , wherein the polymeric material is provided in an irregular form, having dimensions of approximately 3.3 mm×3 mm×2.2 mm. 
     
     
         7 . A process according to  claim 1 , wherein a master batch pigment is utilised in the dope dyeing process whereby the particle size of the master batch is less than the denier of the fibers from which the yarn is formed. 
     
     
         8 . A process according to  claim 1 , wherein the master batch pigment has a particle size in the range of from 20 nanometers to about 2 microns. 
     
     
         9 . A process according to  claim 1 , wherein the dope dyeing process includes the introduction of a softening agent, so as to provide a softening effect to the knitted apparel fabric. 
     
     
         10 . A process according to  claim 1 , wherein the dope dyeing process includes the introduction of a dulling agent in the range of approximately 0.4% to 1.5% by weight, so provide a requisite level of dullness to the knitted apparel fabric. 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . A process according to  claim 1 , wherein the first plurality of yarn and the at least a further plurality of yarn have the same number of yarn. 
     
     
         15 . A process according to  claim 1 , wherein each yarn of the first plurality of n yarn has the same denier such that each yarn has a denier of (D 1 )/n, and wherein each yarn of the at least one further plurality of m yarn has the same denier such that each yarn has a denier of (D 2 )/m. 
     
     
         16 . A process according to  claim 1 , wherein the first denier (D 1 ) is equal to the further Denier (D 2 ). 
     
     
         17 . (canceled) 
     
     
         18 . A process according to  claim 1 , wherein the requisite optical colour and pattern effect is a solid colour effect. 
     
     
         19 . A process according to  claim 1 , wherein the requisite optical colour and pattern effect is a regular pattern effect or an irregular pattern effect. 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . An article of apparel formed from a multi-ply knitted apparel material having a predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties and devoid of optically detectable variants in said requisite optical colour and pattern effect, whererin said apparel fabric comprises:
 a knit of a plurality of multi-ply yarn each formed from two or more yarn, wherein each multi-ply yarn is formed a plurality of n yarn and a further plurality of m yarn;   wherein the total denier of n yarn is equal to a first denier (D 1 ); and m yarn, wherein the total of m yarn is equal to a further Denier (D 2 ), whereby the denier of each yarn of the multi-ply yarn collectively provide the requisite yarn denier for the knitted fabric;   wherein each yarn is comprised of a plurality of coloured dope dyed fibers of a polymeric material, and wherein the plurality of n yarn and the plurality of m yarn provide said predetermined optical colour and pattern effect and said predetermined physical fabric properties.   
     
     
         23 . A process of forming a yarn consisting of dope dyed fibers for production of an apparel fabric of a predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties, said process including the steps of:
 (i) mixing a master batch dye of a requisite colour with a molten polymeric material so as to form a molten polymeric material of said requisite colour;   (ii) extruding said molten polymeric material through a plurality of spinnerets so as to form a plurality of dope dyed fibers of said requisite colour, wherein said spinnerets having a size of approximately 2 to 3 times the requisite size of the fibers from which a yarn is to be formed; and   (iii) winding a plurality of said fibers so as to form a dope dyed yarn for subsequent forming an apparel fabric.   
     
     
         24 . A process according to  claim 23 , wherein the yarn has a denier is in the range of from 45 denier to 200 denier. 
     
     
         25 . A process according to  claim 23 , wherein each yarn consists of a number of fibers in the range of from 40 to 300. 
     
     
         26 . A process according to  claim 23 , wherein each fiber of said yarn has a largest cross sectional diameter in the range of from 0.2 μm to 1.1 μm. 
     
     
         27 .- 34 . (canceled) 
     
     
         35 . A system for forming a multi-ply apparel fabric having predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties from a plurality of yarn having said requisite optical colour and pattern and being formed from a plurality of polymeric dope dyed fibers, said system comprising:
 a knitting assembly for knitting a plurality of yarn so as to form a multi-ply knitted apparel fabric having predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties;   a creel for carrying a plurality of bobbins; and   a plurality of guide members disposed for the guiding n yarn from n bobbins to the knitting assembly for the knitting with m yarn from m bobbins, wherein each guide member guides one or more of the n yarn and one or more of the m yarn to the knitting assembly to form a multi-ply yarn for the knitting by the knitting assembly with another a multi-ply yarn for knitting of the multi-ply yarn with the another multi-ply yarn to form said multi-ply apparel fabric, wherein n and m are integers of two or greater;   wherein upon knitting of said multi-ply yarn to form a multi-ply apparel fabric, said apparel fabric is formed having predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties effect devoid of optically detectable variants in said requisite optical colour and pattern effect; and.   wherein the yarn of n yarn and the yarn of m yarn are selected so as to provide said predetermined optical colour and pattern effect and said predetermined fabric properties.   
     
     
         36 . (canceled) 
     
     
         37 . (canceled) 
     
     
         38 . A multi-ply knitted apparel fabric according to  claim 22 , wherein the first denier (D 1 ) and the further denier (D 2 ) are in the range of from 45 denier to 200 denier. 
     
     
         39 . A multi-ply knitted apparel fabric according to  claim 22 , wherein each yarn of the plurality of n yarn and each yarn of the plurality of m yarn consists of p number of fibers whereby p is in the range of from 40 to 300, and wherein each fiber has a largest cross sectional diameter in the range of from 0.2 μm to 1.1 μm.