Ultra soft fabric and process of manufacturing same

Abstract

An ultra-soft fabric and a process of manufacturing the ultra-soft fabric is described. The ultra-soft fabric is made from polyester staple fiber and high-tenacity, man-made cellulosic staple fiber, and fabrics made therefrom, and has particular reference to fabrics having a high resistance to wear while retaining a high comfort level. Another embodiment improves the durability of the ultra-soft fabric.

What is claimed is: 
     
         1 . A textile fabric, comprising:
 one or more cellulose fiber warp yarns between 100 and 235 ends per inch; and   one or more multi-filament polyester weft yarns between 60 and 1300 picks per inch;   wherein the picks are woven into the fabric in groups of at least one multi filament polyester weft yarns running parallel to each other;   
     
     
         2 . The textile fabric according to  claim 1 , wherein the multi-filament polyester weft yarns are wounded extensively parallel to one another and extensively adjacent to one another on a multi pick yarn package to enable simultaneous inserting of the multi-filament polyester weft yarns a single pick insertion event of a pick insertion apparatus of a loom apparatus. 
     
     
         3 . The textile fabric according to  claim 1 , wherein number of the multi-filament polyester weft yarns conveyed by the pick insertion apparatus through a set o warp yarns in the single pick insertion event of the pick insertion apparatus of the loom apparatus is between two and eight. 
     
     
         4 . The textile fabric according to  claim 1 , wherein the multi-filament polyester weft yarns are wound on the multi pick yarn package at an angle of between 15 and 20 degrees to enable the simultaneous inserting of the multi filament polyester weft yarns during the single pick insertion event of the pick insertion apparatus of the loom apparatus. 
     
     
         5 . The textile fabric according to  claim 1 , wherein the multi-filament polyester weft yarns are wound on the multi pick yarn package at a type a shore hardness of between 65 to 70 to enable the simultaneous inserting of the multi filament polyester weft yarns during the single pick insertion event of the pick insertion apparatus of the loom apparatus. 
     
     
         6 . The textile fabric according to  claim 1 , wherein the cellulose fiber includes staple fiber selected from the group consisting of lyocell, modal and combinations thereof. 
     
     
         7 . The textile fabric according to  claim 1 , wherein the multi filament polyester fiber includes fiber selected from the group consisting of nylon, cotton, rayon, acetate, triacetate, wool, silk, linen, flax, polyamide, polyacrylonitrile, polypropylene, aromatic polyamide, renewable cellulose fiber, natural or artificial staple fiber and combinations thereof. 
     
     
         8 . The textile fabric according to  claim 1 , wherein the fabric is woven. 
     
     
         9 . The textile fabric according to  claim 1 , wherein the lyocell yarns have a warp count between 30 s and 120 s. 
     
     
         10 . The textile fabric according to  claim 1 , wherein the ends per inch is between 100 and 235 with cellulose warp yarn and picks per inch is between 60 and 1300 with multi-filament polyester filament yarn. 
     
     
         11 . The textile fabric according to  claim 1 , wherein total thread count per square inch is between 200 and 1400. 
     
     
         12 . The textile fabric according to  claim 1 , wherein the multi filament polyester yarns can be intermingled or separable filament yarn or roto yarn. 
     
     
         13 . The textile fabric according to  claim 1 , wherein the multi filament polyester yarns contain 10 to 30 filaments each. 
     
     
         14 . The textile fabric according to  claim 1 , wherein the content of lyocellis between 40% and 80%. 
     
     
         15 . The textile fabric according to  claim 1 , wherein the content of polyester is between 20% and 60%. 
     
     
         16 . The textile fabric according to  claim 1 , wherein the yarn surface hardness is above 70. 
     
     
         17 . The fabric according to  claim 1 , wherein the textile fabric weave of selected from the group consisting of 1/1, 2/1, 3/1, 4/1 and combinations thereof. 
     
     
         18 . The textile fabric according to  claim 1 , wherein the textile fabric is bed linen. 
     
     
         19 . A process of manufacturing a textile fabric, comprising the steps of:
 selecting one or more yarns;   mixing the yarns with different parameters at pre-determined percentage;   parallelizing the yarns for uniform mixing;   processing the yarns for critical percentage of parallization;   drafting and spinning using compact technology;   winding on cones with one or more cone hardness;   warping and sizing the yarns with one or more chemical recipes;   weaving the yarns with lyocell warp and polyester weft yarn;   processing the textile fabric with a e-control technology; and   finishing the fabric to achieve dimensional stability.   
     
     
         20 . The process for manufacturing an textile fabric according to  claim 19 , wherein the yarn is selected from the group consisting of polyester (PE), polyethylene terephthalate (PET), polyamide (nylon, polyamide 6, polyamide 66), polypropylene, polyacrylonitrile, lyocell and combinations thereof. 
     
     
         21 . The process according to  claim 19 , wherein the weaving step is performed by a mechanism selected from the group consisting of a projectile loom, air jet loom, rapier loom, water jet loom and combinations thereof.