Fabric with Moisture Management Function

Abstract

A knitted or woven fabric with moisture management function is described that includes an inner layer having a first yarn that is semi-hydrophilic with a first moisture regain, and an outer layer having a second yarn that is hydrophilic with a second moisture regain greater than the first moisture regain of the first yarn. The fabric has a moisture regain gradient between the inner layer and the outer layer that acts to pull moisture through the inner layer in contact with the wearer’s skin and out through the outer layer. In one embodiment, the second yarn is a combination of a core bi-component yarn and at least one outer sheath yarn surrounding the core bi-component yarn.

1 . A fabric with moisture management function comprising:
 an inner layer comprising a first yarn forming the inner layer, the first yarn being semi-hydrophilic with a first moisture regain;   an outer layer comprising a second yarn forming the outer layer, the second yarn being hydrophilic with a second moisture regain;   the second moisture regain of the second yarn is greater than the first moisture regain of the first yarn so as to generate a moisture regain gradient between the inner layer and the outer layer;   wherein the moisture regain gradient between the inner layer and the outer layer acts to pull moisture through the inner layer and push the moisture out through the outer layer; and   wherein the second yarn is a combination of a core bi-component yarn and at least one outer sheath yarn surrounding the core bi-component yarn.   
     
     
         2 . The fabric according to  claim 1 , wherein the at least one outer sheath yarn is spun, wrapped, or twisted around the core bi-component yarn and extends along a length of the core bi-component yarn. 
     
     
         3 . The fabric according to  claim 1 , wherein the core bi-component yarn comprises a synthetic filament and the at least one outer sheath yarn comprises a natural staple yarn. 
     
     
         4 . The fabric according to  claim 3 , wherein the synthetic filament is made of a material that includes acrylic, nylon, polyester, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and/or any blend combination thereof; and
 wherein the natural staple yarn is made of a material that includes cotton, modal, acetate, silk, wool, lyocell, protein fibers, regenerated cellulosic fibers, and/or any blend combination thereof.   
     
     
         5 . The fabric according to  claim 1 , wherein the at least one outer sheath yarn comprises a synthetic filament or staple. 
     
     
         6 . The fabric according to  claim 5 , wherein the synthetic filament is made of a material that includes acrylic, nylon, polyester, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and/or any blend combination thereof. 
     
     
         7 . The fabric according to  claim 1 , wherein the at least one outer sheath yarn comprises two natural staple yarns. 
     
     
         8 . The fabric according to  claim 1 , wherein the fabric is dyed with indigo. 
     
     
         9 . The fabric according to  claim 1 , wherein the second yarn is dyed with indigo. 
     
     
         10 . The fabric according to  claim 1 , wherein the at least one outer sheath yarn is pre-dyed with indigo. 
     
     
         11 . The fabric according to  claim 1 , wherein the first moisture regain of the inner layer is in the range of 0.2% - 6%, the second moisture regain of the outer layer is in the range of 4% - 16%, and the moisture regain gradient is greater than 3%. 
     
     
         12 . The fabric according to  claim 8 , wherein the moisture regain gradient is between 3% to 15%. 
     
     
         13 . A fabric with moisture management function comprising:
 an inner layer comprising at least a first yarn forming the inner layer, the first yarn being semi-hydrophilic with a first moisture regain;   an outer layer comprising at least a second yarn forming the outer layer, the second yarn being hydrophilic with a second moisture regain;   the second moisture regain of the second yarn is greater than the first moisture regain of the first yarn so as to generate a moisture regain gradient between the inner layer and the outer layer;   wherein the moisture regain gradient between the inner layer and the outer layer acts to pull moisture through the inner layer and push the moisture out through the outer layer; and   wherein the outer layer includes a combination of a core bi-component yarn and at least one outer sheath yarn surrounding the core bi-component yarn.   
     
     
         14 . The fabric according to  claim 13 , wherein the combined core bi-component with at least one outer sheath yarn is joined with the second yarn forming the outer layer. 
     
     
         15 . The fabric according to  claim 13 , wherein the fabric is a weft or warp knitted fabric or a woven fabric. 
     
     
         16 . The fabric according to  claim 15 , wherein the fabric is knitted from a single jersey plaited construction, a double jersey plaited construction, a tricot or warp knit construction. 
     
     
         17 . The fabric according to  claim 13 , wherein the combined core bi-component with at least one outer sheath yarn is formed by a single or double spinning process or a vortex spinning process. 
     
     
         18 . The fabric according to  claim 13 , wherein at least one of the inner layer or the outer layer has a fabric wash or mechanical finish applied. 
     
     
         19 . The fabric according to  claim 13 , wherein the inner layer further comprises a third yarn joined together with the first yarn and the outer layer further comprises a fourth yarn joined together with the second yarn; and
 wherein the combined core bi-component with at least one outer sheath yarn comprises the fourth yarn.   
     
     
         20 . The fabric according to  claim 19 , wherein the inner layer is a composite blend of a synthetic polymer plaited with an elastane. 
     
     
         21 . The fabric according to  claim 19 , wherein the outer fabric layer is a composite blend of a natural fiber plaited with an elastane or a blend of natural fiber and synthetic fiber. 
     
     
         22 . An article of apparel comprising a fabric with moisture management function, the fabric including:
 an inner layer of the article of apparel comprising at least a first yarn forming the inner layer, the first yarn being semi-hydrophilic with a first moisture regain;   an outer layer of the article of apparel comprising at least a second yarn forming the outer layer, the second yarn being hydrophilic with a second moisture regain;   the second moisture regain of the second yarn is greater than the first moisture regain of the first yarn so as to generate a moisture regain gradient between the inner layer and the outer layer;   wherein the moisture regain gradient between the inner layer and the outer layer acts to pull moisture through the inner layer and push the moisture out through the outer layer; and   wherein the outer layer includes a combination of a core bi-component yarn and at least one outer sheath yarn surrounding the core bi-component yarn.