Description:TECHNICAL FIELD
The present disclosure relates to the field of the textile industry. More particularly, the present disclosure relates to A method of producing a high-performance fabric.
BACKGROUND
In the realm of sportswear, casual/active wear, and leggings, there is a notable challenge concerning moisture management and comfort in textile materials. Traditional polyester fabrics, often combined with Polyurethane fibers, struggle to effectively absorb moisture due to their lack of hydrophilic properties. This limitation hampers their suitability for sportswear and outerwear where moisture control is essential.
Existing solutions have attempted to enhance fabric wicking and comfort. One approach involves treating fabrics with hydrophilic softeners, significantly improving their moisture-wicking capabilities. Another method incorporates spandex into the fabric, granting it superior elongation and elongation recovery properties, making it ideal for stretchy garments. However, challenges persist with these solutions. The addition of spandex can lead to difficulties in dyeing, as spandex does not readily absorb dye particles, potentially affecting the fabric's color quality. Furthermore, using hydrophilic softeners may reduce a fabric's overall lifespan, particularly concerning tensile strength. Additionally, existing solutions have not adequately addressed considerations regarding the aerodynamics of the fabric, potentially impacting the comfort and performance of textiles in active wear and sportswear applications, where aerodynamic efficiency is crucial. Therefore, there is a need for method that overcomes these drawbacks, by preparing a fabric with effective moisture-wicking and wetting characteristics, coupled with resistance to chlorine, ease of dyeing, and the ability to facilitate air passage through it.
SUMMARY
In one aspect of the present disclosure, a method of producing a high-performance fabric is provided.
The method of producing a high-performance fabric includes rewinding yarn with a specific denier of 81D/Tex, which is then used in the Tricot warp knitting process to create the fabric. To ensure fabric quality and stability, a heat treatment within a temperature range of 215°C to 235°C is applied. Subsequently, the fabric is dyed using a High-Temperature High-Pressure process, involving dye bath immersion and heat application, optionally preceded by pre-treatment steps. The dyeing process maintains a temperature between 100°C and 135°C for 50-70 minutes to enhance dye absorption.
Furthermore, the method employs cooling the fabric to 70°C - 85°C and washing at the same temperature range for 10-20 minutes, followed by an acetic wash. Finally, the fabric is segregated for use in Activewear apparel.
In some aspect of the present disclosure may includes using yarn cones weighing 15 grams, improved workability and yarn tension management during warp knitting, heat treatment to prevent excessive shrinkage or stretching, dye bath temperature variations based on room temperature, inherent moisture-wicking properties promoting wearer comfort, quick-drying characteristics resulting from the tricot warp knit construction and moisture management, and fabric exhibiting inherent elongation properties for comfortable wear. This method represents an innovative and efficient approach to producing high-performance Activewear fabric with a range of desirable attributes.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawing,
Figure 1 illustrates a flowchart that depicts a method of producing a high-performance fabric, in accordance with an aspect of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. Thus, the following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, known details are not described in order to avoid obscuring the description.
References to one or an embodiment in the present disclosure can be references to the same embodiment or any embodiment; and, such references mean at least one of the embodiments.
Reference to "one embodiment", "an embodiment", “one aspect”, “some aspects”, “an aspect” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others.
The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Alternative language and synonyms may be used for any one or more of the terms discussed herein, and no special significance should be placed upon whether or not a term is elaborated or discussed herein. In some cases, synonyms for certain terms are provided.
A recital of one or more synonyms does not exclude the use of other synonyms.
The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and is not intended to further limit the scope and meaning of the disclosure or of any example term. Likewise, the disclosure is not limited to various embodiments given in this specification. Without intent to limit the scope of the disclosure, examples of instruments, apparatus, methods and their related results according to the embodiments of the present disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Unless otherwise defined, technical and scientific terms used herein have the meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions will control.
Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims, or can be learned by the practice of the principles set forth herein.
As mentioned before, there is a need for fabric with effective moisture-wicking and wetting characteristics, coupled with resistance to chlorine, ease of dyeing, and the ability to facilitate air passage through
Figure 1 illustrates a method (100) of producing a high-performance fabric, the process commences with yarn rewinding, specifically yarn with a denier of 81D/Tex. This crucial step ensures the yarn is suitably prepared for subsequent fabric production.
Next, the fabric is created using the Tricot warp knitting process, known for its capability to craft durable and flexible fabrics, ideally suited for athletic and active wear.
Following fabric production, it becomes imperative to stabilize the fabric's dimensions. Achieving this stability is accomplished through heat treatment, meticulously regulated within a temperature range typically spanning from 215°C to 235°C. The heat treatment process plays a pivotal role in setting the fabric's dimensions and enhancing its overall stability.
Subsequently, the fabric undergoes dyeing to attain the desired color and aesthetic qualities. High-Temperature High-Pressure (HTHP) dyeing is employed, encompassing dye bath immersion and the application of heat. This method ensures the fabric achieves the intended color and appearance.
To complete the dyeing process, a roll of fabric is immersed in a dye bath, and the dyeing temperature is carefully maintained within the precise range of 100°C to 135°C for a specific duration, typically between 50 to 70 minutes. Maintaining these parameters is critical to achieving consistent and vibrant dye results.
Following the dyeing phase, the fabric is cooled by gradually reducing its temperature to a range of 70°C to 85°C. This cooling process is a crucial step in the overall fabric treatment.
Subsequent to cooling, the fabric undergoes a washing procedure. The fabric is washed at a controlled temperature, typically between 70°C to 85°C, for a specified duration, ranging from 10 to 20 minutes. This washing step serves to remove any residual substances and ensures the fabric meets quality standards.
Further acetic wash is performed to further enhance the fabric's properties, contributing to its overall performance and quality.
Finally, the fabric is segregated and directed toward the production of Activewear apparel. The method, in its entirety, encompasses a meticulously planned series of steps to create a high-performance fabric, tailored to meet the specific requirements of Activewear apparel, with a focus on quality, durability, and aesthetic appeal.
In an exemplary scenario, In the realm of sportswear, comfort, flexibility, and moisture management are paramount. Traditional fabrics often struggle to strike the right balance between these essential factors. However, the present disclosure, the innovative fabric changes the game in sweat management, quick-drying, elastic recovery, chlorine resistance, and durability. These features collectively contribute to superior and comfortable performance wear, setting a new standard in athletic apparel.
In some exemplary scenarios, imagine a professional athlete gearing up for an intense training session. They don their sportswear, including garments made from our polyester filament tricot warp knitted fabric. Here's how the present disclosure performs exceptionally:
In some exemplary scenarios, As the athlete begins to exert themselves, our fabric's superior sweat management capabilities come into play. It efficiently wicks away moisture from the skin, keeping the athlete dry and comfortable throughout the workout.
In some exemplary scenarios, the present disclosure method enables fabric sweat and moisture to be rapidly evaporated, preventing discomfort and chafing during extended training sessions.
In some exemplary scenarios, during high-intensity movements and stretches, our fabric exhibits remarkable elastic recovery, providing the athlete with unrestricted mobility and support.
In some exemplary scenarios, for athletes who engage in water sports or pool workouts, chlorine resistance is vital. Our fabric's inherent property of chlorine resistance ensures the longevity and color retention of their sportswear.
In some exemplary scenarios, beyond a single training session, our fabric maintains its quality and performance over time. Its durability makes it an ideal choice for athletes who demand the best from their sportswear.
Advantages:
• The present disclosure provides Efficient moisture wicking for dry comfort.
• The present disclosure provides Rapid drying to prevent discomfort.
• The present disclosure provides Exceptional elastic recovery for mobility.
• The present disclosure provides Inherent chlorine resistance for durability.
• The present disclosure provides Long-lasting performance and quality.
• The present disclosure provides Versatile use across multiple applications.
The implementation set forth in the foregoing description does not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail above, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementation described can be directed to various combinations and sub combinations of the disclosed features and/or combinations and sub combinations of the several further features disclosed above. In addition, the logic flows depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claims.
, C , C , Claims:1. A method (100) for producing a high-performance fabric, comprising:
Rewinding (102) yarn with a denier of 81D/Tex;
Producing (104) a fabric by way of Tricot warp knitting process;
Stabilizing (106) fabric dimensions by way of heat treatment within a temperature range of 215°C to 235°C;
Dyeing (108) the fabric by way of High-Temperature High-Pressure (HTHP) process, including dye bath immersion and heat application, with optional pre-treatment steps;
Immersing (110) role of fabric in a dye bath;
Maintaining (112) dying temperature between the range of 100° – 135° c for a period of 50 -70 minutes;
Cooling (114) fabric by reducing temperature down to a range of 70 - 85°C;
Washing (116) the fabric at a temperature of 70 - 85°C for a period of 10 -20 minutes;
Performing (118) acetic wash; and
Segregating (120) the fabric into Activewear apparel.
2. The method (100) for producing a high-performance fabric as claimed in Claim 1, further comprises a plurality of cones with each cone yarn weights 15 grams.
3. The method (100) for producing a high-performance fabric as claimed in Claim 1, the method improves workability and manages yarn tension during warp knitting.
4. The method (100) for producing a high-performance fabric as claimed in Claim 1, the method provides heat treatment to prevent excessive shrinkage or stretching during subsequent processes
5. The method (100) for producing a high-performance fabric as claimed in Claim 1, the method facilitates dye molecules to be absorbed by the fabric by way of maintaining the temperature of the dye bath at 100 – 135° c.
6. The method (100) for producing a high-performance fabric as claimed in Claim 1, ph may varies based on the room temperature.
7. The method (100) for producing a high-performance fabric as claimed in Claim 1, wherein the inherent moisture-wicking property of the fabric promotes moisture removal from the skin, ensuring wearer comfort.
8. The method (100) for producing a high-performance fabric as claimed in Claim 1, wherein the fabric's quick-drying properties result from the tricot warp knit construction and moisture management, facilitating rapid moisture dispersion and evaporation.
9. The method (100) for producing a high-performance fabric as claimed in Claim 1, wherein the fabric exhibits inherent elongation properties and elongation recovery for comfortable wear.