Elastic stitched composite fabric using inextensible yarns
The present invention is directed to a stitch-bonded elastic polymeric composite comprising a non-fibrous elastically extensible substrate stitched with a substantially inextensible yarn system. The composite may have an optional fibrous layer stitch-bonded to the non-fibrous substrate either over or under the non-fibrous elastic substrate. The composite preferably has a shrinkage during boil-off of less than about 10%. The stitching yarn network preferably allows stretch beyond the as-stitched dimensions of about 10–100% in at least one direction, and the composite can recover from this stretch to within 5% in at least one direction.
1. A stitch-bonded elastic composite comprising a non-fibrous elastic sheet, stitch-bonded in a substantially unstretched state with substantially inextensible yarns, wherein the composite can elastically recover from 10–100% stretch within 5%, in at least one direction, wherein the stitch-bonded substantially inextensible yarns comprise a stitched yarn network that allows stretch beyond as-stitched dimensions of 10–100%, in at least a machine or transverse direction and the composite has an elastic modulus in the stretch direction of less than about 400 grams per centimeter width per 10% stretch.
2. The stitch-bonded elastic composite of claim 1 , wherein the elastic sheet has a boil-off shrinkage in any direction of less than about 10%.
3. The stitch-bonded elastic composite of claim 1 , wherein the elastic sheet comprises a polyolefin sheet.
4. The stitch-bonded elastic composite of claim 3 , wherein the polyolefin sheet comprises polyethylene or polypropylene.
5. The stitch-bonded elastic composite of claim 3 , wherein the basis weight of the polyolefin sheet is in a range of about 20 grams/m 2 to about 120 grams/m 2 .
6. The stitch-bonded elastic composite of claim 1 , wherein the elastic sheet comprises polyurethane.
7. The stitch-bonded elastic composite of claim 6 , wherein the basis weight of the polyurethane sheet is in a range of about 20 grams/m 2 to about 100 grams/m 2 .
8. The stitch-bonded elastic composite of claim 1 , wherein the elastic sheet is non-continuous.
9. The stitch-bonded elastic composite of claim 8 , wherein the elastic sheet is perforated.
10. The stitch-bonded elastic composite of claim 1 , wherein the stitched yarns comprise hard/nonelastomeric flat or textured yarns.
11. The stitch-bonded elastic composite of claim 1 , wherein the stretch is in the cross direction.
12. The stitch-bonded elastic composite of claim 11 , wherein the stretch is also in the machine direction.
13. The stitch-bonded elastic composite of claim 1 , wherein the stretch is in the machine direction.
14. The stitch-bonded elastic composite of claim 1 , wherein the yarn system comprises Ripple, Atlas, or Tricot pattern.
15. The stitch-bonded elastic composite of claim 1 , wherein the elastic sheet comprises of more than about half of the composite's weight.
16. The stitch-bonded elastic composite of claim 1 , wherein the composite is partially exposed on its technical back.
17. The stitch-bonded elastic composite of claim 1 , wherein the composite is fully covered with yarn overlaps on its technical back.
18. The stitch-bonded elastic composite of claim 1 , wherein the basis weight of the composite is in a range of about 70 to about 350 grams/m 2 .
19. The stitch-bonded elastic composite of claim 1 further comprises a fibrous layer stitch-bonded to the elastic sheet.
20. The stitch-bonded elastic composite of claim 19 , wherein the fibrous layer is on top of the elastic sheet.
21. The stitch-bonded elastic composite of claim 19 , wherein the fibrous layer is on the bottom of the elastic sheet.
22. The stitch-bonded elastic composite of claim 1 , wherein the elastic sheet comprises fillers.
23. The stitch-bonded elastic composite of claim 22 , wherein the fillers comprise fibers, fibrils, dust or powders.
24. The stitch-bonded elastic composite of claim 22 , wherein the fillers comprise glass, metal, carbonaceous or polymeric materials.
25. The stitch-bonded elastic composite of claim 1 , wherein the elastic sheet is capable of shrinking up to about 35% after being heat treated and remains elastic.
26. The stitch-bonded elastic composite of claim 1 being embossed.
27. The stitch-bonded elastic composite of claim 1 being laminated to another layer by melting the elastic sheet.
28. The stitch-bonded elastic composite of claim 27 , wherein the laminate comprises a smooth surface.