COMPOSITE TEXTILE FABRICS
A composite textile fabric that includes a first (face) fabric layer, and a second (back) fabric layer that is formed concurrently with the first fabric layer in a plaited construction. The second fabric includes a plurality of anchored regions at which the second fabric layer is anchored to, and in intimate contact with, the first fabric layer. The second fabric layer also includes a plurality of floating regions, overlying and unattached to the first fabric layer, interspersed between the anchored regions.
1 . A composite textile fabric including:
a first fabric layer;
a second fabric layer formed concurrently with the first fabric layer in a plaited construction,
the second fabric layer comprising:
a plurality of anchored regions at which the second fabric layer is anchored to, and in intimate contact with, the first fabric layer, and
a plurality of floating regions, overlying and unattached to the first fabric layer, interspersed between the anchored regions.
2 . The composite textile fabric of claim 1 , wherein the fabric has a construction selected from the group consisting of: single jersey and double knit.
3 . The composite textile fabric of claim 1 , wherein the first fabric layer comprises a high shrinkage yarn, and the second fabric layer comprises a low shrinkage or no shrinkage yarn.
4 . The composite textile fabric of claim 3 , wherein the high shrinkage yarn responds to application of dry heat.
5 . The composite textile fabric of claim 3 , wherein the high shrinkage yarn responds to application of wet heat.
6 . The composite textile fabric of claim 3 , wherein the high shrinkage yarn comprises an elastomeric material.
7 . The composite textile fabric of claim 3 , wherein the high shrinkage yarn is in a size range of about 50 denier to about 150 denier.
8 . The composite textile fabric of claim 3 , wherein the low shrinkage or no shrinkage yarn is in a size range of about 50 denier to about 300 denier.
9 . The composite textile fabric of claim 3 , wherein the high shrinkage yarn is a textured yarn or a spun yarn.
10 . The composite textile fabric of claim 3 , wherein the low shrinkage or no shrinkage yarn is selected from the group consisting of: textured filament yarn, flat filament yarn, and spun yarn.
11 . The composite textile fabric of claim 3 , wherein the high shrinkage yarn is finer than the low shrinkage or no shrinkage yarn.
12 . The composite textile fabric of claim 1 , wherein yarn forming the first fabric layer is finer than yarn forming the second fabric layer.
13 . The composite textile fabric of claim 1 , wherein yarn forming the second fabric layer is finer than yarn forming the first fabric layer.
14 . The composite textile fabric of claim 1 , wherein yarn forming the second fabric layer and yarn forming the first fabric layer have substantially the same fineness.
15 . The composite textile fabric of claim 1 , wherein yarn forming the first fabric layer is in a size range of about 50 denier to about 150 denier, and wherein yarn forming the second fabric layer is in a size range of about 50 denier to about 300 denier.
16 . The composite textile fabric of claim 1 , wherein the first fabric layer comprises elastomeric yarn.
17 . The composite textile fabric of claim 15 , wherein the second fabric layer comprises a low stretch or no stretch yarn.
18 . The composite textile fabric of claim 15 , wherein the first fabric layer and/or the second fabric layer comprises flame retardant yarns and/or fibers.
19 . A method of forming a composite fabric article, the method comprising:
combining high shrinkage yarn and low shrinkage or no shrinkage yarn to form a fabric body having a plaited construction, the high shrinkage yarn forming a first fabric layer of the fabric body and the low shrinkage or no shrinkage yarn forming a second fabric layer of the fabric body, the second fabric layer comprising:
a plurality of anchored regions at which the second fabric layer is anchored to, and in intimate contact with, the first fabric layer, and
a plurality of floating regions, overlying and unattached to the first fabric layer, interspersed between the anchored regions; and
exposing the fabric body to heating sufficient to cause the first fabric layer to shrink relative to the second fabric layer such that the floating regions separate from the first fabric layer.
20 . The method of claim 19 , comprising exposing the fabric body to dry heat.
21 . The method of claim 19 , comprising exposing the fabric body to wet heat.
22 . The method of claim 19 , comprising exposing the fabric body to hot water.
23 . The method of claim 19 , comprising exposing the fabric body to heating for about 0.5 minutes to about 60 minutes at about 200° F. to about 450° F.
24 . The method of claim 19 , wherein the high shrinkage yarn comprises an elastomeric material.
25 . The method of claim 19 , wherein the high shrinkage yarn is finer than the low shrinkage or no shrinkage yarn.
26 . The composite textile fabric of claim 19 , wherein the low shrinkage or no shrinkage yarn is finer than the high shrinkage yarn.
27 . The composite textile fabric of claim 19 , wherein the high shrinkage yarn and the low shrinkage or no shrinkage yarn have substantially the same fineness.
28 . The method of claim 19 , wherein the high shrinkage yarn is in a size range of about 50 denier to about 150 denier, and wherein the low shrinkage or no shrinkage yarn is in a size range of about 50 denier to about 300 denier.
29 . The method of claim 19 , wherein the high shrinkage yarn is a textured yarn or a spun yarn.
30 . The method of claim 19 , wherein the low shrinkage or no shrinkage yarn is selected from the group consisting of: textured filament yarn, flat filament yarn, and spun yarn.
31 . A fabric garment comprising:
a composite textile fabric including a first fabric layer and a second fabric layer formed concurrently with the first fabric layer in a plaited construction, the second fabric layer comprising:
a plurality of anchored regions at which the second fabric layer is anchored to, and in intimate contact with, the first fabric layer, and
a plurality of floating regions, overlying and unattached to the first fabric layer, interspersed between the anchored regions,
wherein the second fabric layer defines an inner surface of the fabric garment, the plurality of floating regions together with the plurality of anchored regions defining air gaps between a wearer's skin and the first fabric layer.
32 . The fabric garment of claim 31 , wherein the plurality of anchored regions and the plurality of floating regions are arranged in one or more discrete regions of the second fabric layer, and wherein the second fabric layer further comprises one or more other discrete regions having a plain plaited construction.
33 . The fabric garment of claim 32 , wherein the plurality of floating regions are arranged in a pattern corresponding to one or more discrete regions of the wearer's body.
34 . The fabric garment of claim 32 , wherein the plain plaited construction has a jacquard pattern.
35 . The fabric garment of claim 31 , wherein the plurality of floating regions include floating regions of contrasting size.
36 . The fabric garment of claim 31 , wherein the plurality of floating regions are arranged in patterns of contrasting density.
37 . The fabric garment of claim 31 , wherein the first fabric layer comprises a high shrinkage yarn, and the second fabric layer comprises a low shrinkage or no shrinkage yarn.
38 . The fabric garment of claim 37 , wherein the high shrinkage yarn responds to application of dry heat.
39 . The fabric garment of claim 37 , wherein the high shrinkage yarn responds to application of wet heat.
40 . The fabric garment of claim 37 , wherein the high shrinkage yarn comprises an elastomeric material.
41 . The fabric garment of claim 37 , wherein the high shrinkage yarn is finer than the low shrinkage or no shrinkage yarn.
42 . The composite textile fabric of claim 37 , wherein low shrinkage or no shrinkage yarn is finer than the high shrinkage yarn.
43 . The composite textile fabric of claim 37 , wherein the high shrinkage yarn and the low shrinkage or no shrinkage yarn have substantially the same fineness.
44 . The fabric garment of claim 37 , wherein the high shrinkage yarn is in a size range of about 50 denier to about 150 denier, and wherein the low shrinkage or no shrinkage yarn is in a size range of about 50 denier to about 300 denier.
45 . The fabric garment of claim 37 , wherein the high shrinkage yarn is a textured yarn or a spun yarn.
46 . The fabric garment of claim 37 , wherein the low shrinkage or no shrinkage yarn is selected from the group consisting of: textured filament yarn, flat filament yarn, and spun yarn.
47 . The fabric garment of claim 31 , wherein yarn forming the first fabric layer is finer than yarn forming the second fabric layer.
48 . The composite textile fabric of claim 31 , wherein yarn forming the second fabric layer is finer than yarn forming the first fabric layer.
49 . The composite textile fabric of claim 31 , wherein yarn forming the second fabric layer and yarn forming the first fabric layer have substantially the same fineness.
50 . The fabric garment of claim 31 , wherein yarn forming the first fabric layer is in a size range of about 50 denier to about 150 denier, and wherein yarn forming the second fabric layer is in a size range of about 50 denier to about 300 denier.
51 . The fabric garment of claim 31 , wherein the first fabric layer comprises elastomeric yarn.
52 . The fabric garment of claim 51 , wherein the second fabric layer comprises a low stretch or no stretch yarn.
53 . The fabric garment of claim 31 , wherein the fabric garment has a seamless construction.
54 . The fabric garment of claim 31 , and wherein the first fabric layer and/or the second fabric layer comprises flame retardant yarns and/or fibers.