Fabric construction and method of manufacturing

Abstract

A method of constructing a warp knit fabric is disclosed. The warp knit fabric is constructed using polyester yarn for both the base yarn and the surface yarn. The resulting warp knit fabric is napped on the top side of the fabric to form a fabric that is soft to the touch.

We claim: 
     
         1 . A method of constructing fabric, the method comprising:
 weaving a polyester base yarn and a polyester surface yam using a warp knit process to form a warp knit fabric having a top side and an underside, wherein the top side is napped.   
     
     
         2 . The method of  claim 1 , further comprising napping the underside of the warp knit fabric. 
     
     
         3 . The method of  claim 1 , further comprising heating the warp knit fabric under pressure to about 80° C. and adding one or more dyes. 
     
     
         4 . The method of  claim 3 , further comprising:
 heating the warp knit fabric with the dyes to about 130° C., wherein the warp knit fabric is allowed to absorb the dye for about 30 minutes;   reducing the temperature of the warp knit fabric to about 80° C., wherein the about 80° C. temperature is maintained for about 2 to about 2.5 hours to allow for dye absorption.   
     
     
         5 . The method of  claim 1 , further comprising heating the finished warp knit fabric to about 160° C. after dyeing, moisture removal and napping. 
     
     
         6 . The method of  claim 3  further comprising:
 removing moisture from the fabric after dyeing; 
 adding softeners to the fabric; and 
 heating the warped knit fabric to about 190° C. to about 220° C.