Stretch circular knit fabrics containing elastomeric fiber and polyester bi-component filament, garments made therefrom and a method of making same

Abstract

Stretch circular knit fabric (40, 82, 94) containing two sets of different elastic fiber (12, 18) and optionally hard yarn (14) and methods for their production are provided.

1 . A stretch circular knit fabric comprising elastomeric fiber and polyester bi-component filament. 
     
     
         2 . The fabric of  claim 1  wherein the elastomeric fiber comprises a bare elastomeric yarn. 
     
     
         3 . The fabric of  claim 1  wherein elastomeric fiber comprises spandex. 
     
     
         4 . The fabric of  claim 3  wherein the spandex comprises bare spandex yarn with a count from 11 to 560 dtex. 
     
     
         5 . The fabric of  claim 1  wherein the elastomeric fiber has a denier between 10 denier and 450 denier. 
     
     
         6 . The fabric of  claim 1  wherein the polyester bi-component filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination thereof. 
     
     
         7 . The fabric of  claim 1  wherein the polyester bi-component filament has a count from 15 dtex to 900 Dtex. 
     
     
         8 .- 10 . (canceled) 
     
     
         11 . The fabric of  claim 1  further comprising a hard fiber. 
     
     
         12 . The fabric of  claim 7  wherein the hard fiber yarn has a count from 10 to 900 dtex. 
     
     
         13 . The fabric of  claim 7  wherein the hard yarn is selected from the group consisting of wool, linen, silk, polyester, nylon, olefin, cotton, and combinations thereof. 
     
     
         14 . The fabric of  claim 7  wherein the hard yarn is textured polyester filament. 
     
     
         15 .- 26 . (canceled) 
     
     
         27 . The fabric of  claim 1  wherein the elastomeric fiber and polyester bi-component filament are combined together through a pre-covered yarn process before knitting. 
     
     
         28 . The fabric of  claim 1  having a weight between 100 grams/meter2 and 600 grams/meter2. 
     
     
         29 . A garment prepared from the fabric of  claim 1 . 
     
     
         30 . The garment of  claim 29  which is selected from the group consisting of sport wears, active wear, swimming wear, bras, underwear, intimate wear, leggings, outwear and shoe fabrics. 
     
     
         31 . A method for making a circular knit fabric, said method comprising knitting together at least one elastomeric fiber and at least one polyester bi-component filament into a circular knit fabric. 
     
     
         32 . The method of  claim 31  wherein the elastomeric fiber comprises a bare elastomeric yarn. 
     
     
         33 . The method of  claim 31  wherein elastomeric fiber comprises spandex. 
     
     
         34 . The method of  claim 33  wherein the spandex comprises bare spandex yarn with a count from 11 to 560 dtex. 
     
     
         35 . The method of  claim 31  wherein the elastomeric fiber has a denier between 10 denier and 450 denier. 
     
     
         36 . The method of  claim 31  wherein the polyester bi-component filament comprises poly(trimethylene terephthalate) and at least one polymer selected from the group consisting of poly(ethylene terephthalate), poly(trimethylene terephthalate), and poly(tetramethylene terephthalate) or a combination thereof. 
     
     
         37 . The method of  claim 31  wherein the polyester bi-component filament has a count from 15 dtex to 900 Dtex. 
     
     
         38 . The method of  claim 31  wherein the polyester bi-component filament has a denier of from about 10 to about 450. 
     
     
         39 . The method of  claim 31  wherein the elastomeric fiber weight is about 3% or higher of total fabric weight, the polyester bi-component filament weight is about 5% or higher of total fabric weight; and fabric stretch level is at least 15% or higher in both wales and course direction. 
     
     
         40 . The method of  claim 31  wherein the fabric comprises 100% elastic yarns. 
     
     
         41 . The method of  claim 31  further comprising knitting a hard fiber into the circular knit fabric. 
     
     
         42 . The method of  claim 41  wherein the hard fiber yarn has a count from 10 to 900 dtex. 
     
     
         43 . The method of  claim 41  wherein the hard yarn is selected from the group consisting of wool, linen, silk, polyester, nylon, olefin, cotton, and combinations thereof. 
     
     
         44 . The method of  claim 41  wherein the hard yarn is textured polyester filament. 
     
     
         45 . The method of  claim 41  wherein the hard yarn is cotton spun yarn. 
     
     
         46 .- 47 . (canceled)