Multi-directional elastic woven fabric

Abstract

This disclosure relates to techniques for designing and manufacturing an elastic fabric, and fabric manufactures therefrom. An example method includes (i) determining a density ratio of the elastic fabric based on a set of rules; (ii) determining a weft density of a weft yarn of the elastic fabric based on the set of rules and the density ratio; (iii) determining a warp density of a warp yarn of the elastic fabric based on the density ratio, the weft density, and the set of rules; (iv) forming warp yarns of the elastic fabric based on the warp density; and (v) forming weft yarns of the elastic fabric based on the weft density. Example multi-directional elastic woven fabrics may have a density ratio of the elastic fabric from a range of 1.1 to 2.625, depending on the weaving pattern and a set of rules disclosed here.

What is claimed is: 
     
         1 . A fabric, comprising:
 a warp yarn in a first direction; and   a weft yarn in a second direction perpendicular to the first direction,   
       wherein:
 both the warp yarn and the weft yarn include elastic fibers; 
 the elastic fibers have a linear density of 10D to 300D; 
 the warp yarn has a warp density of 110 to 210 counts per inch; and 
 the weft yarn has a weft density of 80 to 100 counts per inch. 
 
     
     
         2 . The fabric of  claim 1 , wherein the elastic fabric has a density ratio determined based on the warp density and the weft density. 
     
     
         3 . The fabric of  claim 1 , wherein the density ratio has a range from 1.1 to 2.625, the density ratio being a ratio of the warp density to the weft density. 
     
     
         4 . The fabric of  claim 1 , wherein the elastic fabric has a stretch attribute of 10% to 50%. 
     
     
         5 . The fabric of  claim 1 , wherein the elastic fabric has a growth attribute of 1% to 10%. 
     
     
         6 . The fabric of  claim 1 , wherein the elastic fabric has a recovery attribute of 40% to 99%. 
     
     
         7 . The fabric of  claim 1 , wherein the elastic fibers contribute 1% to 20% by weight of the fabric. 
     
     
         8 . The fabric of  claim 1 , wherein the fabric includes a poplin pattern. 
     
     
         9 . The fabric of  claim 1 , wherein the warp yarn and the weft yarn each include a secondary fiber. 
     
     
         10 . The fabric of  claim 9 , wherein the secondary fiber includes a natural fiber. 
     
     
         11 . The fabric of  claim 9 , wherein the secondary fiber includes an artificial fiber. 
     
     
         12 . The fabric of  claim 1 , wherein the elastic fibers include a polyurethane-based fiber. 
     
     
         13 . The fabric of  claim 1 , wherein the warp yarns and the weft yarns are single-ply yarns with a count number of Ne10 to Ne100. 
     
     
         14 . The fabric of  claim 1 , wherein the warp yarns and the weft yarns are two-ply yarns with a count number of Ne20/2 to Ne160/2. 
     
     
         15 . A method of manufacturing an elastic fabric, comprising:
 determining a density ratio of the elastic fabric based on a set of rules, wherein the density ratio has a range from 1.1 to 2.625, the density ratio being a ratio of a warp density to a weft density;   determining the weft density of a weft yarn of the elastic fabric based on the set of rules and the density ratio;   determining the warp density of a warp yarn of the elastic fabric based on the density ratio, the weft density, and the set of rules; and   forming warp yarns of the elastic fabric based on the warp density; and   forming weft yarns of the elastic fabric based on the weft density.   
     
     
         16 . The method of  claim 15 , further comprising selecting the warp density from a range of 110 to 210 counts per inch. 
     
     
         17 . The method of  claim 15 , further comprising selecting the weft density from a range of 80 to 100 counts per inch. 
     
     
         18 . The method of  claim 15 , wherein selecting a density ratio of the elastic fabric is further based on a weaving pattern. 
     
     
         19 . The method of  claim 18 , wherein the weaving pattern is a poplin pattern, and wherein the warp yarn has a warp specification of 60c+30D, and wherein the weft yarn has a weft specification of 60c+30D, and wherein the warp density is 154 counts per inch, and wherein the weft density is 84 counts per inch. 
     
     
         20 . A manufacturing system having one or more pieces of machinery for manufacturing an elastic fabric, the system configured to perform steps comprising:
 receiving an input about a weaving pattern;   determining a density ratio of the elastic fabric based on a set of rules and the received weaving pattern, wherein the density ratio has a range from 1.1 to 2.625, the density ratio being a ratio of a warp density to a weft density;   determining the weft density of a weft yarn of the elastic fabric based on the set of rules and the density ratio;   determining the warp density of a warp yarn of the elastic fabric based on the density ratio, the weft density, and the set of rules; and   forming warp yarns of the elastic fabric based on the warp density; and   forming weft yarns of the elastic fabric based on the weft density.