Preparation of engineered fabrics with superior absorption properties

Abstract

This disclosure relates generally to the preparation of eco-friendly engineered fabric, and more particularly to terry fabric and variations thereof. In one embodiment, a terry fabric is comprised of a soluble fiber blend, blended with cotton fibers, where the soluble fibers are dissolved in a caustic or enzyme solution to create highly porous yarns.

What is claimed is: 
     
         1 . A method of creating a sustainable engineered fabric comprising:
 a. creating an engineered yarn with primary and soluble fibers;   b. dissolving the soluble fibers during yarn dyeing with a process involving a wetting agent, hydrogen peroxide, alkali and/ or enzyme or combination thereof, peroxide stabilizer, lubricant, core alkali neutralizer/buffer, a leveling agent and dye; and   c. weaving the engineered yarn into fabric.   
     
     
         2 . The method of  claim 1 , wherein the primary fibers comprise one or more of cotton, linen, hemp, kapok, nettle, bamboo, lyocell, viscose, polyester (sustainable or recycled), PLA, PBT, nylon, acrylic, etc., and suitable combinations thereof. 
     
     
         3 . The method of  claim 1 , wherein the soluble fibers comprise one or more of wool, or silk, or a combination thereof. 
     
     
         4 . The method of  claim 1 , wherein the primary fibers comprise cotton. 
     
     
         5 . The method of  claim 1 , wherein the soluble fibers comprise recycled wool, virgin wool, or a combination thereof. 
     
     
         6 . The method of  claim 1 , wherein the soluble fibers comprise recycled silk, virgin silk, or a combination thereof. 
     
     
         7 . The method of  claim 1 , wherein the primary fibers comprise cotton and the soluble fibers comprise virgin or recycled wool or combination thereof. 
     
     
         8 . The method of  claim 1 , wherein the primary fibers comprise cotton and the soluble fibers comprise virgin or recycled silk or combination thereof. 
     
     
         9 . The method of  claim 1 , wherein the primary fiber is cotton, and the soluble fiber is virgin wool or virgin silk or recycled wool or recycled silk or combination thereof. 
     
     
         10 . The method of  claim 1 , wherein the soluble fibers are dissolved during yarn dyeing process. 
     
     
         11 . The method of  claim 1 , wherein the wetting agent is an-ionic or non-ionic wetting agent. 
     
     
         12 . The method of  claim 1 , wherein the desizing agent is a group of enzymes. 
     
     
         13 . The method of  claim 1 , wherein the hydrogen peroxide stabilizer is anionic in nature. 
     
     
         14 . The method of  claim 1 , wherein the lubricant is cryptanionic in nature. 
     
     
         15 . The method of  claim 1 , wherein the core alkali neutralizer/buffer is anionic in nature. 
     
     
         16 . The method of  claim 1 , wherein the leveling agent is anionic in nature. 
     
     
         17 . A method of creating an engineered fabric comprising:
 a. creating a yarn with primary and soluble fibers wherein the soluble fibers are comprised of wool and/or silk fibers;   b. weaving the yarn into a fabric;   c. dissolving the soluble fibers using a process involving a wetting agent, desizing agent, hydrogen peroxide, alkali and/ or enzyme or combination thereof, peroxide stabilizer, lubricant, core alkali neutralizer/buffer, and a leveling agent; and 
. 
     
     
         18 . An engineered fabric as described in  claim 17 , wherein the primary fiber includes cotton, linen, hemp, kapok, nettle, bamboo, lyocell, viscose, polyester (sustainable or recycled), PLA, PBT, nylon, acrylic, etc., and suitable combinations thereof. 
     
     
         19 . An engineered fabric as claimed in  claim 17 , wherein the primary fiber is cotton, and the soluble fiber is virgin or recycled wool or combination thereof. 
     
     
         20 . An engineered fabric as claimed in  claim 17 , wherein the primary fiber is cotton, and the soluble fiber is virgin or recycled silk or combination thereof. 
     
     
         21 . An engineered fabric as claimed in  claim 17 , wherein the primary fiber is cotton, and the soluble fiber is virgin wool or virgin silk or recycled wool or recycled silk or combination thereof. 
     
     
         22 . An engineered fabric as claimed in  claim 17 , wherein the fabric may undergo plasma treatment. 
     
     
         23 . The method of  claim 17 , wherein the wetting agent is an-ionic or non-ionic wetting agent. 
     
     
         24 . The method of  claim 17 , wherein the desizing agent is a group of enzymes. 
     
     
         25 . The method of  claim 17 , wherein the hydrogen peroxide stabilizer is anionic in nature. 
     
     
         26 . The method of  claim 17 , wherein the lubricant is cryptanionic in nature. 
     
     
         27 . The method of  claim 17 , wherein the core alkali neutralizer/buffer is anionic in nature. 
     
     
         28 . The method of  claim 17 , wherein the leveling agent is anionic in nature. 
     
     
         29 . The method of  claim 17 , wherein after the soluble fibers are dissolved during yarn dyeing process.