C92C3 Dimensional Stability, Aesthetic and Mechanical Properties of Micro-Fiber Blended Knitted Fabrics PI(s): S.

Rose Matic-Leigh Relevance to NTC Goals: The introduction of polyester finer (so called micro-denier fiber) fibers by the man-made fiber producer for use especially in apparel industry has created tremendous possibilities to achieve improved physical, mechanical, and aesthetic properties of apparel fabrics. It is well known that fiber fineness has profound ~fluence on the physical, mechanical, and aesthetic including dyeing behavior of fibers. However, this relationship 1s strongly affected by the yam structure (both in woven and knitted fabrics) which in turn is dependent on the system of spinning and especially in blended spun yarns. Our limited laboratory studies have shown that the fibers segregate, and this segregation is a function the geometric and mechanical properties of fiber, when spun on ring or open end spinning systems. Due to the development of new knit fabric sttuctures it is the idea to determine the characteristics of the micro-fibers with and without other fibers in the blend. Influence of the micro-fiber properties on the yarn characteristics produced for the knitting purposes. Knitting efficiency, fabric performance and dimensional stability of micro-fiber knit structures. The generation of fundamental knowledgewill,help the knitting industry to go forward and retain primary position in the world competition, which are the basic NTC goals. All the studies reported in the literature including the reports from our laboratories have been carried out on fibers that are no more finer than 1 - 2 denier. Studies on the effect of very fine denier polyester fibers of the order of 0.648 denier range in blends with cotton fibers of equal fineness need to be carried out if a better understanding of the role of yarn structure in influencing the processing dynamics and the physical and aesthetic properties of knitted fabrics is to be obtained. The distribution of fibers will influence the yarn and metal friction during knitting which in turn will affect the limited tension and consequently the machine efficiency and the fabric characteristics. Micro-fibers are opening new possibilities of application for spun and continuous filament yarns in different areas of textile production. This study will be performed to determine the effect of staple yarns fotmed of micro-fibers on knit fabric performance, dimensional stability, mechanical properties, and knitting efficiency. The concept is to use the micro-fiber blends with natural fibers to increase the production speed, lower the twist number, to add strength, improve hand, reduce harshness, achieve superior drape, and produce a stable knit structure.

Objectives: 1. To generate the characteristics of micro-fibers and their blends with natural fibers when spun on ring,openend (rotor), and airjet spinning systems. Genented data will be used for the accurate estimation of yarn properties when produced for knitting purposes. With the regard to the nature of the relationships between fiber and yarn properties, optimal yarns will be used for knitting. To study the function between geometric and mechanical properties of micro-fibers, and their blends, as well as the yarns on knitting efficiency and knit fabric performance. To generate equations capable of accurately predicting influence of yarn characteristics on knit fabric behavior in use. To understand and predict knit fabric characteristics for the known micro-fiber yarns and their blends. Blends with cotton and wool will provide fabrication of knit fabrics with better physical, mechanical and aesthetic properties which include better strength, improved hand, reduced harshness and good drape, and dimensional stability. It is dedicated to solve the problems of knitting manufacturing and achieving stable knit-goods properties.

2.

3.

c92c3, Page 1

National Textde Center Annual Report: September 30,1993

81

4.

To develop a mathematical model and a computer software for predicting the dimensions and characteristics of finished knit fabrics. This part is designed to collect such a data base using appropriate, reliable, and reproducible test methods to derive from it a series of prediction equations which would link the major manufacturing variables: yarn, knitting machine, average loop length, wet processing method for relaxed dimension of the finished micro-fiber knit fabrics. Rheological models will be the base for predicting dimensional behavior and establish parameter for dimensional stability of micro-fiber knits.

Structure Property Relation in Yarns for Knitting: Spun Yarns Made from PES Micro-Fibers and with Blends of Cotton on Ring, Rotor, and Airjet Systems The micro-fibers for yarn production were received from Du Pont Different micromattique fibers were used to produce 100% microfiber yarns, as well as blends of polyester microfibers and cotton. Several groups of microfibers were used to produce different types of yarns. Mechanical Properties of Knit Fabrics Using Ring Spun Yarns Several ring spun yarns were used to establish regression equations between physical and mechanical characteristics of knit fabrics using geometrical and dimensional pammeters. Regression equations for ring spun yarns in single jersey knit fabrics are shown in Table II. Developed regression equations &ill be used to establish mathematical models for predicting knit fabric characteristics. Correlation coefficients are showing good agreement with the experimental data Established relationships were developed from some ring spun yams used for knitting.
_

TABLE I

Blend

Fiber

( I-4UA .Li I _I __ IvllL.r&iber ( D-915W 1 .._ I III GIOUD of Fibers (Micromattique) \ I I 1 A Microfiber D-9 19W U./ - I - 50 ( 3.80 )C ? 7n ;:;, ,I b2.I T-40A PES 1:: : T-107W 1 so I 3.90 PES Yams produced from all the fibers and blends will be in several yam counts single and plied using three spinning systems: (1) ring (2) rotor (3) airjet l

C92C3, Page 2

82

National Tcxtilc Center Annual Report: Septnnba 30,1993

TABLE II Regression equations established for following relationship 1 . Sntch Length (4) + Fabnc Thxkness (D) D=0.164 + 1.247 . Log (p) R = 0.96 Correlation Coeficient R = 0.98 2. Sntch Length (Q) + Fabric Mass (M) M = 0.521 x l$. R2 = 0.95 Cordation Coefficient R = 0.97 . Stitch Length (I) + Ball Burst Strength (B) B = 63.051 x loo. R2 = 0.76 Correlation Coefficient R = 0.87 1, Coefficient of Determination

1.

Knit Cover Factor (k) + Stitch Count (y)

a/courses
YC = 31.335 x lo++ p)

(c) R2 = 0.84 Correlation Coefficient R = 0.92

b/wales (w) yW = 14.778 x lO+ + a) R2 = 0.82 Correlation Coefficient R = 0.91

Tightness Factor (TF) + Dimensional Parameters (&, k,,)

kc

= 28.25 - 1.6Sl-F

R2 = 0.76 Correlation Coefficient R = 0.87 b/knit wale constant (kJ

k_, = 28.89 - 1.48TF R2 = 0.71 Correlation Coefficient R = 0.84 6. Tightness Factor (TF) + Knit Fabric Constant (AC,._ = k, /k&y

kw

= 2.12 x NV= +m R2 = 0.67 Correlation Coefficient R = 0.82

C92C3, Page 3

National Textile CenterAnnual Report: September30,1993

83

Physical and Mechanical Properties of Knit Fabric Made from Rotor Spun Yams Geometrical characteristics of circular single jersey knit fabrics produced of open-end (rotor) yarns which were produced and estimated from evaluated knit structures. Yams used for formation of different knit structure-s were produced using a rotor spinning system. Yarns produced were: Cotton/PES (regular) Cotton/PES (microfiber-D919W) PES (microfiber-D9 19W) PES (microtiber-D915W)
TABLE III

50/50%

OPEN-END YARN FOR KNllllNG

Single jersey fabrics were produced using rotor spun yarns with (4) different tightness factors and (4) designs. Using testing data from knit samples produced from blends of cotton with regular PES, Microfiber PES, and 100% Microfiber PES, rotor yarn relationships between geometrical, dimensional, physical, and mechanical characteristics was established. Geometrical characteristics of knit fabrics were: loop length ( P ). yarn count (tex) cover factor Q, and stitch count (c x w) and their effect on tensile properties of knit fabrics were studied. Dimensional parameters were: knit constants in course and wale direction (k, and k,,,), stitch density (s - cw), knit density constant <kJ and knit fabric constant (kw = k&J were calculated from geometrical characteristics. Equations used for the calculation of dimensional and geometrical parameters are as follows: TABLE IV GEOMETRICAL CHARACTERISTICS OF KNIT FABRICS 1. 2. 3. 4.
C = k, /a; w

= k, /Q

s = cw = k, IQ2 k,, = kc k,

K = Jtex/P

Physical and mechanical characteristics of tested single jersey knit fabrics were dependent of knit fabric design, stitch length, and tightness factor. Physical and mechanical behavior of knit fabrics was correlated to geometrical and dimensional properties. C92C3. Page 4

84

N&~ouQ~ Textile

Center Annual Report:Septmber 30,1993

TABLE V

GEOMETRICAL CHARACTERISTICS OF MICROFIBER KNIT FABRICS

..

TABLE VI

PHYSICAL AND MECHANICAL PROPERnES OF COTlON/MICROFIBER KNIT FABRICS

CL

YARN TYPE

FABRtC DESIGN

Stitch length I (Inch)

l-i
STITCH COUNT Courses per In. CFI Wales per tn. WPt

Moss @z/xl. In)

Knit Fabrtc Thickness (mm) 0.17 0.22 0.26 0.29

Ball Burst (lb)

Stttch Density S=cllxwPt

Mochlne Tightness Factor

29.76

10.70 11.23 11.63

1 74 1 1 75 1

34.26 39.06

I Weft Lockntt I

20

30

0.116

For analysis of fabric behavior, several knit fabric characteristics were taken into consideration: fabric weight, ball burst, dimensional stability, and abrasion resistance. During analyzing of knit fabric behavior, seven independent variables were invoduccd (twist multiple, C, W, stitch length, yarn count, tightness factor, and yarn strength) for developing a multiple regressional model. For each fabric characteristic, the effective parameters are not really known. However, each p value indicates the significance of the effects by introducing the relative independent variable into the regression model. The lower p value has the most significant effect to the regression model and vice versa. Since the more independent variables to be introducing to the model always come with a higher R-squared value, it is reasonable to use the technique of stepwise regression to decide the proper parameters to be introduced. The results show that R-squared values for fabric weight and ball burst are always higk and these indicate good multiple regression equations have been built. Some results of the relationship between fabric weight and ball burst strength are shown in Figures 1-5. Other fabric characteristics varied very much and showed relatively low coefficient of correlation for used independent variables. Dimensional stability showed the most variation, so a different approach was established to solve the problem. Use of rheological models to solve the problem of dimensional stability of micro-denier knit fabrics was investigated. When all mathematical equations are established, using all different $rn types, and knit fabric structures, a mathematical model will be developed for a computer software to predict dimensions and some physical and mechanical characteristics of single jersey knit fabrics.

FIGIJM 1
S T I T C H C0UN-f & FABFUC WEIGHT I _ .
,z,17 . 34.o~~OG(x)

R-2 -

ass1 pq

u-2 - o.nso (q

--

26

24

* 28 Stllch

JO Count

JZ

34

11

(cpl. rpl)

C92C3. Page 7

National Textile Center Annual Report: Sqtcmber30,1993

87

o.0.24

030

0.10

0.41

0.44

STITCH LENGTH AND BALL BURST STRENGTH , I 17x1 . ,.s.zaerl. . ..n?1..4x-2 . ..11r2...ti R-2 I om1

C92C3. Page 8

88

National Textile

Center

Annual Report: September 30,1993

Conclusion:

The purpose of this research project is to generate the equations of the accurate estimation of dimensional stability and mechanical properties of knit goods produced of micro-fiber and their blends. The research activity in this project are focused on the development of a very simple and easy usable software which will be able to predict the micro-fiber knit fabrics in the fully relaxed (reference state). Computer software has to help the manufacturer to improve the consistency and reliability of the knit products while increasing the efficiency of the knitting operation by reducing time (higher production speed) and receiving better fabric performance as lower twist number, better strength, improved hand, reduced harshness, and superior drape. It is showing that in order to develop a masonably accurate and pmctical prediction system, an extensive empirical data-base and actual measurements of fully relaxed dimensions of wide range of knit fabrics has to be collected. Developed computer software will help knitting manufacturers to improve the consiste& of their product, as well as to be able to predict in advance, the dimensions of single jersey knit fabrics. Dimensional stability is approached and using rheological models to study the influence of load and deformation in microfiber knit fabrics is established. Application of rheological models were used to explain and predict deformation of knit fabrics under different loads. RheologicaI models can establish relationships between knitting process and knit fabric strain and predict the dimensional stability of knits produced of micro-fiber yarns and their blends. During manufacturing and use, knit fabrics are exposed to the effect of different forces that can be used to study behavior of knit fabrics during snain. Time dependence of strain on deformation, and time of deformation can be used to predict dimensional stability of micro-fiber knits using Rheology. Fabric geometry will be the indicator of the knit fabric characteristics. To achieve the best fabric performance it is necessary to evaluate the geometry and mechanics of greige fabrics. It will be developed a system for measuring yam configuration and fabric geometry using image analysis system. Knit fabric dimensional measurements will be collected using a new developed method of image analysis yarn contigumtion and knit fabric geometry measurements.

C92C3. Page 9

National Textile CenterAnnual Report: !hptember30,1993

89

Literature Cited
1.

Structural Mechanics Fibers, Yarns and Fabrics, J.W.S. Hearle, P. Grosberg, S. Backer. John Wiley Interscience, 1969 The Mechanics of Wool Suuctures, R. Pestle, GA. Camaby. S. De Jong, John Wiley & Sons, 1988 Boltz, GJ., Needed--A Scientific Approach to Fabric Engineering, Kniuing Times 56 (1). 23-24, 28-30 (1987) Heap, S.A., Greenwood, P.F., Leah R-D., Eaton, J.T.. Stevens, J.C., and Kfher, P. Prediction of Finished Weight and Shrinkage of Cotton Knits--The Starfish Project Part i: Introduction and G,enerai Overview, Textile Res. J. 53 (2). 109-119 (1983) Johnson, R.A., Wichem D.W., Applied Multivariate Statistical Analysis, Third Edition, Prentice-Hall Inc., New Jersey, 1992 Matic, S.R., Computer Produced Models for Knit Fabric Characteristics, Knifting Times 57 (2). 33-38 (1988)

2. 3. 4.

5.

6.

C92C3, Page 10

90

National Textile Center Annual Report: September 30,1993