Sara Lee Corporation

Hbi Branded Apparel Enterprises, LLC Corporation

Saramar Corporation

Sonny B Driggars

Philip Renda

Steve B Brooks

Bill R Anderson

James R Earnhardt, Jr

Carroll D Lineberry

Charles J Lyerly

A print-receptive, pill-resistant, knitted fabric and printed article of apparel. The fabric is knitted from yarn formed from high-tenacity, staple synthetic fiber having a tenacity value of greater than about 4 grams/denier and preferably about 6 grams/denier. The resulting knitted fabric has a pilling resistance value of greater than about 3. In the preferred embodiment, the high-tenacity, staple synthetic fiber is selected from the group consisting of air jet spun polyester; nylon; acrylic; and polypropylene. The use of staple fibers improves the hand, drape and comfort of the knitted fabric. Also, in the preferred embodiment, the knitted fabric is a double-knit fabric having a front side and a back side, the front side being formed from the high-tenacity, staple synthetic fiber and the back side being substantially formed from cellulosic yarns, such as cotton and synthetic cellulosic fibers. This construction improves both comfort and opacity of the knitted fabric while, at the same time, provides a print-receptive face and good print resolution of the article of apparel after multiple home washings.

Print-receptive, pill-resistant, knitted fabric

An apparatus for forming a cotton/rayon blended yarn. The apparatus includes a supply of cotton fibers and a supply of rayon fibers. A blending operation line blends the cotton fibers and the rayon fibers. The fibers are then spun in an open end spinning turbine having a twist multiple of less than about 3.7 at a rotor speed of less than about 112,000 RPM. A roughing navel downstream from the open and spinning turbine distressing the surface of the cotton/rayon blended yarn to further improve the hand of yarn. The yarn is then knitted or woven into fabric and finished. The resulting fabric, and apparel made therefrom, has the advantage of having a particularly soft and luxurious hand, particularly compared to fabric knit from 100% cotton yarn.

Method and apparatus for forming a cotton/rayon blended yarn

A low-shrinkage, stable print platform circular knitted, cotton/synthetic fabric. The fabric is a two end fleece fabric having a weight of between about 8 to 12 oz. per sq.yd., a stitch density of between about 800 to 1000; and a face yarn count of the fabric is between about 16 to 20. In the preferred embodiment, the backing yarn count of the fabric is between about 7 to 12. The resulting fabric construction of the present invention has stretch of less than about 3% stretch in the width direction and less than about 3% stretch in the length direction when tested according to a standard stretch chart. In addition, the fabric of the present invention has shrinkage in the range of less than 5% when tested according to a standard one wash cycle. The resulting fabric is an exceptionally stable print platform, circular knitted fabric and improved pilling resistance.

Low-shrinkage, stable print platform knitted fabric

An apparatus for forming a cotton/rayon blended yam. The apparatus includes a supply of cotton fibers and a supply of rayon fibers. A blending operation line blends the cotton fibers and the rayon fibers. The fibers are then spun in an open end spinning turbine having a twist multiple of less than about 3.7 at a rotor speed of less than about 112,000 RPM. A roughing navel downstream from the open and spinning turbine distressing the surface of the cotton/rayon blended yarn to further improve the hand of yarn. The yarn is then knitted or woven into fabric and finished. The resulting fabric, and apparel made therefrom, has the advantage of having a particularly soft and luxurious hand, particularly compared to fabric knit from 100% cotton yarn.

Open end spun, cotton/rayon blended yarn

A print-receptive, pill-resistant, knitted fleece fabric and printed article of apparel. The fabric is knitted from yarn formed from high-tenacity, staple synthetic fiber having a tenacity value of greater than about 4 grams/denier and preferably about 6 grams/denier. The resulting knitted fleece fabric has a pilling resistance value of greater than about 3. In the preferred embodiment, the high-tenacity, staple synthetic fiber is selected from the group consisting of air jet spun polyester; nylon; acrylic; and polypropylene. The use of staple fibers improves the hand, drape and comfort of the knitted fabric. Also, in the preferred embodiment, the knitted fabric is a 3 end fleece fabric having a face yarn side and a lay-in yarn side, the face yarn side being formed from the high-tenacity, staple synthetic fiber and the lay-in yarn side being substantially formed from cellulosic yarns, such as cotton and synthetic cellulosic fibers or a synthetic/cellulosic blend. This construction improves both comfort and opacity of the knitted fabric while, at the same time, provides a print-receptive face and good print resolution of the article of apparel after multiple home washings.

Print-receptive, pill-resistant, knitted fleece fabric

A low-shrinkage, stable print platform circular knitted fabric. The fabric is a two end fleece fabric having a weight of between about 8 to 12 oz. per sq.yd., a stitch density of between about 800 to 1000; and a face yarn count of said fabric is between about 16 to 20. In the preferred embodiment, the backing yarn count of said fabric is between about 7 to 12. The resulting fabric construction of the present invention has stretch of less than about 3% stretch in the width direction and less than about 3% stretch in the length direction when tested according to a standard stretch chart. In addition the fabric of the present invention has shrinkage in the range of less than 5% when tested according to a standard one wash cycle. The resulting fabric is an exceptionally stable print platform, circular knitted fabric.

Low-shrinkage stable print platform knitted fabric

A convertible circular knitting machine having a creel and feeders which is adapted to be converted from producing fleece fabric to producing jersey fabric or back. The apparatus includes a knitting cylinder adapted to receive a plurality of knitting needles and a bed for supporting the cylinder. A plurality of fleece section blocks are adapted to be attached to the bed and arranged along the perimeter of the cylinder to produce fleece fabric. The apparatus also includes a plurality of jersey section blocks each having the same number of feeders and peripheral dimensions as each fleece section block and adapted to be attached to the bed and arranged along the perimeter of the cylinder to produce jersey and a plurality of fleece sinkers for use with the fleece section blocks for producing fleece fabric and a plurality of jersey sinkers for use with the jersey section blocks for producing jersey fabric. As a result, the circular knitting machine may be converted from producing fleece fabric to producing jersey fabric or back without extensive modifications or replacement of the creel, feeders or cylinder.

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Advance, NC, United States of America

Sonny B Driggars