Apparel fabric manufacturing process; system and product thereof

An article of apparel formed from a multi-ply knitted apparel material having a predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties and devoid of optically detectable variants in said requisite optical colour and pattern effect, whererin said apparel fabric comprises:

• a knit of a plurality of multi-ply yarn each formed from two or more yarn, wherein each multi-ply yarn is formed a plurality of n yarn and a further plurality of m yarn;
• wherein the total denier of n yarn is equal to a first denier (D1);
• and m yarn, wherein the total of m yarn is equal to a further Denier (D2), whereby the denier of each yarn of the multi-ply yarn collectively provide the requisite yarn denier for the knitted fabric;
• wherein each yarn is comprised of a plurality of coloured dope dyed fibers of a polymeric material, and wherein the plurality of n yarn and the plurality of m yarn provide said predetermined optical colour and pattern effect and said predetermined physical fabric properties.

A process of forming a yarn consisting of dope dyed fibers for production of an apparel fabric of a predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties, said process including the steps of:

• (i) mixing a master batch dye of a requisite colour with a molten polymeric material so as to form a molten polymeric material of said requisite colour;
• (ii) extruding said molten polymeric material through a plurality of spinnerets so as to form a plurality of dope dyed fibers of said requisite colour, wherein said spinnerets having a size of approximately 2 to 3 times the requisite size of the fibers from which a yarn is to be formed;
• and
• (iii) winding a plurality of said fibers so as to form a dope dyed yarn for subsequent forming an apparel fabric.

A system for forming a multi-ply apparel fabric having predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties from a plurality of yarn having said requisite optical colour and pattern and being formed from a plurality of polymeric dope dyed fibers, said system comprising:

• a knitting assembly for knitting a plurality of yarn so as to form a multi-ply knitted apparel fabric having predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties;
• a creel for carrying a plurality of bobbins;
• and
• a plurality of guide members disposed for the guiding n yarn from n bobbins to the knitting assembly for the knitting with m yarn from m bobbins, wherein each guide member guides one or more of the n yarn and one or more of the m yarn to the knitting assembly to form a multi-ply yarn for the knitting by the knitting assembly with another a multi-ply yarn for knitting of the multi-ply yarn with the another multi-ply yarn to form said multi-ply apparel fabric, wherein n and m are integers of two or greater;
• wherein upon knitting of said multi-ply yarn to form a multi-ply apparel fabric, said apparel fabric is formed having predetermined requisite optical colour and pattern effect and having predetermined physical fabric properties effect devoid of optically detectable variants in said requisite optical colour and pattern effect;
• and.
• wherein the yarn of n yarn and the yarn of m yarn are selected so as to provide said predetermined optical colour and pattern effect and said predetermined fabric properties.