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Durable fabric including bulk continuous filament yarn

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Durable fabric including bulk continuous filament yarn


wherein said yarn is interlaced. (d) a tenacity of about 2.0 to about 7.0 grams per denier; (c) a denier per filament of about 1 to about 20; and (b) a denier of about 200 to 2000; (a) a plurality of bulked continuous filaments; An article comprising a yarn; wherein said yarn comprises:
Related Terms: Interlace

Browse recent Invista North America S.a R.l. patents - Wilmington, DE, US
USPTO Applicaton #: #20130059495 - Class: 442181 (USPTO) - 03/07/13 - Class 442 
Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.) > Woven Fabric (i.e., Woven Strand Or Strip Material)

Inventors: David S. Dempster, Allen W. Mortimer, Todd C. Barnes

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The Patent Description & Claims data below is from USPTO Patent Application 20130059495, Durable fabric including bulk continuous filament yarn.

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FIELD OF THE DISCLOSURE

The disclosure related to durable fabrics which are resistant to tearing and abrasion, which include synthetic yarns including a bulked and entangled yarn.

BACKGROUND

Polymer filaments, such as polyamide, polyolefin and polyester, are useful for a variety of textile products. When these filaments are textured and/or have a high tenacity/tensile strength, they are especially useful where durable yarns are needed. Examples of such products are useful for performance outdoor wear; contract, automotive/transportation and home upholstery; military apparel and gear; denim and sweaters; activewear; outdoor gear; backpacks; luggage; and footwear, among others.

These yarns are typically made through the process of air-jet texturing. The air-jet texturing process can provide both bulk and/or texture to the yarn in addition to entangling the yarn which provides a yarn that is capable of being incorporated into a fabric. However, this equipment required for this process and conducting this process can be cost-prohibitive.

SUMMARY

Multiple filament polymer yarns can also be prepared as bulked continuous filaments. However, without further treatment, these filaments do not form an integrated yarn that can be knit or woven into a fabric.

One aspect provides an article including a yarn; where the yarn includes:

(a) a plurality of bulked continuous filaments;

(b) a denier of about 200 to about 2000, including about 300 to about 1200;

(c) a denier per filament of about 1 to 20, including about 1 to about 8; and including about 3 to about 6;

(d) a tenacity of about 2.0 to about 7.0 grams per denier, including about 4.0 to about 6.0;

where the yarn is interlaced.

In order to provide yarns with the tenacity required for durable fabrics, the yarn preparation includes specific drawing conditions, which increase the tenacity of the yarns. One suitable method for preparing the yarns includes:

(a) spinning a synthetic yarn;

(b) drawing the yarn;

(c) bulking the yarn in the absence of air jet texturing; and

(d) interlacing the yarn; and

(e) winding the yarn onto a package.

The method may be a coupled or in-line process which excludes the need for separately spinning the yarn and then subsequently providing the texturing or bulk to the yarn. Subsequent to the bulking of the yarn, which occurs in the absence of air jet texturing, the yarn is interlaced. By interlacing the yarn, the multiple filaments form an integrated yarn, which may be subsequently knit or woven into a fabric. The interlacing process also provides the yarn with a means for maintaining the bulk of the yarn, which may otherwise be removed under the tension of knitting or weaving processes.

Another aspect provides an article including the bulked and interlaced yarn. The article may also include a fabric prepared from the bulked and interlaced yarn. The bulked and interlaced yarn includes:

(a) a plurality of bulked continuous filaments;

(b) a denier of about 200 to about 2000;

(c) a denier per filament of about 1.0 to 8.0, and

(d) a tenacity of about 2.0 to about 7.0 grams per denier;

where the yarn is interlaced.

Another aspect provides an article including a fabric which is knit or woven from a bulked and interlaced polymer yarn. The yarn includes polyamide, such as nylon 6 or nylon 6,6, having a plurality of bulked continuous filaments. The yarn has a denier of about 200 to about 2000; including a denier of about 200 to about 1500 or about 500 to about 1500 or about 900 to about 1000; a denier per filament (dpf) of about 1 to 20, including about 1 to about 8, or including about 3 to about 6 and a tenacity of about 2.0 to about 7.0 grams per denier. The number of filaments may also vary such as about 50 to about 1000 filaments. This includes about 100 to about 500 filaments or about 140 to about 350 filaments or about 140 to 280 filaments.



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Industry Class:
Fabric (woven, knitted, or nonwoven textile or cloth, etc.)
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stats Patent Info
Application #
US 20130059495 A1
Publish Date
03/07/2013
Document #
13600894
File Date
08/31/2012
USPTO Class
442181
Other USPTO Classes
57287, 57351, 28240, 28263, 428364, 428397, 428221, 442312
International Class
/
Drawings
0


Interlace


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