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Durable fabric including bulk continuous filament yarn / Invista North America S.a R.l.




Title: Durable fabric including bulk continuous filament yarn.
Abstract: 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: ...


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USPTO Applicaton #: #20130059495
Inventors: David S. Dempster, Allen W. Mortimer, Todd C. Barnes


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

FIELD OF THE DISCLOSURE

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

BACKGROUND

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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

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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.

DETAILED DESCRIPTION

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For the purpose of this disclosure, the term “air jet texturing” is meant to include a method of providing texture to a yarn, where a yarn is led through the turbulent region of an air jet at a rate faster than it is drawn off on the far side of the jet. In the jet, the yarn structure is opened, loops are formed, and the structure is closed again. Some loops are locked inside and others are locked on the surface of the yarn. The yarn made by this process is characterized by its bulkiness and the presence of a multitude of filament loops irregularly spaced along the length of the yarn.

For the purposes of this invention, “a method of providing texture” means a process of introducing fine distortions along the length of a continuous filament yarn, where such distortions are limited to the introduction of crimp including edge crimping, gear crimping, and stuffer box crimping. Other methods that are sometimes referred to as texturing, but are specifically excluded from the definition for the purposes of this invention, include false twist texturing, knit-deknit texturing and air-jet texturing.

For the purposes of this invention, “bulking” means a process specifically intended to increase the specific volume of continuous filament yarn wherein said processes impart crimping (bending or folding) to the yarn and its constituent filaments so that the yarn and constituent filaments deviate from a linear path. Bulking, as used herein, specifically excludes air-jet texturing.

The term “bulked”, for purposes of this invention, refers to yarns of permanently crimped filaments; i.e. the filaments retain their crimp upon removal from the yarn.

“% Crimp”, for the purposes of this invention, is a property measured according to the method provided herein that provides a measure of the extent of crimp achieved. It is essentially the percentage elongation exhibited by a crimped yarn when tension is applied to the yarn. The specific volume or bulk of yarn (cm3/g) increases as of extent of crimp increases. The extent of crimp can therefore be used as a proxy for characterizing yarn bulk.

For the purposes of this invention, the term “edge crimp” method refers to a method of providing texture and/or bulk to a yarn, including but not limited to, where the yarn is heated and stretched over a crimping edge, then cooled.

For the purposes of this invention, the “gear crimp” method is meant to include, but is not limited to, a method for providing texture and/or bulk to a yarn where the yarn is fed through the meshing teeth of two gears, where the yarn takes the shape of the two gears.

For the purposes of this invention, the term “stuffer box” method is meant to include, but is not limited to, a method for providing bulk to a yarn where the crimping unit includes two feed rolls and a stuffer box. By compressing the yarn into the stuffer box, the individual filaments are caused to fold or bend at a sharp angle, while being optionally, simultaneously set by a heating device.




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stats Patent Info
Application #
US 20130059495 A1
Publish Date
03/07/2013
Document #
File Date
12/31/1969
USPTO Class
Other USPTO Classes
International Class
/
Drawings
0


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Invista North America S.a R.l.


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Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.)   Woven Fabric (i.e., Woven Strand Or Strip Material)  

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20130307|20130059495|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 |Invista-North-America-S-a-R-l
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