Patent Application
20240376642
The present disclosure relates to low-density yarn products, methods of making such yarn products and articles of manufacture employing same.
Insulation and/or filler for winter clothing and other articles is widely used. For example, insulation for winter clothing provides a means for temperature regulation upon exposure to the elements. Such insulation may be required in outer garments and/or equipment used during exposure to cold temperatures as for example, sleeping bags and/or blankets. Goose or duck down is light but does not work in wet conditions. Also, natural down it is expensive and not animal friendly. Synthetic fiber clusters, fiber battings, or non-woven fabrics currently used as insulation in winter clothing are typically bulky, relatively heavy, and do not compress well into storage bags.
Similarly, filler used for pillows, furniture cushions and the like often contain a mixture of inexpensive feathers and expensive down, and the feathers escape because the semi-rigid quill pushes through the fabric enclosure. Further, feather and down mixtures do not rebound well after compression, and down by itself offers little resistance to compression seen in these types of applications.
Thus, a better yarn product for these types of fillers is needed.
Disclosed is a yarn product comprising a plurality pieces of a low-density yarn formulated as a three-dimensional matrix. In certain embodiments, the yarn product has a density of less than 30 grams per liter. In an embodiment, the disclosed yarn product comprises two components: a relatively straight base yarn and an effect yarn that is overfed compared to the base yarn. The base and effect yarns entangle together to make a low-density yarn. In certain embodiments, the low-density yarn may be chopped into discrete pieces and mixed to form a three-dimensional fluffy matrix.
In other embodiments, disclosed is a twisted yarn product comprising a core yarn and a low-density yarn. The low-density yarn may be formulated as loops that extend substantially radially from the core yarn. The twisted yarn product may further comprise a binder yarn, wherein the binder yarn is twisted around the core and the low-density yarn to hold the low-density yarn in position relative to the core yarn. In certain embodiments, the twisted yarn product is formulated as a three-dimensional matrix. For example, the twisted yarn may be chopped into discrete pieces and mixed to form a three-dimensional fluffy matrix.
Also disclosed are methods for making such yarn products and articles of manufacture that include such yarn products.
The disclosure may be better understood by referencing the following non-limiting figures.
The present disclosure now will be described more fully hereinafter. The disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will satisfy applicable legal requirements. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, applications, published applications and other publications referred to herein are incorporated by reference in their entireties. If a definition set forth in this section is contrary to or otherwise inconsistent with a definition set forth in a patent, application, published application and/or other publications that are herein incorporated by reference, the definition set forth in this section or as used elsewhere herein prevails over the definition that is incorporated herein by reference.
When introducing elements of the present disclosure or the embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. It is understood that aspects and embodiments of the disclosure described herein include “consisting” and/or “consisting essentially of” aspects and embodiments.
The term “and/or” when used in a list of two or more items, means that any one of the listed items can be employed by itself or in combination with any one or more of the listed items. For example, the expression “A and/or B” is intended to mean either or both of A and B, i.e. A alone, B alone or A and B in combination. The expression “A, B and/or C” is intended to mean A alone, B alone, C alone, A and B in combination, A and C in combination, B and C in combination or A, B, and C in combination.
Various aspects of this disclosure are presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.
As used herein, the term “about” includes a range of measurements within a certain percentage of the value, including a variation of from 0 to 20%, or 0 to 10%, or 0 to 5%, or 0 to 1% of the value.
As used herein, a “core yarn” or “core” is a yarn around which a second yarn may be wrapped. In certain embodiments, the core yarn is formulated to be relatively straight. The core yarn may include a base yarn and an effect yarn. The core yarn can be a combination of yarns of different types. The corn yarn can be made on a texturing machine.
As used herein, a “low-density yarn” is a yarn that is specifically made to have a low density to offer insulating properties. The low-density yarn may comprise a base yarn and an effect yarn. The low-density yarn can be a combination of yarns of different types. The low-density yarn can be the made on a texturing machine. In some cases, the low-density yarn is an “overfeed yarn”, or “low-density overfeed yarn”.
As used herein, a “binder yarn” or “binder” is a yarn that wraps around a core yarn and a low-density overfeed yarn to hold (i.e., bind) loops of the low-density overfeed yarn in place around the core yarn. The binder yarn may include a base yarn and an effect yarn. The binder yarn can be a combination of yarns of different types. The binder yarn can be made on a texturing machine.
As used herein, an “overfeed yarn” is a yarn that is delivered to a twisting procedure in a manner such that the yarn is overfed, i.e., delivered to the twisting procedure at a faster rate than another yarn. In certain cases, the overfeed yarn is twisted around a core yarn such that the overfeed yarn makes loops in relation to the core yarn. In some embodiments, the overfeed yarn is the same as the low-density yarn.
As used herein, a “base yarn” is a relatively straight yarn in the center of a core yarn, a low-density yarn, or a binder yarn.
As used herein, an “effect yarn” is a yarn that is over-fed into a yarn product as compared to a base yarn to make hair. In certain embodiments, the base yarn and an effect yarn are combined using a texturing machine wherein the effect yarn is over-fed into the texturing machine at a faster rate than the base yarn.
As used herein, “multifilament strands” or “multifilament yarns” are yarns containing more than one individual filament. In some cases, multifilament yarns comprise multiple filaments of the same type. In other cases, multifilament yarns contain a plurality of yarn types (e.g., polyester and polypropylene yarns).
As used herein, a “denier” describes linear mass density of filaments, yarns, or fibers and is the mass in grams of 9000 meters of yarn.
As used herein, “hair” is defined as filaments of a yarn that are not parallel to the longitudinal axis of the yarn itself.
Typically, yarns are designed and made to have a tight, strong, and abrasion resistant structure. Disclosed herein are yarn products comprising yarn that is formulated as a low-density or fluffy product. Also disclosed are methods of making such yarn products and articles of manufacture that comprise the yarn products. Such yarn products have surprising utility. For example, such yarn products may be used for insulation as part of apparel or other articles, including building structures, as padding or filling for pillows, furniture cushions, comforters, mattress tops, and the like. The yarn products may be embodied in a variety of ways.
In one embodiment, disclosed is a yarn product comprising a plurality pieces of a low-density yarn formulated as a three-dimensional matrix. In an embodiment, each of the pieces of the low-density yarn are mixed such that each of the pieces of the low-density yarn are not attached or physically secured to each other.
In some embodiments, the low-density yarn comprises a base yarn and an effect yarn. The low-density yarn may have a relatively straight base yarn and the effect yarn may be overfed as compared to the base yarn. In certain embodiments, the effect yarn may be 30% to 1000% overfed, or 50% to 500%, or 100% to 300% overfed as compared to the base yarn, where 100% overfeed is a feed rate of twice (i.e., 2×) the original feed rate used for the base yarn. In certain embodiments, the low-density yarn comprising a base yarn and an effect yarn is made on a texturing machine. In an embodiment, the combination of base yarn and effect yarn makes a textured yarn.
In some embodiments, the combination of base yarn and effect yarn makes a yarn with hair, referred to herein as a low-density yarn. In one embodiment, the low-density yarn is used as a final yarn product. For example, the low-density yarn may be chopped into smaller pieces to make a three-dimensional matrix of low-density yarn. In another embodiment, the low-density yarn can be used as an overfeed yarn in a twisted yarn product to make loops when combined with a relatively straight core yarn and an binder yarn as disclosed in detail herein.
In certain embodiments, the base yarn may comprise polyethylene, polypropylene and/or polyester (e.g., polyethylene teraphthalate). Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
The effect yarn may comprise the same fiber as the base yarn, or a different fiber. In some embodiments, the effect yarn may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used. The effect yarn may comprise multiple component yarns added to give the yarn additional thickness and or fluff. For example, the low-density yarn may be formulated such that the effect yarn extends substantially radially from the base yarn. Additionally and/or alternatively, the effect yarn may be formulated as loops that extend substantially radially from the base yarn.
The low-density yarn may comprise a defined density and/or denier. In certain embodiments, the low-density yarn may comprise a denier ranging from 150 denier to 15,000 denier with a preferred range between 1000 to 5000 denier.
The cross section of filament or fibers used for the low-density yarn may be round, hollow fiber, tri-lobal, or any other shape. Hollow fibers are lighter than solid fibers of the same diameter and have additional places to trap dead air than a solid yarn, which can be advantageous. Also, any size yarn, or any size of the component yarns, or any size of the filaments or fibers making the low-density yarn may be used.
The low-density yarn may comprise yarns that have multiple filaments (i.e., multifilament yarns). Also, the low-density yarn may have a different amount of filaments in the base and/or effect yarns. In various embodiments, each of the base and/or effect yarns may comprise 5-1,000, or 10-500, or about 10-100 filaments. Or, ranges within these ranges may be used. For example, in some embodiments, the low-density yarn may have 34 filaments in the base yarn and 68 filaments in the effect yarn. In other embodiments, the low-density yarn may have 34 filaments in the base yarn and 96 filaments in the effect yarn. In other cases, the base yarn may have more filaments than the effect yarn. Or monofilament yarns can also be used.
When the yarn product is formulated as a matrix it may have a defined density. For example, the matrix may comprise a density of less than or equal to 60, 45, 30, 25, 20, 15, 10 or 5 grams per liter or any range between 5 to 60, or 10 to 45, or about 10 to 35 grams per liter. In certain embodiment, the density is less than 30 grams per liter. In certain embodiments, the density is about 15 grams per liter.
The disclosed yarn products may also be formulated to contain additives such as, but not limited to, substances that reflect or absorb heat and infrared radiation to control radiant heat loss, fire retardants and/or antimicrobials.
In certain embodiments, the matrix can be formed by cutting the low-density yarn product into a plurality of pieces thereby creating a three-dimensional matrix that has padding and/or insulating properties.
In other embodiments, disclosed is a twisted yarn product comprising two or more types of yarn. Thus, in certain embodiments, disclosed is a twisted yarn product comprising a low-density yarn and a core yarn. The low-density yarn may be formulated as loops that extend substantially radially from the core yarn.
The yarn product may additionally include a third type of yarn. Thus, in certain embodiments, the twisted yarn product may comprise a binder yarn. The binder yarn may, in certain embodiments, be twisted around the core yarn and the low-density yarn to hold the low-density yarn in position relative to the core yarn.
In certain embodiments, the twisted yarn product comprising a core yarn, a low-density yarn and optionally, a binder yarn may have a defined density and/or denier. In certain embodiments, the twisted yarn product may comprise a denier ranging from 300 denier to 20,000 denier with a preferred range of 1500 to 7500 denier.
In certain embodiments, the twisted yarn product may be formulated as a three-dimensional matrix. When the twisted yarn product is formulated as a matrix it may have a defined density. For example, the matrix may comprise a density of less than or equal to 60, 45, 30, 25, 20, 15, 10 or 5 grams per liter or any range between 5 to 60, or 10 to 45, or about 8 to 30 grams per liter. In an embodiment, the density is less than about 24 grams per liter. In an embodiment, the density is about 12 grams per liter.
In some embodiments, any one of the core yarn, the low-density yarn, and/or the binder yarn used in the twisted yarn product comprises a base yarn and/or an effect yarn. The base yarn may be relatively straight and the effect yarn may be overfed as compared to the base yarn. In certain embodiments, the effect yarn may be 30% to 1000% overfed, or 50% to 500%, or 100% to 300% overfed as compared to the base yarn. In an embodiment, the combination of base yarn and effect yarn makes a yarn with significant hair, thereby decreasing the density of the yarn significantly. In certain embodiments, any one of the core yarn, the low-density yarn and/or the binder yarn used in the twisted yarn product is made on a texturing machine. In an embodiment, the combination of base yarn and effect yarn makes a textured yarn. The effect yarn may be added to give the yarn additional thickness and/or fluff. For example, the core, low-density, or binder yarn may be formulated such that the effect yarn extends substantially radially from the base yarn. Additionally and/or alternatively, the effect yarn may be formulated as loops that extend substantially radially from the base yarn.
In certain embodiments, the base yarn used for the low-density component of the twisted yarn product may comprise polyethylene, polypropylene and/or polyester (e.g., polyethylene teraphthalate). Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
The effect yarn used in the low-density yarn may comprise the same fiber as the base yarn, or a different fiber. In some embodiments, the effect yarn may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
In certain embodiments, the low-density yarn used in the twisted yarn product is an overfeed yarn, i.e., a yarn that is delivered to a twisting procedure in a manner such that the yarn is overfed, i.e., delivered to the twisting procedure at a faster rate than another yarn. In certain embodiments, the low-density yarn may be 50% to 1000% overfed, or 120% to 500%, or 150% to 300% overfed into the twister as compared to the core yarn, where 100% overfeed is a feed rate of twice (i.e., 2×) the original feed rate used for the core yarn. In certain cases, the low-density overfeed yarn is twisted around the core yarn such that the overfeed yarn makes loops in relation to the core yarn. The loops created by the low-density overfeed yarn may be any size depending upon the final use for the yarn product. Also, the loop size and frequency with which the loops interact with the core yarn may be varied, for example by varying the settings on a hollow spindle novelty yarn twister making the final twisted yarn. In an embodiment, the low-density overfeed yarn enters the twister at a faster speed than the core yarn to make loops. Also, in some embodiments, the turns per meter of a binder yarn in the hollow spindle twister also effects the height of the loops and the frequency of the loops. In certain embodiments, individual loops extend from the core about every 0.05-300 mm or every 1-50 mm or every 2-10 mm. Or ranges within these ranges may be used.
In some embodiments, the core yarn used for the twisted yarn product may comprise a base yarn and/or an effect yarn. In certain embodiments, the base yarn used for the core of the twisted yarn product may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
If included, the effect yarn used for the core may comprise the same fiber as the base yarn, or a different fiber. In some embodiments, the effect yarn may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
In some embodiments, the optional binder yarn used for the twisted yarn product may comprise a base yarn and/or an effect yarn. In certain embodiments, the base yarn used for the binder may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
If used, the effect yarn used for the binder may comprise the same fiber as the base yarn, or a different fiber. In some embodiments, the effect yarn may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used. The effect yarn may be added to give the yarn additional thickness and or fluff.
For example, disclosed is a twisted yarn product comprising: a core yarn; a low-density yarn, wherein the low-density yarn is formulated as loops that extend substantially radially from the core yarn; and a binder yarn, wherein the binder yarn is twisted around the core and the low-density yarn to hold the low-density yarn in position relative to the core yarn. In certain embodiments, the twisted yarn product is formulated as a three-dimensional matrix having a density of less than or equal to 60, 30, 25, 20, 15, 10 or 5 grams per liter or any range between 5 to 60, or 10 to 45, or about 8 to 30 grams per liter. In certain embodiments, the density of the matrix is less than 24 grams per liter. In certain embodiments, the density of the matrix is about 12 grams per liter.
Thus, in certain embodiments, the disclosed twisted yarn product is comprised of a yarn for a core and a low-density yarn formulated as large loops protruding from the core. In an embodiment, the low-density yarn of large loops (i.e., loopy yarn) is an overfeed yarn. In an embodiment, the core is straight or relatively straight. The low-density yarn protruding from the core may be manufactured to have portions of the fiber extending outwards to provide hair (i.e., make the yarn fuzzy). In an embodiment, the yarn product further comprises a binder yarn twisted around the core and the low-density loopy yarn at the points where the low-density yarn intersects the core to hold the loops in place along the core yarn. The loops can trap air and make the yarn product spring back into shape after it is compressed. In yet another embodiment, all three yarns (the core, the low-density overfeed yarn, and the binder) include an effect yarn to create hair that extends from a base yarn. Such hair adds to the insulating properties.
The cross section of filament or fibers used for any of the core, low-density and/or binder yarns may be round, hollow fiber, tri-lobal, or any other shape. Hollow fibers are lighter than solid fibers of the same diameter and have additional places to trap dead air than a solid yarn, which can be advantageous. Also, any size yarn, or any size of the component yarns, or any size of the filaments or fibers making the component core, low-density and/or binder yarn may be used.
Each of the low-density yarn, core yarn and binder yarn may comprise yarns that have multiple filaments (i.e., multifilament yarns). Also, each of the low-density, core and/or binder yarns may have a different amount of filaments in the base and/or effect yarns. In various embodiments, each of the base and/or effect yarns used for the core yarn, or low-density yarn, or the binder yarn may comprise 5-1,000, or 10-500, or about 10-100 filaments. Or, ranges within these ranges may be used. For example, in some embodiments, the low-density yarn may have 34 filaments in the base yarn and 68 filaments in the effect yarn. In other embodiments, the low-density yarn may have 34 filaments in the base yarn and 96 filaments in the effect yarn. The core yarn may have, for example, a base yarn of about 34 filaments and an effect yarn of about 34 filaments. The binder yarn may, in certain embodiments, have a base yarn of about 34 filaments with an optional effect yarn of about 34 filaments. In other cases, the low-density, core and/or binder base yarn may have more filaments than the effect yarn. Or monofilament yarns can also be used.
Each of the low-density yarn 6, the core yarn 2, and the binder yarn 10 may comprise a base yarn and an effect yarn. For example, as shown in
The basic principle of insulation and/or filler material is to trap dead air that does not conduct heat well or to minimize heat loss due to convection and/or conduction. In some embodiments, a strand, or a plurality of strands of the twisted yarn product comprised of a core, a low-density overfeed yarn, and a binder yarn may be bunched in a manner to create a three-dimensional matrix. In this embodiment, different portions of the single strand or plurality of strands may grip the loops and/or hair of other portions of the strand's or strands' overfeed yarn to make a sustainable three-dimensional structure for insulation. For example, a strand of the twisted yarn product comprised of a core yarn, a low-density overfeed (e.g., loopy) yarn and a binder yarn may be cut lengthwise into a plurality of pieces and then the pieces combined to form a three-dimensional matrix. The plurality of pieces may be combined in a random manner so as to maximize the ability of the matrix to trap air and/or form an insulation material that is light and springy. The loops and/or hair from individual strands of the yarns used in the yarn product may grip the loops and/or hair of other strands of the yarn to make a sustainable three-dimensional structure for insulation. In certain embodiments, the plurality of smaller pieces of yarn may have the ends melted either during or after cutting to prevent the three components (i.e., core, loops and binder) from unraveling.
In some embodiments, a lower melting yarn, like polyethylene and/or polypropylene, can be added to the core, binder and/or low-density yarn to act like a glue when heated to help in preventing the three components from unraveling. This glue enables individual strands of the twisted yarn to be mechanically chopped into pieces in a method that is quicker than melting the strand of twisted yarn into smaller pieces. There are a variety of ways to heat the yarn to melt the lower-melting (i.e., glue) yarn including heating in an autoclave, winding the yarn through a tube heater, batch heating in hank form, or using large production belt heaters that are used to heat-set carpet yarns.
The components used in the twisted yarn product (i.e., core, low-density and binder yarns) can be made of any natural or synthetic fiber or blend of natural and synthetic components including filament or spun fiber. Although the loops made by the low-density overfeed yarn may be held in place by a binder yarn, any other type of process or method that would maintain the loopy structure such as knitting stitches with a knitting machine or having a lower melting yarn in a component that melts with heat and act as a glue may be used.
As discussed herein, the sizes of each of the component yarns may be varied. For example, the core yarn may comprise continuous multi-filament strand(s) of 4 denier for each filament to generate a core yarn of about 650 denier using an air jet texturing machine where the effect strand(s) is fed into an air jet texturing machine at a greater speed than the base strand(s) to make the core yarn have hair. The low-density overfeed yarn used for the loops may comprise continuous multi-filament strand(s) of about 4 denier for each filament to generate an overfeed yarn of about 1700 denier where the effect strand(s) is fed into the air jet texturing machine at a greater speed than the base strand(s) to make the overfeed yarn have hair. The binder yarn may comprise continuous multi-filament strand(s) of about 4 denier per filament to generate a binder yarn of about 300 denier using an air jet texturing machine or a false-twist texturing machine. Or other sized component yarns and or filament sizes can be used.
The disclosed twisted yarn products may also be formulated to contain additives such as, but not limited to, substances that reflect or absorb heat and infrared radiation to control radiant heat loss, fire retardants and/or antimicrobials.
In certain embodiments, the disclosed yarn products may be used in an article of manufacture. In certain embodiments, the article of manufacture may comprise a yarn product utilizing a single low-density yarn as disclosed herein. Additionally and/or alternatively, the article of manufacture may comprise a yarn product utilizing a twisted yarn product as disclosed herein.
Thus, in certain embodiments disclosed is an article of manufacture comprising a plurality pieces of a low-density yarn product formulated as a three dimensional matrix. In an embodiment, each of the pieces of the low-density yarn are mixed such that each of the pieces of the low-density yarn are not attached or physically secured to each other.
In some embodiments, the low-density yarn comprises a base yarn and an effect yarn. The low-density yarn may have a relatively straight base yarn and the effect yarn may be overfed as compared to the base yarn. In certain embodiments, the effect yarn may be 30% to 1000% overfed, or 50% to 500%, or 100% to 300% overfed as compared to the base yarn. In certain embodiments, the low-density yarn comprising a base yarn and an effect yarn is made on a texturing machine. In an embodiment, the combination of base yarn and effect yarn makes a textured yarn. In an embodiment, the combination of base yarn and effect yarn makes a yarn with hair.
In certain embodiments, the base yarn may comprise polyethylene, polypropylene and/or polyester (e.g., polyethylene teraphthalate). Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
The effect yarn may comprise the same fiber as the base yarn, or a different fiber. In some embodiments, the effect yarn may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used. The effect yarn may comprise multiple component yarns added to give the yarn additional thickness and or fluff. For example, the low-density yarn may be formulated such that the effect yarn extends substantially radially from the base yarn. Additionally and/or alternatively, the effect yarn may be formulated as loops that extend substantially radially from the base yarn.
The low-density yarn may comprise a defined density and/or denier. In certain embodiments, the low-density yarn may comprise a denier ranging from 150 denier to 15,000 denier with a preferred range between 1000 to 5000 denier.
The cross section of filament or fibers used for the low-density yarn may be round, hollow fiber, tri-lobal, or any other shape. Hollow fibers are lighter than solid fibers of the same diameter and have additional places to trap dead air than a solid yarn, which can be advantageous. Also, any size yarn, or any size of the component yarns, or any size of the filaments or fibers making the low-density yarn may be used.
The low-density yarn may comprise yarns that have multiple filaments (i.e., multifilament yarns). Also, the low-density yarn may have a different amount of filaments in the base and/or effect yarns. In various embodiments, each of the base and/or effect yarns may comprise 5-1,000, or 10-500, or about 10-100 filaments. Or, ranges within these ranges may be used. For example, in some embodiments, the low-density yarn may have 34 filaments in the base yarn and 68 filaments in the effect yarn. In other embodiments, the low-density yarn may have 34 filaments in the base yarn and 96 filaments in the effect yarn. In other cases, the base yarn may have more filaments than the effect yarn. Or monofilament yarns can also be used.
When the yarn product is formulated as a matrix it may have a defined density. For example, the matrix may comprise a density of less than or equal to 60, 45, 30, 25, 20, 15, 10 or 5 grams per liter or any range between 5 to 60, or 10 to 45, or about 10 to 35 grams per liter. In certain embodiment, the density is less than 30 grams per liter. In certain embodiments, the density is about 15 grams per liter.
In certain embodiments, the matrix can be formed by cutting the disclosed yarn product into a plurality of pieces thereby creating a three-dimensional matrix that has padding and/or insulating properties.
The low-density yarn products may also be formulated to contain additives such as, but not limited to, substances that reflect or absorb heat and infrared radiation to control radiant heat loss, fire retardants and/or antimicrobials.
In other embodiments, the article of manufacture comprises a twisted yarn product as disclosed herein. Thus, in certain embodiments, disclosed is an article of manufacture comprising a core yarn and a low-density yarn. In certain embodiments, the twisted yarn product may further comprise a binder yarn as disclosed herein. Thus, in certain embodiments, disclosed is an article of manufacture comprising: a twisted yarn product comprising a core yarn; a low-density yarn, wherein the low-density yarn is formulated as loops that extend substantially radially from the core yarn; and a binder yarn, wherein the binder yarn is twisted around the core yarn and the low-density yarn to hold the low-density yarn in position relative to the core yarn.
Each of the core yarn, the low-density yarn and the optional binder yarn may comprise a base yarn and optionally, an effect yarn as disclosed herein. The base yarn may be relatively straight base yarn and the effect yarn may be overfed as compared to the base yarn. In certain embodiments, the effect yarn may be 30% to 1000% overfed, or 50% to 500%, or 100% to 300% overfed as compared to the base yarn. The effect yarn may comprise multiple component yarns added to give the yarn additional thickness and or fluff. For example, any one of the core yarn, the low-density yarn, and/or the binder yarn may be formulated such that the effect yarn extends substantially radially from the base yarn. Additionally and/or alternatively, the effect yarn may be formulated as loops that extend substantially radially from the base yarn.
In certain embodiments, the low-density yarn used in the twisted yarn product is an overfeed yarn, i.e., a yarn that is delivered to a twisting procedure in a manner such that the yarn is overfed, i.e., delivered to the twisting procedure at a faster rate than another yarn. In certain embodiments, the low-density yarn may be 100% to 1000% overfed, or 120% to 500%, or 150% to 300% overfed into the twister as compared to the core yarn, where 100% overfeed is a feed rate of twice (i.e., 2×) the original feed rate used for the core yarn. In certain cases, the low-density overfeed yarn is twisted around the core yarn such that the overfeed yarn makes loops in relation to the core yarn. The loops created by the low-density overfeed yarn may be any size depending upon the final use for the yarn product. Also, the loop size and frequency with which the loops interact with the core yarn may be varied, for example by varying the settings on a hollow spindle novelty yarn twister making the final twisted yarn. In an embodiment, the low-density overfeed yarn enters the twister at a faster speed than the core yarn to make loops. Also, in some embodiments, and the turns per meter of a binder yarn in the hollow spindle twister also effects the height of the loops and the frequency of the loops. In certain embodiments, individual loops extend from the core about every 0.05-300 mm or every 1-50 mm or every 2-10 mm. Or ranges within these ranges may be used.
The base and/or effect yarn for any of the core, low-density or binder yarns may be polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
In certain embodiments, the twisted yarn product used in the article of manufacture is formulated as a three-dimensional matrix having a density of less than or equal to 60, 30, 25, 20, 15, 10 or 5 grams per liter or any range between 5 to 60, or 10 to 45, or about 8 to 30 grams per liter. In certain embodiments, the density of the matrix is less than 24 grams per liter. In certain embodiments, the density of the matrix is about 12 grams per liter.
In certain embodiments, the twisted yarn product used in the article of manufacture and comprising a core yarn, a low-density yarn and optionally, a binder yarn may have a defined denier. In certain embodiments, the twisted yarn product may comprise a denier ranging from 300 denier to 20,000 denier with a preferred range of 1500 to 7500 denier.
The cross section of filament or fibers used for any of the core, over-feed, low-melting and/or binder yarns may be round, hollow fiber, tri-lobal, or any other shape. Hollow fibers are lighter than solid fibers of the same diameter and have additional places to trap dead air than a solid yarn, which can be advantageous. Also, any size yarn, or any size of the component yarns, or any size of the filaments or fibers making the component core, low-density and/or binder yarn may be used.
Each of the low-density yarn, core yarn and binder yarn may comprise yarns that have multiple filaments (i.e., multifilament yarns). Also, each of the low-density, core and/or binder yarns may have a different amount of filaments in the base and/or effect yarns. In various embodiments, each of the base and/or effect yarns used for the core yarn, or low-density yarn, or binder yarn may comprise 5-1,000, or 10-500, or about 10-100 filaments. Or, ranges within these ranges may be used. For example, in some embodiments, the low-density yarn may have 34 filaments in the base yarn and 68 filaments in the effect yarn. In other embodiments, the low-density yarn may have 34 filaments in the base yarn and 96 filaments in the effect yarn. The core yarn may have, for example, a base yarn of about 34 filaments and an effect yarn of about 34 filaments. The binder yarn may, in certain embodiments, have a base yarn of about 34 filaments with an optional effect yarn of about 34 filaments. In other cases, the low-density, core and/or binder base yarn may have more filaments than the effect yarn. Or monofilament yarns can also be used.
The yarn products made using a low-density yarn(s) alone or as a twisted yarn product may be used as insulation for any application requiring temperature control. Thus, in certain embodiments, the article of manufacture may comprise apparel, sporting equipment, household items, a building structure, insulation for an automobile, aircraft, industrial equipment, or any other application requiring temperature control. For example, winter clothing needs to be able to be washed in a washing machine or stuffed into small bags with minimal impact on the insulation material. Thus, in certain embodiments, the disclosed yarn products can be used in sleeping bags, gloves, footwear, jackets, coats, vests, pants, bib overalls used for winter sports, blankets, comforters, quilts and any other article that is related to temperature control. In certain embodiments, the disclosed yarn products may be used as insulation for a building structure, such as a house. Additionally and/or alternatively, the disclosed yarn products may be combined with barriers to control radiant heat loss. The disclosed yarn products can be sewn in a large variety of sewing techniques and arrangements in a garment.
In other embodiments, the disclosed yarn products can be used to fill pillows or cushions on furniture. The yarn products are fluffy and bounce back when compressed which is an advantageous property for insulation, padding, or filling for pillows and mattresses. The disclosed yarn products may also be formulated to contain additives such as, but not limited to, substances that reflect or absorb heat and infrared radiation to control radiant heat loss, fire retardants and/or antimicrobials. These substances may be extruded into the synthetic fiber or applied to naturally occurring fibers. The disclosed yarn products can also be combined with down, batting, synthetic fiber clusters, non-woven fabric, or any type of insulation.
Also disclosed are methods of making the disclosed yarn products. The methods may be embodied in a variety of ways.
In one embodiment, disclosed is a method of making a yarn product comprising a plurality pieces of a low-density yarn formulated as a three dimensional matrix, the method comprising: exposing yarn to a process to generate a low-density yarn; cutting the yarn product into a plurality pieces; and combining the plurality of pieces of yarn product to form the three-dimensional matrix. In an embodiment, each of the pieces of the low-density yarn are mixed such that each of the pieces of the low-density yarn are not attached or physically secured to each other.
A variety of techniques may be used to generate the low-density yarn. In one embodiment, the method to generate the low-density yarn comprises air-jet texturing.
In some embodiments, the low-density yarn comprises a base yarn and an effect yarn. The low-density yarn may have a relatively straight base yarn and the effect yarn may be overfed as compared to the base yarn. In certain embodiments, the effect yarn may be 30% to 1000% overfed, or 50% to 500%, or 100% to 300% overfed as compared to the base yarn. In an embodiment, the combination of base yarn and effect yarn makes a textured yarn. The effect yarn may be added to give the yarn additional thickness and or fluff. For example, the low-density yarn may be formulated such that the effect yarn extends substantially radially from the base yarn. Additionally and/or alternatively, the effect yarn may be formulated as loops that extend substantially radially from the base yarn.
In certain embodiments, the base yarn may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
The effect yarn may comprise the same fiber as the base yarn, or a different fiber. In some embodiments, the effect yarn may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
The low-density yarn may comprise a defined density and/or denier. In certain embodiments, the low-density yarn may comprise a denier ranging from 150 denier to 15,000 denier with the preferred range between 1000 to 5000 denier.
The cross section of filament or fibers used for the low-density yarn may be round, hollow fiber, tri-lobal, or any other shape. Hollow fibers are lighter than solid fibers of the same diameter and have additional places to trap dead air than a solid yarn, which can be advantageous. Also, any size yarn, or any size of the component yarns, or any size of the filaments or fibers making the low-density yarn may be used.
The low-density yarn may comprise yarns that have multiple filaments (i.e., multifilament yarns). Also, the low-density yarn may have a different amount of filaments in the base and/or effect yarns. In various embodiments, each of the base and/or effect yarns may comprise 5-1,000, or 10-500, or about 10-100 filaments. Or, ranges within these ranges may be used. For example, in some embodiments, the low-density yarn may have 34 filaments in the base yarn and 68 filaments in the effect yarn. In other embodiments, the low-density yarn may have 34 filaments in the base yarn and 96 filaments in the effect yarn. In other cases, the base yarn may have more filaments than the effect yarn. Or monofilament yarns can also be used.
When the yarn product is formulated as a matrix it may have a defined density. For example, the matrix may comprise a density of less than or equal to 60, 30, 25, 20, 15, 10 or 5 grams per liter or any range between 5 to 60, or 10 to 45, or about 10 to 35 grams per liter. In certain embodiments, the density is less than 30 grams per liter. In an embodiment, the density is about 15 grams per liter.
In certain embodiments, the matrix can be formed by cutting the yarn product into a plurality of pieces and then mixing the plurality of pieces to create a three-dimensional matrix that has padding and/or insulating properties. In certain embodiments, the yarn product is formulated as a three-dimensional matrix by assembling pieces of the yarn product after cutting.
In other embodiments, disclosed is a method to make twisted yarn product comprising a core yarn and a low-density overfeed yarn comprising the steps of: combining a core yarn and a low density yarn and twisting the core yarn and the low-density yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis and the low-density yarn forms loops that protrude from the core yarn.
In an embodiment, a twister is used to perform the step of twisting the core yarn and the low-density yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis and the low-density yarn forms loops that protrude from the core yarn. Or other techniques known in the art may be used.
In some embodiments, the twisted yarn product may comprise a binder yarn. Thus, in certain embodiments, the method may further comprise combining a binder yarn with the core yarn and the low-density yarn and twisting all three of the core yarn, the low-density yarn and the binder yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis, the low-density yarn forms loops that protrude from the core yarn, and the binder yarn holds the loops in place. In an embodiment, a twister may be used to perform the step of twisting all three of the core yarn, the low-density yarn and the binder yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis, the low-density yarn forms loops that protrude from the core yarn, and the binder yarn holds the loops in place. Or other techniques known in the art may be used.
The method may further comprise the step of formulating the twisted yarn product as a three-dimensional matrix. For example, the three-dimensional matrix may be formed by cutting and/or melting the yarn after the step of twisting the core yarn and the low-density yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis and the low-density yarn forms loops that protrude from the core yarn. When the yarn product is formulated as a matrix it may have a defined density. For example, the matrix may comprise a density of less than or equal to 60, 30, 15, 10 or 5 grams per liter or any range between 5 to 60, or 10 to 45, or about 8 to 30 grams per liter. In an embodiment, the density is less than 24 grams per liter. In an embodiment, the density is about 12 grams per liter.
Any one of the core yarn, the low-density yarn and/or the optional binder yarn may comprise a base yarn and/or an effect yarn. For each of the core yarn, the low-density yarn and/or the optional binder yarn, the base yarn may be relatively straight base yarn and the effect yarn may be overfed as compared to the base yarn. In certain embodiments, the effect yarn may be 30% to 1000% overfed, or 50% to 500%, or 100% to 300% overfed as compared to the base yarn. In an embodiment, the combination of base yarn and effect yarn makes a textured yarn.
In certain embodiments, the base yarn for any of the core yarn, the low-density yarn and/or the binder yarn may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. Also, blends of such fibers may be used.
The effect yarn for any of the core yarn, the low-density yarn and/or the binder yarn may comprise the same fiber as the base yarn, or a different fiber. In some embodiments, the effect yarn may comprise polyethylene, polypropylene and/or polyester. Or other types of fiber, such as, but not limited to, nylon, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, carbon fiber, silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool may be used. The effect yarn may be added to give the yarn additional thickness and or fluff. For example, the core, low-density and/or binder yarn may be formulated such that the effect yarn extends substantially radially from the base yarn. Additionally and/or alternatively, the effect yarn may be formulated as loops that extend substantially radially from the base yarn. Also in some embodiments, the process used generate any one of the core yarn and/or the low-density yarn and/or the base yarn comprises air-jet texturing.
In certain embodiments, the low-density yarn used in the twisted yarn product is an overfeed yarn, i.e., a yarn that is delivered to a twisting procedure in a manner such that the yarn is overfed, i.e., delivered to the twisting procedure at a faster rate than another yarn. In certain embodiments, the low-density yarn may be 100% to 1000% overfed, or 120% to 500%, or 150% to 300% overfed into the twister as compared to the core yarn, where 100% overfeed is a feed rate of twice (i.e., 2×) the original feed rate used for the core yarn. In certain cases, the low-density overfeed yarn is twisted around the core yarn such that the overfeed yarn makes loops in relation to the core yarn. The loops created by the low-density overfeed yarn may be any size depending upon the final use for the yarn product. Also, the loop size and frequency with which the loops interact with the core yarn may be varied, for example by varying the settings on a hollow spindle novelty yarn twister making the final twisted yarn. In an embodiment, the low-density overfeed yarn enters the twister at a faster speed than the core yarn to make loops. Also, in certain embodiments, the turns per meter of the binder yarn in the hollow spindle twister also effects the height of the loops and the frequency of the loops. In certain embodiments, individual loops extend from the core about every 0.05-300 mm or every 1-50 mm or every 2-10 mm. Or ranges within these ranges may be used.
The yarn product comprising a low-density yarn, a core yarn, and optionally, a binder yarn may comprise a defined density and/or denier. In certain embodiments, the twisted yarn product may comprise a denier ranging from 300 denier to 20,000 denier with the preferred range of 1500 to 7500 denier.
In an embodiment, the cross section of filament or fibers used for any of the base or effect yarns for any of the core, low-density and or binder yarns may be round, hollow fiber, tri-lobal, or any other shape. Hollow fibers are lighter than solid fibers of the same diameter and have additional places to trap dead air than a solid yarn, which can be advantageous. Higher denier per filament components helps in compression recovery. Lower denier per filament gives more loops to trap air. Also, any size yarn may be used for the core and optional effect yarns in the texturing process. Thus, the sizes of each of the component yarns may be varied.
Each of the low-density yarn, core yarn and binder yarn may comprise yarns that have multiple filaments (i.e., multifilament yarns). Also, each of the low-density, core and/or binder yarns may have a different amount of filaments in the base and/or effect yarns. In various embodiments, each of the base and/or effect yarns used for the core yarn, or low-density yarn, or binder yarn may comprise 5-1,000, or 10-500, or about 10-100 filaments. Or, ranges within these ranges may be used. For example, in some embodiments, the low-density yarn may have 34 filaments in the base yarn and 68 filaments in the effect yarn. In other embodiments, the low-density yarn may have 34 filaments in the base yarn and 96 filaments in the effect yarn. The core yarn may have, for example, a base yarn of about 34 filaments and an effect yarn of about 34 filaments. The binder yarn may, in certain embodiments, have a base yarn of about 34 filaments with an optional effect yarn of about 34 filaments. In other cases, the low-density, core and/or binder base yarn may have more filaments than the effect yarn. Or monofilament yarns can also be used.
In some embodiments, a lower melting yarn, like polyethylene and/or polypropylene, can be added to the core, binder and/or low-density yarn to act like a glue when heated to help in preventing the three components from unraveling. This glue enables individual strands of the twisted yarn to be mechanically chopped into pieces in a method that is quicker than melting the strand of twisted yarn into smaller pieces. There are a variety of ways to heat the yarn to melt the lower-melting (i.e., glue) yarn including heating in an autoclave, winding the yarn through a tube heater, batch heating in hank form, or using large production belt heaters that are used to heat-set carpet yarns.
Thus, in certain embodiments, the method may comprise combining a core yarn with a low-density overfeed yarn in a manner such that large loops from the low-density overfeed yarn protrude from the core yarn. The method may further comprise twisting a binder yarn around the core and the loops to hold the overfeed yarn or large loops in place where the overfeed yarn intersects with the core.
The core yarn may be bound to the overfeed yarn by twisting a binder yarn around the core and overfeed yarns using a hollow spindle novelty yarn twister or a ring twister with overfeed capabilities to make large loops. Or other techniques may be used. Thus, in certain embodiments, the multi-yarn product is made by feeding a core yarn into a twister along with an excess amount (i.e., overfeed) of a low-density yarn. The twister turns in a circular manner around the longitudinal axis of the core yarn as it is fed through the twister. As there is excess (i.e., overfeed) low-density yarn compared to the core yarn, the excess low-density overfeed yarn is not completely elongated as it travels through the twister and so, due to the circular turning of the twister relative to its longitudinal axis, the low-density overfeed yarn loops or bunches around the circumference of the core as the two yarns move through the twister.
In an embodiment, the loops are not in a flat plane but may be in varying positions is relationship to the core yarn. Or the loops may be in a flat plane. In an embodiment, the method of creating loops may comprise using a specialized knitting machines and/or a weaving loom.
In some embodiments, a third binder yarn may be thread through the twister with the core yarn and the low-density overfeed yarn. In an embodiment, the amount of binder yarn is less than the amount of the low-density overfeed yarn. As the twister turns, the binder yarn wraps around the extended (straightened) core yarn and the looped low-density overfeed yarn, to hold the looped low-density overfeed yarn in place where the looped low-density overfeed yarn intersects with the core yarn. In an embodiment, the binder yarn is not in a flat plane but may be in varying positions is relationship to the core and overfeed (looped) yarn. Or the binder yarn may be in a flat plane.
In some embodiments, a strand, or a plurality of strands of the twisted yarn product comprised of a core, a low-density overfeed yarn, and a binder yarn may be bunched in a manner to create a three-dimensional matrix. In this embodiment, different portions of the single strand or plurality of strands may grip the loops and/or hair of other portions of the strand's or strands' overfeed yarn to make a sustainable three-dimensional structure for insulation. For example, a strand of the twisted yarn product comprised of a core yarn, a low-density overfeed (e.g., loopy) yarn and a binder yarn may be cut lengthwise into a plurality of pieces and then the pieces combined to form a three-dimensional matrix. The plurality of pieces may be combined in a random manner so as to maximize the ability of the matrix to trap air and/or form an insulation material that is light and springy. The loops and/or hair from individual strands of the yarns used in the yarn product may grip the loops and/or hair of other strands of the yarn to make a sustainable three-dimensional structure for insulation. In certain embodiments, the plurality of smaller pieces of yarn may have the ends melted either during or after cutting to prevent the three components (i.e., core, loops and binder) from unraveling.
The sizes of each of the component yarns may be varied. For example, the core yarn 2 may comprise continuous multifilament strand(s) of 4 denier for each filament to generate a core yarn 2 of about 650 denier using an air jet texturing machine where the effect strand(s) (4 in
The loops created by the low-density overfeed yarn may be any size depending upon the final use for the yarn product. Any one or all of the three component yarns (core yarn, low-density overfeed yarn, and binder yarn) may be made by combining one or more strands of continuous multifilament polypropylene on an air jet texturing machine to give close to the maximum amount of hair. Air jet texturing machines tend to make the hair in a loopy structure that also creates small pockets for dead air which is helpful as insulation. The hairy nature of the component yarns also tends to stick to other strands of the yarn to help maintain a sustainable three-dimensional structure suitable for insulation. In other embodiments, the component yarns (e.g., low-density, core or binder) may also be made on a false twist texturing machine, spun out of fibers, made with flat yarns with no texturing, or any other type of yarn manufacturing process. The component yarns (e.g., low-density, core or binder) can be multi-filament or monofilament.
In certain embodiments of the disclosed methods, the twisted yarn may be cut by melting into shorter segments. The melting process may be performed so as to hold the core, low-density overfeed and binder together so the yarn does not untwist, and the loops do not come out. The short segments of final insulating yarn may then be mixed so they are not parallel with each other. In this way, a multi-directional mass of insulation is created. It is also foreseen that the yarn product (twisted or low-density alone) may be wads of yarn that are not cut into segments.
In certain embodiments, the disclosed yarn products may be made on knitting or weaving machines. Such yarn products may have leno yarns or a knitting stitch hold the loopy insulating yarn together without melting the ends.
Another method of holding the twisted products together is to include a lower melting point filament or fiber, such as polyethylene or polypropylene, in one or more of the component yarns. The lower melting yarn can act like a glue when heated which helps in preventing the three components for unraveling. This glue enables the twisted yarn product to be mechanically chopped into pieces in a quicker method than melting the yarn product into pieces.
In another embodiment, the disclosed single and/or twisted multi-yarn products (or segments thereof) may maintain adequate structural integrity by heat setting the yarn product itself and not melting the ends of the segments. In another embodiment, the yarn products (or segments thereof) may maintain adequate structural integrity by the component yarns sticking to each other due to the hair of one component yarn sticking or entangling to the hair of another component yarn and not melting the ends of the segments.
In certain embodiments, polypropylene may be chosen for one or more of the component yarns, i.e., any of the core, low-density overfeed yarn or binder yarn. Polypropylene is light, hydrophobic, and inexpensive. Additionally and/or alternatively, any synthetic, like nylon, polyester, polyethylene, acrylic, polyvinylchloride, polybutylene terephthalate, polyurethane, aramid, fiberglass, and carbon fibers may be used to make a yarn product as disclosed herein. A low-density yarn product can also be created with natural fibers such as silk, cotton, hemp, jute, sisal, linen, asbestos, rayon, or wool. Or, in certain embodiments, a polyester insulating yarn from component yarns made from polyester (polyethylene terephthalate) may be used.
In an embodiment, multifilament effect strands strand(s) (e.g., 4, 8, and 12 of
The disclosed yarn products may also be formulated to contain substances that reflect or absorb heat and infrared radiation to control radiant heat loss. These substances may be extruded into the synthetic fiber or applied to naturally occurring fibers. In an embodiment, the yarn product may also contain fire retardants. In another embodiment, the yarn product may also contain antimicrobial substances. The disclosed yarn products can also be combined with down, batting, synthetic fiber clusters, non-woven fabric, or any type of insulation.
Also disclosed is insulating yarn using polymer molding or polymer processing rather than yarn manufacturing to generate a loopy material used for insulation.
The three component yarns (core yarn, low-density overfeed yarn, and binder yarn) were made from continuous multifilament polypropylene on an air jet texturing machine to give close to the maximum amount of hair by combining the base multi-filament strands and the effect multi-filament strands as shown in
In this example, the core yarn was made from a base of 300/72 and an effect of 300/72 to generate a core yarn of 650 denier using an air jet texturing machine. The effect yarn was fed into an air jet texturing machine at a greater speed than the base strand(s) to make the core yarn have hair.
The low-density overfeed yarn used for the loops was made with a base yarn of 300/72 and the effect was two yarns of 300/72. The base and two effect yarns were processed in an air jet texturing machine to make an overfeed yarn of 1700 denier. The effect strand(s) were fed into the air jet texturing machine at a greater speed than the base strand(s) to make the overfeed yarn have hair. The binder yarn was made from a 300/72 base to generate a binder yarn of 325 denier using an air jet texturing machine.
The core yarn was bound to the low-density overfeed yarn by twisting the binder yarn around the core and low-density overfeed yarns using a hollow spindle novelty yarn twister making large loops from the low-density overfeed yarn. The low-density overfeed yarn was fed into the twister at a 150% faster speed than the core yarn. The loops were not in a flat plane but were in varying positions is relationship to the core yarn.
The final twisted yarn product was then cut by melting into shorter segments. The melting process held the core, overfeed and binder together so the yarn did not untwist and the loops did not come out. The short segments of final yarn were then mixed so they were not parallel with each other and a multi-directional mass of insulation was created.
A polyester twisted yarn product from component yarns made from polyester (polyethylene terephthalate) was produced. The polyester can be virgin or recycled. In this example, the starting material was polyester partially oriented yarn (POY), whereas Example 1 used fully drawn polypropylene components. The core yarn was made using a multifilament base yarn and a multifilament effect yarn, each of which were 255/150/34 (i.e., 255 denier, drawn to 150 denier during texturing, and contained 34 individual filaments). Both the base and effect yarns had a trilobal cross-section. Two ends were textured together in an air jet texturing process as base and effect yarns to make the polyester component of the core yarn.
A low-density overfeed yarn was made in an air jet texturing machine using a multifilament trilobal cross-section base yarn of 255/150/34 polyester POY and a multifilament trilobal cross-section effect yarn of 500/300/96 polyester POY and a second round cross-section multifilament yarn of 255/150/68 polyester POY. The resulting low-density overfeed yarn was made to minimize its weight and maximize its diameter with significant hair while maintaining the ability to rebound after being comparted.
A lower melting 200 denier polyethylene yarn was also fed into the hollow spindle novelty yarn twister with the core yarn to act as a glue to hold the insulation yarn together in subsequent heating. The binder yarn used in the yarn twister was a 150/34 fully drawn false twist textured polyester. The overfeed yarn was fed into the twister at a 150% faster speed than the core yarn.
The twisted yarn was then heated in a loose hank to melt the polyethylene. The final twisted yarn product was then mechanically chopped into segments. The polyethylene glue yarn kept the insulation from unraveling and held during washing and drying cycles of home laundry machines.
The three-dimensional matrix formed by mixing the yarn segments had a density of about 12 grams/liter when the segments were placed in a graduated cylinder and lightly tapped so the segments settle. The yarn before cutting into a plurality of pieces is shown in
The polyester low-density yarn of Example 3 can be used as economical insulation by mechanically chopping it up into smaller pieces. It was fluffy with abundant hair and was made to minimize the weight and maximize the fluff and diameter. This economical yarn product eliminates the need to use a novelty twister (and subsequent heating if a melting glue yarn is used). The three-dimensional matrix formed by mixing the yarn segments had a density of about 15 grams/liter when the segments are placed in a graduated cylinder and lightly tapped so the segments settle. An example of this yarn is shown in
The disclosure may be better understood by referencing the following exemplary embodiments.
A.1. A yarn product comprising a plurality pieces of a low-density yarn formulated as a three-dimensional matrix.
A.2 The yarn product of any of embodiment A.1, wherein the low-density yarn comprises a base yarn and an effect yarn.
A.3 The yarn product of embodiments A.1-A.2, wherein the low-density base yarn comprises polyethylene, polypropylene and/or polyester.
A.4 The yarn product of embodiments A.1-A.3, wherein the low-density effect yarn comprises polyethylene, polypropylene and/or polyester.
A.5 The yarn product of embodiments A.1-A.4, wherein the low-density yarn is formulated such that the effect yarn extends substantially radially from the base yarn.
A.6 The yarn product of embodiments A.1-A.5, wherein the low-density effect yarn is formulated as loops that extend substantially radially from the base yarn.
A.7 The yarn product of embodiments A.1-A.6, wherein the density is less than 30 grams per liter.
B.1 A twisted yarn product comprising a low-density yarn and a core yarn.
B.2 The twisted yarn product of embodiment B.1, wherein the low-density yarn is formulated as loops that extend substantially radially from the core yarn.
B.3 The twisted yarn product of embodiments B.1-B.2, further comprising a binder yarn.
B.4 The twisted yarn product of embodiments B.1-B.3, wherein the binder yarn is twisted around the core yarn and the low-density yarn to hold the low-density yarn in position relative to the core yarn.
B.5 The twisted yarn product of embodiments B.1-B.4, formulated as a three-dimensional matrix.
B.6 The twisted yarn product of embodiments B.1-B.5, wherein the low-density yarn comprises a base yarn and an effect yarn.
B.7 The twisted yarn product of embodiments B.1-B.6, wherein the low-density base yarn comprises polyethylene, polypropylene and/or polyester.
B.8 The twisted yarn product of embodiments B.1-B.7, wherein the low-density effect yarn comprises polyethylene, polypropylene and/or polyester.
B.9 The twisted yarn product of embodiments B.1-B.8, wherein the low-density yarn is formulated such that the effect yarn extends substantially radially from the base yarn.
B.10 The twisted yarn product of embodiments B.1-B.9, wherein the low-density effect yarn is formulated as loops that extend substantially radially from the base yarn.
B.11 The twisted yarn product of embodiments B.1-B.10, wherein the low-density yarn is an overfeed yarn.
B.12 The twisted yarn product of embodiments B.1-B.11, wherein the core yarn comprises a base yarn.
B.13 The twisted yarn product of embodiments B.1-B.12, wherein the core yarn further comprises an effect yarn.
B.14 The twisted yarn product of embodiments B.1-B.13, wherein the core effect yarn extends substantially radially from the base yarn.
B.15 The twisted yarn product of embodiments B.1-B.14, wherein the core base yarn comprises polyethylene, polypropylene and/or polyester.
B.16 The twisted yarn product of embodiments B.1-B.15, wherein the core effect yarn comprises polyethylene, polypropylene and/or polyester.
B.17 The twisted yarn product of embodiments B.1-B.16, wherein the binder yarn comprises a core yarn.
B.18 The twisted yarn product of embodiments B.1-B.17, wherein the binder yarn comprises an effect yarn.
B.19 The twisted yarn product of embodiments B.1-B.18, wherein the binder core yarn comprises polyethylene, polypropylene and/or polyester.
B.20 The twisted yarn product of embodiments B.1-B.19, wherein the binder effect yarn comprises polyethylene, polypropylene and/or polyester.
B.21 The twisted yarn product of embodiments B.5-B.20, wherein the density is less than 24 grams per liter.
C.1 A twisted yarn product comprising:
C.2 The twisted yarn product of embodiment C.1, wherein the yarn product is formulated as a three-dimensional matrix.
C.3 The twisted yarn product of embodiments C.1-C.2, wherein the density is less than 24 grams per liter.
D.1 An article of manufacture comprising a plurality pieces of a low-density yarn formulated as a three dimensional matrix.
D.2 The article of manufacture of embodiment D.1, wherein the plurality pieces of a low-density yarn formulated as a three dimensional matrix used comprise a density of less than 30 grams per liter.
E.1 An article of manufacture comprising a yarn product comprising:
E.2 The article of manufacture of embodiment E.1, wherein the yarn product is formulated as a three-dimensional matrix.
E.3 The article of manufacture of embodiments E.1-E.2, wherein the density of the matrix used is less than 24 grams per liter.
F.1 A method of making a yarn product comprising a plurality pieces of a low-density yarn formulated as a three dimensional matrix, the method comprising:
F.2 The method of embodiment F.1, wherein the process used generate the low-density yarn comprises air-jet texturing.
F.3 The method of embodiments F.1-F.2, wherein the density of the yarn product is less than 30 grams per liter.
F.4 The method of embodiments F.1-F.3, wherein the low-density yarn comprises a base yarn and an effect yarn.
F.5 The method of embodiments F.1-F.4, wherein the low-density base yarn comprises polyethylene, polypropylene and/or polyester.
F.6 The method of embodiments F.1-F.5, wherein the low-density effect yarn comprises polyethylene, polypropylene and/or polyester.
F.7 The method of embodiments F.1-F.6, wherein the low-density yarn is formulated such that the effect yarn extends substantially radially from the base yarn.
F.8 The method of embodiments F.1-F.7, wherein the low-density effect yarn is formulated as loops that extend substantially radially from the base yarn.
F.9 The method of embodiments F.1-F.8, wherein the yarn product is formulated as a three-dimensional matrix by assembling pieces of the yarn product after cutting or melting.
G.1 A method to make a twisted yarn product comprising a core yarn and a low-density overfeed yarn comprising the steps of:
G.2 The method of embodiment G.1, comprising using a twister to perform the step of twisting the core yarn and the low-density yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis and the low-density yarn forms loops that protrude from the core yarn.
G.3 The method of embodiments G.1-G.2, wherein the process used generate the low-density yarn comprises air-jet texturing.
G.4 The method of embodiments G.1-G.3, further comprising step (c) of formulating the yarn product as a three-dimensional matrix.
G.5 The method of embodiments G.1-G.4, further comprising combining a binder yarn with the core yarn and the low-density yarn in step (a) and twisting all three of the core yarn, the low-density yarn and the binder yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis, the low-density yarn forms loops that protrude from the core yarn, and the binder yarn holds the loops in place in step (b).
G.6 The method of embodiments G.1-G.5, comprising using a twister to perform the step of twisting all three of the core yarn, the low-density yarn and the binder yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis, the low-density yarn forms loops that protrude from the core yarn, and the binder yarn holds the loops in place.
G.7 The method of embodiments G.1-G.6, wherein the three-dimensional matrix is formed by cutting and/or melting the yarn after the step of twisting the core yarn and the low-density yarn around a longitudinal axis in a manner such that the core yarn extends along the longitudinal axis and the low-density yarn forms loops that protrude from the core yarn.
G.8 The method of embodiments G.1-G.7, wherein the density of the yarn product is less than 24 grams per liter.
G.9 The method of embodiments G.1-G.8, wherein the low-density yarn comprises a base yarn and an effect yarn.
G.10 The method of embodiments G.1-G.9, wherein the low-density base yarn comprises polyethylene, polypropylene and/or polyester.
G.11 The method of embodiments G.1-G.10, wherein the low-density effect yarn comprises polyethylene, polypropylene and/or polyester.
G.12 The method of embodiments G.1-G.11, wherein the low-density yarn is formulated such that the effect yarn extends substantially radially from the base yarn.
G.13 The method of embodiments G.1-G.12, wherein the low-density effect yarn is formulated as loops that extend substantially radially from the low-density base yarn.
G.14 The method of embodiments G.1-G.13, wherein the low-density yarn is an overfeed yarn.
G.15 The method of embodiments G.1-G.14, wherein the core yarn comprises a base yarn.
G.16 The method of embodiments G.1-G.15, wherein the core yarn further comprises an effect yarn.
G.17 The method of embodiments G.1-G.16, wherein the core effect yarn extends substantially radially from the core base yarn.
G.18 The method of embodiments G.1-G.17, wherein the core base yarn comprises polyethylene, polypropylene and/or polyester.
G.19 The method of embodiments G.1-G.18, wherein the core effect yarn comprises polyethylene, polypropylene and/or polyester.
G.20 The method of embodiments G.1-G.19, wherein the binder yarn comprises a core yarn.
G.21 The method of embodiments G.1-G.20, wherein the binder yarn further comprises an effect yarn.
G.22 The method of embodiments G.1-G.21, wherein the binder core yarn comprises polyethylene, polypropylene and/or polyester.
G.23 The method of embodiments G.1-G.22, wherein the binder effect yarn comprises polyethylene, polypropylene and/or polyester.
This application claims priority from U.S. Provisional Patent Application No. 63/466,075, entitled Compositions for Insulation and Methods of Making Same, and filed May 12, 2023. The disclosure of U.S. Provisional Patent Application No. 63/466,075 is incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63466075 | May 2023 | US |
