Claims
- 1. A self-coating composite yarn for outdoor fabrics comprising:a. a polymeric high melt effect constituent having a melt temperature of at least 280° F., said high melt constituent being selected from the group consisting of acrylic, high melt polyester, high melt polypropylene and nylon; b. a polymeric low melt binder constituent having a melt temperature no greater than 300° F., said low melt constituent being selected from the group consisting of polyethylene low melt polyester, and low melt polypropylene; c. the difference between the low melt constituent and the high melt constituent being at least 40° F.; d. the high melt and low melt constituents being intermingled to form the composite yarn; e. the composite yarn having a denier of 400-4,000; f. when the composite yarn is subjected to heat, the composite yarn becomes self-coating and self-bonding.
- 2. The self-coating composite stabilizing yarn according to claim 1 wherein the denier of the low melt constituent prior to the intermingling step is about 250 d and the high melt constituent is in the range of 150 d-3,500 d.
- 3. The self-coating composite stabilizing yarn according to claim 1 having minimal or zero raveling.
- 4. The self-coating composite stabilizing yarn according to claim 1 wherein the low melt constituent comprises at least one end of continuous filament low melt yarn, and the high melt constituent comprises at least one end of continuous filament high melt yarn, the low melt and high melt yarns being air textured.
- 5. The self-coating composite stabilizing yarn according to claim 4 wherein the low melt yarn is 750 denier drawn at a 3-1 ratio to 250 denier and each high melt yarn is initially 250 denier-5,700 denier drawn at a ratio of 1.65-1 to a denier in the range of 150-3,500.
- 6. The self-coating composite stabilizing yarn according to claim 5 wherein the composite yarn has a composite denier in the range of 400-4,000 d.
- 7. The self-coating composite stabilizing yarn according to claim 1 comprising a blend of low melt and high melt staple fibers homogeneously mixed and processed according to conventional blended yarn forming procedures.
- 8. The self-coating composite stabilizing yarn according to claim 7 wherein the low melt and high melt staple fibers comprise polyethylene binder fibers and acrylic high melt effect fibers respectively.
- 9. The self-coating composite stabilizing yarn according to claim 7 wherein the ratio of high melt effect fibers to low melt binder fibers is approximately 10-1.
- 10. The self-coating composite stabilizing yarn according to claim 7 wherein the low melt fibers are low melt polyester and the high melt fibers are acrylic.
- 11. The self-coating composite stabilizing yarn according to claim 7 wherein the low melt fibers are low melt polypropylene and the high melt fibers are acrylic.
- 12. The self-coating composite stabilizing yarn according to claim 7 wherein the homogeneously mixed staple fibers are sufficiently strong before heat setting to withstand high speed carding, spinning, winding and twisting.
- 13. The self-coating composite stabilizing yarn according to claim 7 wherein the final product has a denier in the range of 400-4,000 d.
- 14. The self-coating composite stabilizing yarn according to claim 4 wherein the low melt yarn comprises one end of 250 denier polyethylene filament yarn air textured with one end of 300 denier high melt filament polypropylene.
- 15. The self-coating composite stabilizing yarn according to claim 14 wherein two ends of each are air textured for a 1300 denier stabilizing yarn.
- 16. The self-coating composite stabilizing yarn according to claim 4 wherein the low melt yarn comprises one end of 250 denier polyethylene filament yarn and said high melt yarn is one end of 300 denier filament polyester.
- 17. The self-coating composite stabilizing yarn according to claim 16 wherein two ends of each are air textured for a 1300 denier stabilizing yarn.
- 18. The self-coating composite stabilizing yarn according to claim 4 wherein the high melt yarn comprises one end of 18/2 blended acrylic yarn and the low melt yarn is two ends of 250 denier polyethylene.
- 19. The self-coating composite stabilizing yarn according to claim 18 wherein one end of 8/1 acrylic yarn may be air textured with two ends of 250 denier polyethylene.
- 20. The self-coating composite stabilizing yarn according to claim 4 wherein the low melt yarn comprises two ends of 250 denier polyethylene filament yarn and the high melt yarn is two ends of 1000 denier polyester.
REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. application Ser. No. 09/659,324 filed Sep. 12, 2000, now abandoned which is a continuation of U.S. application Ser. No. 09/216,516 filed Dec. 18, 1998, which issued into U.S. Pat. No. 6,117,548 on Sep. 12, 2000.
US Referenced Citations (22)
Foreign Referenced Citations (2)
Number |
Date |
Country |
629724 |
Nov 1995 |
EP |
816544 |
Feb 1998 |
EP |
Continuations (1)
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Number |
Date |
Country |
Parent |
09/216516 |
Dec 1998 |
US |
Child |
09/659324 |
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US |
Continuation in Parts (1)
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Number |
Date |
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Parent |
09/659324 |
Sep 2000 |
US |
Child |
09/867943 |
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US |