KR20140059275A - Durable fabric including bulked and entangled yarn - Google Patents

Abstract

The present invention relates to a continuous filament comprising (a) a plurality of vulcanized continuous filaments, (b) from about 200 to 2000 denier, (c) from about 1 to about 20 denier / filament, and (d) from about 2.0 to about 7.0 g / And a yarn containing the yarn is provided.

Description

[0001] DURABLE FABRIC INCLUDING BULKED AND ENTANGLED YARN [0002]

This publication is directed to a durable and wear resistant durable fabric comprising a composite yarn comprising a bald and entangled yarn.

Polymer filaments such as polyamides, polyolefins and polyesters are useful in a variety of textile products. When the filament is textured / textured or has high tenacity / tensile strength, it is particularly useful when a durable yarn is needed. Examples of such products include functional outdoor wear; Contracts, cars / vehicles and home furnishings; Military clothing and gear; Denim and sweaters; Active wear; Outdoor gear; backpack; Hydrate; And shoes.

This chamber is typically manufactured through an air jet texturing process. The air jet texturing process can provide both bulk and / or texture in addition to entangling the yarn, thus providing a thread that can be included in the fabric. However, this equipment required for this process and performing this process can be expensive enough to be out of the question.

In addition, a multi-filament polymeric chamber can be produced as a vulcanized continuous filament. However, without further processing, the filaments do not form an integrated yarn that can be knitted or woven into the fabric.

One aspect is

(a) a plurality of vulcanized continuous filaments,

(b) from about 200 to about 2000 denier, including from about 300 to about 1200,

(c) about 1 to 20 denier / filaments comprising from about 1 to about 8 and comprising from about 3 to about 6,

(d) a toughness of from about 2.0 to about 7.0 g / denier, including from about 4.0 to about 6.0

And an interlaced article is provided to the yarn.

To provide the yarn with the toughness required of the durable fabric, yarn fabrication includes specific stretching conditions that increase the toughness of the yarn. One suitable way to produce such yarns is

(a) spinning a synthetic chamber,

(b) stretching the yarn,

(c) baling the yarn under an air jet textured member,

(d) intertwining the thread,

(e) winding the yarn into a package

.

The method may be a coupled or inline process that eliminates the need to separately spin the yarn and then provide texturing or bulk to the yarn. After balancing the yarn occurring under the air jet textured member, the yarn is entangled. By entangling the yarn, a plurality of filaments form an integrated yarn, which can then be knitted or woven into the fabric. In addition, the entanglement process provides a means for holding the bulk of the yarn in the yarn, and otherwise the bulk of the yarn may be removed under the tension of the knitting or weaving process.

Another aspect provides an article comprising a baled and entangled yarn. The article may also comprise fabrics made from baled and entangled yarns. Enameled and interwoven yarn

(a) a plurality of vulcanized continuous filaments,

(b) from about 200 to about 2000 denier,

(c) about 1.0 to 8.0 denier / filament, and

(d) a toughness of from about 2.0 to about 7.0 g / denier

And this thread is entangled.

Another aspect provides an article comprising a fabric knitted or woven from a polymerized yarn that is baled and entangled. This thread comprises a polyamide having a plurality of vulcanized continuous filaments, such as nylon 6 or nylon 6,6. Wherein the yarn is from about 200 to about 2000 denier, including from about 200 to about 1500, or from about 500 to about 1500, or from about 900 to about 1000 denier; From about 1 to about 20 denier / filament (dpf) comprising from about 1 to about 8, or from about 3 to about 6, and from about 2.0 to about 7.0 g / denier. In addition, the number of filaments may vary and may be, for example, from about 50 to about 1000 filaments. Which comprises about 100 to about 500 filaments or about 140 to about 350 filaments or about 140 to 280 filaments.

For purposes of this publication, the term "air jet texturing" includes a method of providing a texture to the yarn that leads the yarn through the turbulent flow region of the air jet at a higher rate than drawing the yarn at the far side of the air jet . In the jet, the yarn structure is opened, the loop is formed, and the structure is closed again. Some loops are fixed inside and others are fixed to the surface of the seal. The yarns produced in this process are characterized by the presence of a large number of filament loops that are irregularly spaced along their baldness and yarn length.

For purposes of the present invention, "method of providing textures" refers to the process of introducing fine distortions along the length of a continuous filament yarn, where such distortions include edge crimping, gear crimping and stuffer box crimping . Other methods, sometimes referred to as texturing, that are explicitly excluded from the objective definition of the present invention include flammable texturing, knit-de-knit texturing, and air jet texturing.

For purposes of the present invention, "vulcanization" refers to a process that is specifically intended to increase the bulk of a continuous filament yarn, wherein the process comprises crimping the yarn and its constituent filaments (Bending or folding). The vulcanization used herein specifically excludes air jet texturing.

For purposes of the present invention, the term " vulcanized "refers to a thread of a permanently crimped filament, i.e., retains its crimp when the filament is removed from the yarn.

For the purposes of the present invention, "% crimp" is a property measured according to the method provided herein to provide a measure of the degree of crimp achieved. It is essentially the elongation of the crimped yarn when tension is applied to the yarn. As the crimp degree increases, the specific volume or bulk (cm3 / g) of the yarn increases. Thus, the degree of crimp can be used as a substitute to characterize the yarn bulk.

For purposes of the present invention, the term " edge crimp "means a method of providing textures and / or bulk to yarns, including but not limited to heating the yarn and stretching on a crimping edge followed by cooling .

For purposes of the present invention, the term "gear crimp" method includes, but is not limited to, providing yarns to the yarns through texturing and / or bulking yarns that follow the shape of the two gears It is not intended.

For purposes of the present invention, the term "stuffer box" method includes but is not limited to a method by which a crimping unit provides bulk to a chamber comprising two feed rolls and a stuffer box. By compressing the yarn into the stuffer box, the individual filaments are folded or bent at an acute angle and, optionally, simultaneously fixed with a heating mechanism.

For the purpose of the present invention, "entanglement" entangles the continuous filaments in the multifilament yarn of the present invention, resulting in dense nodal regions of high filament entanglement, which are periodically frequent along the length of the yarn, Quot; refers to a process that is separated by the more bulky and relatively open regions of the substrate. The entanglement process performed in this manner provides a coherent seal. This periodic node structure distinguishes the entangled yarn from an air jet textured yarn that contains a consistently high degree of entanglement along the entire length of the airjet textured yarn. For the purposes of the present invention, entanglement and entanglement can be used interchangeably. The entanglement is observed when existing nodes along the length of the yarn prevent separation of the crimped filaments and is necessary to machine the yarn into a fabric, for example by weaving or knitting.

Some side yarns are useful in the manufacture of vulcanized fabrics. The vulcanized and entangled yarn can be woven or knitted directly under tension without the need for secondary processing of the yarn to form a vulcanized fabric. For example, the yarns are spun, stretched, vulcanized and entangled in a single inline or coupled process. The yarn produced from this process is then formed into a fabric vulcanized through weaving or knitting without further twisting, entangling or air jet texturing of the yarn.

Some side multi-filament yarns that may be included in fabrics or other articles are bulkied and entangled, but also have higher toughness due to the particular stretching process. The toughness of the yarn may be from about 2.0 to about 7.0 g / denier. Other suitable toughness ranges include about 3.0 to about 7.0 g / denier, about 3.0 to about 6.0 g / denier, about 3.5 to about 7.0 g / denier, about 3.5 to about 6.0 g / denier, and about 4.0 to about 6.0 g / Lt; / RTI > Also, higher toughness can be useful. However, if the toughness is less than 2 g / denier, fabrics made from such yarns will lack the desired durability.

The toughness of the yarn is increased by the stretching process. Suitable stretching methods include single step or multi-step stretching methods. In a suitable one-step process, a surface speed of from about 2000 to about 4000 m / min, or from about 2500 to about 4000 m / min, and a temperature of from about 2O 0 C to about 210 0 C or from about 180 0 C to about 210 0 C, A heated roll with a surface speed of about 4000 m / min and a temperature of about 150 ° C to about 220 ° C, or 150 ° C to about 190 ° C is stretched. The stretching ratio may be from about 2.5 to about 4.0. Suitable stretch ratio ranges include from about 2.6 to about 4.0, from about 2.8 to about 4.0, from about 3.1 to about 4.0, and other ranges of greater than about 4.0. Multistage or multi-stretch roll methods known in the art are also suitable. If a multi-step process is involved, the final set of stretching rolls may include the conditions described in this paragraph.

The vulcanizing process involves providing bulk to the yarn in the absence of expensive air jet texturing methods. Suitable baling processes include but are not limited to stuffer boxes, edge crimping, gear crimping or combinations thereof.

The entanglement process may include any of those known in the art. The entangled yarn may comprise a degree of entanglement of about 2 to about 60 bars / m, and another suitable range may include about 15 to about 55 bars / m and about 20 to about < RTI ID = 0.0 > It contains about 40 nodes / m. The yarn may be entangled at any suitable pressure of greater than 0 psi, e.g., greater than 0 psi to 150 psi. Also, suitable entrainment pressures include 30 psi to 130 psi, and 40 psi to 90 psi, and 50 psi to about 110 psi. For nylon 6, 6 yarns of about 1000 denier and 3.0 to 3.5 dpf (denier per filament), a suitable entanglement pressure may be from about 60 psi to about 80 psi.

The vulcanizing process may be carried out in a bulk of from about 1.0 to about 12.0 cm3 / g comprising from about 3 to about 12.0 cm3 / g of yarn and from about 3 to about 12.0 cm3 / g of from about 6.0 cm3 / g to about 12 cm3 / Lt; / RTI > Consistency at the bulk level throughout the yarn is desired and is more important than the measured bulk level. Thus, the bulk can be measured by any suitable method known in the art. One suitable method of measuring bulk is disclosed in U.S. Patent No. 3,471,702. The bulk of the seal is provided in cm < 3 > / g. Alternatively, the bulk can be calculated from the% Crimp based on the following equation.

Bulk = 2 (% Crimp) + 4.2

The bulk calculation utilizes the correlation between bulk and% crimp, which is substantially linear in the range of interest given herein. The% crimp can be any suitable transfer, for example from about 0.50 to about 3.0. Other suitable ranges of percent crimps include from about 0.75 to about 2.0 and from about 0.5 to about 2.0.

Any of a variety of polymers other than nylon may be included in the yarn and fabric being posted. The polymer may include polyolefins, polyesters, polyamides, copolymers thereof, and combinations thereof. In addition, aramid and oxidized polyacrylonitrile may be suitable. Specific examples of suitable polyolefins include, but are not limited to, polyethylene and polypropylene, and polyesters include polyethylene terephthalate, polypropylene terephthalate and polybutylene terephthalate, and suitable polyamides include nylon 6, nylon 6, 6, nylon 11, nylon 12, nylon 6, nylon 10, nylon 6,12, and partially aromatic polyamide such as MXD6. For example, polyamides such as nylon 6 and nylon 6,6 are useful as a blend, as a copolymer or as a homopolymer. In addition, the polymer may be derived from recycled after-consumption and recycle-after-production changes of these polymers.

Various cross-sections are useful for enveloped and entangled multi-filament yarns. In one aspect, the cross section of the filament is circular. Useful cross-sections include, among others, circular, hollow, trilobe, elliptical, scallop-shaped ellipses, and combinations thereof, well known in the art.

A variety of different additives are useful in the yarns, fabrics and articles described herein. Specific examples of yarns having additives include dyed nylon. Typical and non-restrictive lists are included. However, additional additives are well known in the art. Examples include, but are not limited to, antioxidants, UV stabilizers, colorants, pigments, crosslinking agents, phase change materials (paraffin wax), antimicrobials, minerals (ie copper), additives encapsulated in microcapsules (ie vitamin E gels, (E.g., quarternary ammonium, quartz, nicotine, caffeine, fragrance, or aroma), nanoparticles (i.e., silica or carbon), calcium carbonate, flame retardants, vitamins, pharmaceuticals, fragrances, electrically conductive additives, (Hindered phenol, zinc oxide, hindered amines), and combinations thereof, as well as additives, additives, additives, additives, additives, additives, salts, optical brighteners, electroconductive additives, light emitting additives, lubricants, organic and inorganic fillers, preservatives, .

Some side threads may be fabricated as a fabric. This includes woven or woven fabrics. Suitable woven fabrics include, among others, plain weave, twill weave, satin, basket, lip stop and various fancy weave fabrics. Suitable knit fabrics include lightly knitted or knitted fabrics. The specific knitted fabric may be, inter alia, a single knitted fabric, such as a tricot or Russell knitted fabric.

Some side fabrics have properties that make them particularly useful for durable products such as luggage, outdoor clothing, outdoor gear, denim, footwear and military apparel and gears. The fabric may also be a narrow band fabric that may include closely woven fabrics. The fabric properties include from about 80 to about 1200 pounds of grab strength, depending on the yarn denier used. The fabric also exhibits a tear strength of from about 8 to about 150 pounds, including from about 40 to about 70 pounds, as well as greater than 70 pounds, depending on the yarn denier used. In addition, the fabric exhibits Taber abrasion resistance of about 80 to about 4000 cycles, which includes about 400 to about 800 cycles, as well as more than 800 cycles, depending on the yarn denier used.

Further, the fabric can be coated as required for the specific article, and air or moisture permeability reduction requires this modification. Suitable coatings include polyurethane, acrylic, waterproof / breathable membranes, laminates, and various coatings specifically designed for furniture and leisure fabrics.

The features and advantages of the present invention are more fully illustrated by the following examples which are provided for illustrative purposes and which are not to be construed as limiting the invention in any way.

Tables 1 and 2 below show the properties of several inventive yarns (Examples 5 to 24) and comparative yarns (Examples 1 to 4) as shown in the table. The mean was calculated as shown. The yarns were spun from nylon 6,6 polymer and the yarns each contained 280 filaments. The yarn was stretched at a high roll temperature measured at a first stage stretching roll of about 160 DEG C at a draw ratio of about 3.1, vulcanized by a stirrer box at 180 DEG C measured in a stuffing jet, and entangled as shown.

Test Methods:

Interbreeding

The entanglement is measured according to ASTM standard method D4724-87 (re-approved in 1992). This method involves a common procedure of intercostal measurement by needle insertion. The result is recorded as the number of interlocking bars per m of interlaced yarn. A suitable apparatus for measuring the interlocking node is the Rothschild R2071 / 72 automatic entanglement tester from Rothschild Measurement Instruments (Zurich Traubenstrasse 3, Switzerland).

Filament denier

Denier is the linear density of filaments expressed in weight (g) of filament 9000 m. The denier can be measured with a Vibroscope from Textechno (Munich, Germany). 10/9 times the denier is the same as dtex. The denier / filament can be determined in weight form according to ASTM D 1577.

Fracture toughness

The fracture toughness (T) is the maximum or breaking strength of the filament, expressed in force per unit cross-sectional area. Toughness can be measured with Instron Model 1130 available from Instron (Canton, Mass., USA) and reported in g / denier (g / dtex). The breaking toughness (and elongation at break) of the filament can be measured according to ASTM D 885.

[Table 3A]

[Table 3B]

As mentioned above, the% Crimp is a measure of the elongation under tension. For Table 3B,% Crimps were measured using the following method:

Textured  Thread Crimp  Measure

1. Verify the mass of the 10.5 g wire weight.

2. PATIENT-A total of three 100 warp threads per package

3. Apply a lease to the top and bottom of all scales. Do not cut the skins.

4. Drop the rod onto the scale drawer, carefully hold the upper and lower lees and carefully remove the first scale to eliminate twisting of the scale itself.

5. Hanging on the upper hook of the shrink plate, still grip the bottom, carefully add 10.5 g weight to the bottom of the scale (not the lease) and measure after 15 seconds. Record "light weight". This 10 g weight will remain there for the entire test.

6. Hang the 300 g spindle (with 10.5 g spindle), measure the length of the skeleton after 30 seconds, and record as "Heavy spindle length".

7. Repeat steps 6 - 8 for the remaining schedules and repeat until each of the 3 scales from each package is wrapped and measure the light length / heavy length.

Calculation:

% Crimp = 100% (Heavy Chest Length - Light Chest Length) / (Light Chest Length)

Several fabrics were woven from the yarns shown in Tables 1 and 2. Fabrics containing comparative yarns 1 - 4 in the warp or weft direction were not suitable as vulcanized fabrics. This comparative fabric was observed to have a smooth appearance. This is contrasted with fabrics made from yarns 5 to 24 of the present invention in both warp and weft directions. The fabrics comprising the yarns of the present invention exhibit various suitability for the vulcanized fabrics. Thread combinations that provide the most fit for a vulcanized fabric were fabric threads entangled in both warp and weft from about 40 to 90 psi.

It will be appreciated by those skilled in the art that changes and modifications may be made without departing from the spirit of the present invention and that all such changes and modifications as fall within the true scope of the invention / RTI >

Claims (29)

(a) a plurality of vulcanized continuous filaments,
(b) about 200 to 2000 denier,
(c) from about 1 to about 20 denier / filament, and
(d) a tenacity of from about 2.0 to about 7.0 g /
And an interlaced yarn, wherein the interlaced yarn comprises a yarn. The article of claim 1, wherein the filament has a circular cross-section. The article of claim 1, wherein the filament has a non-circular cross-section. The article of claim 1, wherein the denier / filament is from about 1 to about 8. The article of claim 1, wherein the yarn comprises a polymer selected from the group consisting of polyamides, polyesters, polyolefins, copolymers thereof, and combinations thereof. 6. The article of claim 5, wherein the polymer comprises a polyamide selected from nylon 6 and nylon 6,6. 6. The article of claim 5, wherein the polymer comprises MXD6. 6. The article of claim 5, wherein the polymer comprises oxidized polyacrylonitrile. The article of claim 1, wherein the vulcanized continuous filament comprises a polymer additive. 6. The article of claim 5, wherein the polymer comprises dyed nylon. The article of claim 1, wherein the yarn has a bulk of from about 1.0 to about 12.0 cm 3 / g. The article of claim 1, wherein the yarn has a toughness of from about 3.0 to about 7.0 g / denier. The article of claim 1, wherein the yarn has a toughness of from about 4.0 to about 6.0 g / denier. The article of claim 1, wherein the yarn has a degree of entanglement between 2 and 60 bars / m. The article of claim 1, wherein the article is a fabric. 16. The article of claim 15, wherein the fabric is knitted or woven. 16. The article of claim 15, wherein the fabric is coated. 16. The article of claim 15, wherein the fabric has a grab strength of from about 80 to about 1200 pounds. 16. The article of claim 15, wherein the fabric has a tear strength of from about 8 to about 150 pounds. 16. The article of claim 15, wherein the fabric has Taber abrasion resistance of from about 80 to about 4000 cycles. (a) spinning a synthetic chamber,
(b) stretching said yarn,
(c) balancing said yarn under an air jet textured member,
(d) entangling said yarn,
(e) winding the yarn into a package
≪ / RTI > 22. The method of claim 21, wherein the bulking is performed by stuffer box, edge crimping or gear crimping. 22. The method of claim 21, wherein the stretching ratio is from about 2.5 to about 4. & 22. The method of claim 21, wherein the stretching step provides a toughness of from about 2 to about 7 g / denier. 22. The method of claim 21, wherein the stretching step comprises a stretching roll having a surface speed of from about 2500 to about 4000 m / min and a temperature of from about 160 < 0 > C to about 210 < 0 > C. 22. The method of claim 21 wherein said step is part of an inline / coupling process. (a) a plurality of vulcanized continuous filaments,
(b) from about 300 to about 2000 denier,
(c) about 1 to 8 denier / filament, and
(d) a toughness of from about 2.0 to about 7.0 g / denier
≪ / RTI >
≪ / RTI >
≪ / RTI > 28. The article of claim 27, wherein the yarn has a toughness of from about 200 to about 1200 denier, from about 2 to about 5 denier / filament, and from about 4.0 to about 6.0. 28. The article of claim 27, wherein the filament has a circular cross-section.