Classifications

• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
  • D01F6/46—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polyolefins
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
  • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
  • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
  • D01D5/30—Conjugate filaments; Spinnerette packs therefor
  • D01D5/34—Core-skin structure; Spinnerette packs therefor
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F1/00—General methods for the manufacture of artificial filaments or the like
  • D01F1/02—Addition of substances to the spinning solution or to the melt
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
  • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
  • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
  • D06P1/16—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using dispersed, e.g. acetate, dyestuffs
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
  • D06P3/79—Polyolefins
  • D06P3/794—Polyolefins using dispersed dyes

Definitions

• the present invention relates to textile fabrics manufactured using olefin fibers or yarns modified to dye using disperse dyes. These fabrics are conventionally colored using existing disperse dye or printing systems. Either solid shades or multiple tones of a shade are achieved in a single dye bath or print application.
• the fabrics in this invention are manufactured into greige goods produced by the knitting, weaving or non- woven process. Solid shades are achieved by grafting into the olefin yarn or fiber with one level of dye additive and subjecting the fabric to a disperse dye bath. Multiple ends of yarn each containing differing percentages of dye additives are manufactured into fabrics. The fabric will dye to multiple tones in a single dye bath.
• the affinity for disperse dye increases accordingly.
• the fabrics manufactured according to this invention are stored at the dye house undyed. Color is then 'added using conventional disperse dye machines or print dye methods. Surprising and novel effects are achieved using economical conventional disperse dye systems known to those skilled in the art.
• This invention is of particular usefulness in the apparel and home furnishings industry. The fabrics produced feel and, appear as conventional fabrics but are approximately 30-38% lighter in weight. This is due to the fact that the specific gravity of olefin is .91 while the specific gravity of cotton or polyester is 1.38. In addition, the light fastness and wash fastness properties are similar to those of polyester.
• Knitted and woven fabrics and textile articles are an enormous worldwide enterprise.
• Cotton is the predominant choice of fiber used to make woven or knitted textile fabrics. Cotton has been used through the ages to make yarn and textile articles. Cotton is a natural fiber and is grown in many parts of the world. Many cotton-spinning systems exist worldwide. Cotton yarns are easily produced for both apparel and home furnishings using the cotton spinning system. Egyptian and United States cotton staple is the most widely used cotton to produce yarn and fabrics.
• the cotton spinning system starts with bales of cotton picked from the fields.
• the fiber is called "staple” and is usually 3 A" to 1.5" in length.
• the longer length cotton is more expensive than the shorter length staple.
• Longer length staple will result in a superior spun yarn.
• Machines clean, card, and make roving to various sizes.
• Cotton is made into yarn of various sizes by twisting or "spinning" the roving on machines well known in this art.
• a yarn is produced to be either knitted or woven to create fabric for apparel or home furnishings. By using varying sizes of large or small yarns the knitting or weaving manufacturer can make various types of garments or furnishings. If the cotton fabric is manufactured and kept in the undyed state the fabric is called, a .greige fabric.
• the most common system of putting color on cotton apparel fabric is to dye the woven, knitted or non-woven fabric.
• the fabric is placed in a machine containing water, vat or direct dyes and chemicals.
• the temperature of the liquor or dye bath is adjusted to the desired degree.
• the skilled operator will use this process to produce the desired shade on the cotton fabric.
• the fabric is dried, and finished according to the customer's specifications.
• the dye house is a capital-intensive operation that contains expensive dye and finishing equipment.
• a dye house in addition to dyeing will have drying and finishing equipment such as compactors, chemical applicators and rolling or folding equipment.
• a good substitute for cotton would ideally be able to be processed using present cotton spinning, dyeing and finishing equipment systems to dye and finish cotton are in place worldwide.
• Cotton is easily converted into yarn because it grows to standard staple lengths.
• Cotton fabrics are soft to the touch and feel comfortable to the users body. . i
• Cloth knitted or woven of cotton has standard nomenclature and is purchased as a commodity from most parts of the world. A manufacturer can buy a standard cotton fabric from anywhere in the world. Then the manufacturer sends the cloth to a dye house to be stored as uncolored greige cloth awaiting orders for colored cloth. The dyed cloth is cut and sewn into apparel garments or home furnishing items such as draperies, bedspreads, or upholstery.
• Synthetic fiber made using the acrylonitrile process is also used to make a soft fiber. Brands such as Acrilan from the Solutia Co., Creslan from American Cyanamid and Mannacryl from Mann Industries are examples. This fiber is not easily dyed and is mostly produced in large pigment dyed lots. Additionally acrylic is more expensive than cotton. It has a specific gravity of 1.17, which makes it ideal for a blend with wool for sweaters and for use in hosiery. Because it is solution dyed the yarn made from acrylic fibers is suited ideally for outdoor use in awnings, lawn and garden upholstery. Acrylic fiber is not a good substitute for cotton.
• Synthetics the majority being polyester, account for almost one half of all fibers used to produce textile fabrics.
• polyester staple was introduced by the Dupont Company to be a replacement for cotton. It did not replace cotton but it is commonly used to mix or blend with cotton. Initially polyester was harsh and coarse. It did not absorb moisture well and is very difficult to dye. Over a long period of years polyester fibers were engineered to feel soft, and to blend with cotton so that a yarn could be made using the cotton spinning system. The most popular polyester is called "micro denier". Micro denier is extruded, through ispinneret holes that make a size of fiber that is smaller than cotton. It is very common to find blends of 60% cotton, with 40% polyester. There are many blends of cotton/polyester. These blends are found in knitted and woven textile fabrics.
• Polyester has many drawbacks. It is difficult to dye and great skill is needed to dye a uniform shade of polyester and cotton.
• the polyester fibers require high temperatures under pressure to absorb high energy disperse dyes.
• polyester is a very large enterprise. Approximately 33 billion pounds of polyester are produced world wide for application in apparel and home furnishings. While polyester is widely used world wide, it has many disadvantages.
• Polyester is warm to the body .,;• , ⁇ r. . :
• Polyester will not wick moisture
• the synthetic fiber could be used to make a yarn for a fabric that would be similar to a fabric made from 100% cotton. Polyester does not meet these standards
• Olefin polypropylene, polyethylene
• Olefin is a manufactured fiber, which is composed of at least 85% ethylene, propylene or other olefin units.
• Olefin is an ideal substitute for cotton except for the fact that is not easily dyed on conventional dyeing or printing systems.
• Olefin is easy and economical to produce into fiber that feels just like cotton. I have found that an olefin of 1.8 denier per filament and a 1.5" to 2" staple length is an ideal substitute for cotton.
• olefin fiber has the following characteristics:
• Olefin fiber is easily converted into yarn using existing spinning systems Olefin yarn will process well on knitting, weaving machines. Olefin yarn is soft to the touch Olefin staple processes well on non woven machines Olefin fabrics feel similar to cotton Olefin will dry quickly
• Olefin will pass moisture but retain body heat. Olefin is very stain resistant
• Olefin Fiber and Yarn The main disadvantage -of olefin is the fact that it is a fiber that is not.dyeable by conventional dye systems. Almost all olefin fiber and yarn is pigment or solution dyed. Fabric made from pigment dyed yarn cannot be dyed to fashion shades as orders are received. This makes fabric manufacture prohibitively expensive and inventories too large to manage in the apparel and home furnishings industry. Polypropylene is presently used mainly for making carpet and rugs.
• the object of the present invention is to create a novel knitted woven or non-woven fabric using synthetic yarn that has most of the characteristics of cotton fabrics and overcomes the disadvantages of polyester fabrics.
• the fabric has to be available in greige goods, be easy to dye on conventional systems, be soft to touch; the fabric must "breathe” and wick moisture away from the body.
• the fabrics made using the synthetic yarns of the invention will be easy to wash either by hand or machine and will not stain by ordinary household food stains.
• the fabrics made using the invention are lighter in weight using standard size yarns and dry faster than cotton fabrics at room temperature.
• the fabrics made using this invention have superior light and wash fastness.
• cotton spinning system is the most widely used system, one skilled in the art can produce fiber that can be made into yarn using any conventional spinning system. Worsted, woolen and modified worsted are some of the more common spinning methods. The fiber length and denier can be varied to fit any spinning system.
• the present invention relates to a method of using disperse dyeable synthetic olefin yarn and fibers to manufacture knitted woven and non woven fabric greige goods that are easy to dye and process using commercially available disperse dye systems.
• the novel advantages of these greige goods over cotton, and blends of cotton polyester will be apparent from the detailed description.
• This invention also shows the preferred novel additives to be grafted onto Olefin to make it disperse dyeable.
• the present invention relates to manufacturing a knitted, woven or non-woven fabric using an olefin yarn or fiber that has been enhanced to accept disperse dye.
• the olefin does not dye but the additive that is grafted to the olefin of the present invention will accept any disperse dye that is used at dye facilities used to dye polyester or blends of polyester and cotton. No special dyes have to be purchased to achieve shades of all description.
• the olefin of the invention will only accepts disperse dyes.
• This invention uses grafted additives in olefin to create yarns that are made into woven, knitted or non-woven greige goods fabric.
• the fabric of this invention is stored as uncolored inventory.
• the greige goods are colored using disperse dyes usually used to dye polyester. Very high temperatures used to dye polyester are not necessary to dye the olefin fabrics. A temperature of 22O 0 F - 25O 0 F is ideal. Bright deep shades of any color are achieved when dyeing olefin fabrics using this invention.
• Multitones ⁇ . .;,. ⁇ ; ; ; ; ! . ⁇ ⁇ • ;. -. ⁇
• Multitones are dyed in addition to just one solid color.
• Olefin yarns with dye enhancer grafted of from 1 % to 15% is used to make fabrics dye to multi-tones of the same shade in one dye bath containing disperse dyes. This is achieved by grafting varying strengths of the concentrate dye enhancer specified in this invention into the olefin fibers or yarns.
• I will call a yarn with 5% dye enhancer A, a yarn with 3% dye enhancer B and a yarn with 1.5% dye enhancer C.
• yarn A, B, and C are placed together on fabric forming machines, such as a weaving machine, the resultant fabric is dyed into novel three self tones of a color in a single dye bath. One will be dark, one medium and one light.
• the preferred range of concentrate grafted is from 1 % to 7%.
• Solid Shades Fabric made from olefin yarn will dye a solid shade when made using yarn that has only one level of concentrate grafted.
• the preferred concentrate grafted should be 5% on the weight of the goods.
• Other concentrations can be used to vary the dye take up but I have found the preferred mixture to be 5% on the weight of the goods to make solid shades.
• Olefin fabric is wash fast in warm water. ⁇ ' ⁇ ' ⁇
• Olefin fabric can be line dried or quickly machine dried at a cool temperature. ,:. .
• Disperse dyed olefin fabric does not stretch or shrink in the wash process.
• Olefin fabric dries substantially wrinkle free.
• Olefin fabric is stain resistant.
• Olefin fabric is soft to the touch.
• Olefin fabric is 38% lighter than cotton. 8. Olefin fabric will wick moisture and breathe.
• Olefin fabrics will resist mildew and algae growths.
• Olefin has a higher bulk than most fibers.
• Olefin yarn can be manufactured by either spinning or continuous filament.
• An olefin fabric is characterized by being an easy care, travel friendly garment.
• Olefin Dye Enhancers :
• a preferred method of rendering polyolefin disperse dyeable is as follows:
• a mixture of amorphous PETG is the preferred ingredient used to graft onto polyolefin.
• Amorphous PETG is selected because it melts at a temperature similar to that of polypropylene. This enables one skilled in the art to make dyeable Polyolefin using a conventional olefin fiber extrusion machine. No special equipment is needed to perform this operation. The advantage of this additive is the fact that drying and moisture reduction is not necessary to add the graft.
• this invention used maleic anhydride to improve the dispersion and graft cohesion in the olefin fiber.
• a preferred product is amorphous PETG No. 1428 from :•.
• Maleic anhydride is used to help the graft securely anchor onto the polyolefin.
• the maleic anhydride is not necessary to make the olefin disperse dyeable. However I found that if the maleic anhydride is eliminated, the amorphous PETG does not disperse evenly. This results in uneven dispersion and unlevel dyeing.
• Dyeable Olefin Fiber and yarn :
• Pellets containing 48% amorphous PETG (polyester) 2% Maleic Anhydride and 50% polypropylene are fed to an olefin fiber extruder using 10% owg (on weight of the goods).
• the result is a fiber containing 5% disperse dyeable mix grafted onto 95% olefin.
• One skilled in the art will vary the blend of graft to olefin to achieve the desired shade when subjected to a dye bath containing disperse dye. I have varied the mix and dyed the fiber and found the preferred enhancement to be 5% owg for deep solid shades and 2.5% owg for lighter shades.
• Pellets containing a blend of 50% olefin, 48% amorphous PETG and 2% Maleic Anhydride is preferred for the following reasons:
• Disperse dye is the only dye that the graft will absorb. :
• the blend melts at the processing temperature of olefin
• the blend combines and easily extrudes into pellets.
• the blended pellets do not have to be bone dry to feed into the olefin fiber extruder
• the blend mixes evenly and is well dispersed within the olefin during fiber extrusion.
• the dyeable graft is stable when subjected to any dyeing conditions Grafted yarn or fabric will dye or print using standard disperse dyes.
• Printing is easily achieved and requires only 2 to 4 minutes exposure to steam at a 212 0 F. temp.
• Example I Single Color Fabrics a.) Pellets of olefin with a Melt Flow Index of 8-22 are extruded and intimately mixed with the blend using the above-preferred mixture of PETG and Maleic Anhydride .
• the blend of 95% olefin and 5% PETG/Maleic is extruded into a staple mass using conventional staple extrusion equipment.
• the fiber dpf is 1.8 and is cut to 1.5".
• Approximately 1 ,000 pounds of staple are produced and baled.
• the denier per filament is close to that of cotton and so is the staple length.
• the roving made using conventional cotton equipment is ring spun into a
• This manufacturing process forms an undyed greige goods fabric that is ideal to make cut and sewn sweaters.
• the sweater greige goods fabric is dyed in a conventional jet- dyeing machine ordinarily used to dye polyester.
• the temperature is kept at 25O 0 F to avoid damage to the olefin.
• a disperse dye Terasil Blue BRL at .005% owg is used with standard dye dispersion chemicals and water.
• the resultant sweater fabric is a novel and pleasing bright shade of deep blue.
• the fabric is dried in a relatively cool oven. The temperature is kept below the melt temperature of olefin or at 200 0 F. The water flashes off the olefin leaving a dry bright fabric, which is rolled and wrapped for shipment. Drying time is greatly reduced in comparison to a cotton or cotton polyester blend because the olefin only holds limited amounts of water.
• the sweater fabric is cut and sewn and is surprisingly novel. It is at least 30% lighter in weight than a cotton sweater made to the same specifications. This is because the olefin specific gravity is .91 Vs 1.38 for cotton or cotton polyester. 5
• the sweater will actually float in water.
• the sweater has the look and feel of cotton yet is substantially lighter in weight. It is understood by one skilled in the art that different weight fabrics using various sizes of yarn can be produced in the same manner.
• Pellets of olefin with a Melt Flow Index of 8-22 are intimately mixed and grafted with an olefin dye enhancement blend described above.
• the mixture is 95% olefin with 5% disperse dye enhancement concentrate
• the mixture is extruded into a staple mass using conventional staple extrusion equipment.
• the dpf is 1.8 and the staple is cut to 1.5".
• Approximately 1 ,000 pounds of staple are produced and baled.
• the denier per filament is close to that of cotton and so is the staple length.
• This batch is called "staple B”.
• staple B Separately the olefin bales of staple fiber are blended at the cotton carding process and made into roving.
• the roving is made using conventional cotton equipment is spun into a 10/1 cotton count and taken up on 3 pound packages. Approximate 1000 pounds of each yarn is 5 produced for a total of 1 ,000 pounds of olefin with 5% concentrate (yarn A) and 1000 pounds of olefin grafted with 3% concentrate (yarn B). Both will accept disperse dyes.
• Olefin Yarn A containing a 5% concentrate, and Olefin yarn B 0 containing a 3% concentrate are placed side by side on a 10 cut knitting machine. Both yarns are 10/1.
• the olefin yarns are knitted on a 10 cut circular knitting machine. This manufacturing process forms an undyed greige goods fabric that is ideal to make sweaters when cut and sewn.
• the sweater greige fabric is dyed in a conventional jet-dyeing v ., machine ordinarily used to dye polyester. The temperature is kept at
• a disperse dye Terasil Blue BRL at
• the resultant sweater fabric is a novel and pleasing two-tone shade of 0 blue. Only one dye bath is used to obtain more than one shade on the fabric.
• the fabric is dried in relatively cool oven. The temperature is kept below the melt temperature of olefin or 200 0 F. Drying time is greatly reduced in comparison to a cotton or cotton polyester blend. The water flashes off the olefin leaving a dry bright two-tone blue fabric, which is 5 rolled and wrapped for shipment.
• the two-tone sweater fabric is cut and sewn and is surprisingly novel.
• the two-tone effect is novel and looks natural like a wool or linen. It is 30% lighter in weight than a cotton sweater made to the same 0 specifications. This is because the olefin specific gravity is .91 Vs 1.38 for cotton or cotton polyester.
• This novel sweater will actually float in water. It is to be understood that by varying the amount of concentrate and the number of olefin yarns fed to a knitting or weaving machine a person skilled in the art can create numerous fashionable and novel greige goods fabrics made from olefin, or blends of olefin with other yarns fed to various knitting or weaving machines. It is understood by one skilled in the art that different weight fabrics using various sizes of yam can be produced in the same manner.
• Example 111 - Solid Shade of Continuous Filament Fabric Pellets of olefin with a Melt Flow Index of 8-22 are extruded and intimately mixed with the blend using the above-preferred mixture of PETG and Maleic Anhydride
• the blend of 95% olefin and 5% PETG/Maleic is extruded into a continuous filament yarn using conventional extrusion equipment.
• the filament fiber dpf is 5.4. Approximately 1 ,000 pounds of yarn are produced and wound on perns.
• the undrawn yarn is drawn 3.0 to 1 and false twist textured on a conventional texturing machine.
• the textured yam has 277 filaments of
• the yarn is soft and feels like cotton.
• the yarn is bright and uncolored and put up on 3 pound cones. Proper spin finish is applied in the process.
• the textured yarn is knitted on a ten cut knitting machine.
• the result is a bright soft looking sweater greige fabric that is not dyed.
• the bright textured continuous filament sweater greige goods fabric is dyed in a conventional jet-dyeing machine ordinarily used to dye polyester.
• the temperature is kept bellow 25O 0 F to avoid damage to the olefin.
• a disperse dye Terasil Blue BRL at .005% owg is used with standard dye dispersion chemicals.
• the resultant sweater fabric is a novel and pleasing bright shade of solid colored deep blue.
• the fabric is dried in relatively cool oven. The temperature is kept below the melt temperature of olefin or 200 0 F. Drying time is greatly reduced in comparison to a cotton or cotton polyester blend. The water flashes off the olefin leaving a dry bright slinky fabric, soft to the touch, which is rolled and wrapped for shipment.
• the continuous filament sweater fabric is cut and sewn and is surprisingly novel. It is bright, "slinky" and fashionable. It is a solid color but by using the same technique as in example Il above, one skilled in the art can vary the olefin yarns and achieve a two or three tone novel effect from one dye bath. It is 30% lighter in weight than a sweater made from polyester. This is because the olefin specific gravity is .91 Vs 1.38 for polyester. This novel sweater will actually float in water. It is wash and wear and would be ideal for a travel garment.
• Pellets of olefin with a Melt Flow Index of 8-22 are extruded and intimately mixed with the blend using the above-preferred mixture of PETG and Maleic Anhydride
• the blend of 95% olefin and 5% PETG/Maleic is extruded into a staple mass using conventional staple extrusion equipment.
• the fiber dpf is 1.8 and is cut to 1.5".
• Approximately 1 ,000 pounds of staple are produced and baled.
• the denier per filament is close to that of cotton and so is the staple length.
• the olefin bales of staple fiber. are blended together at the cotton carding process and made into roving.
• the roving is made using conventional cotton equipment is spun into, a 10/1 cotton count and taken up on 3 pound packages. Approximately 1000 pounds of yarn is produced The 10/1 grafted olefin is plied to make a 10/2 dyeable olefin.
• Knitted Sleeve The 10/2 olefin yarn is knitted into a single endless sleeve.
• the resultant sleeve is de knitted or wound onto a yarn package using a winding operation well know to those skilled in the art.
• the yarn is a pleasing beige color with dots of dark brown and dark charcoal and is put up on 3-pound cones.
• the 10/2 olefin space dyed yarn is knitted on a 10 cut knitting machine.
• a pleasing three-tone space dyed fabric is the result.
• the space dyed fabric of olefin is surprisingly free of patterns usually associated with skein or dip dyeing of sweater yarns.
• the fabric is washed with hot water in a jet dye or winch dye machine to add bulk and to clarify the colors. This also assures the fact that the finished sweater will not shrink when washed by the end user.
• the fabric is dried in a cool oven at 200 0 F. While it is not necessary to wash the fabric, it is worth the extra step to make the fabric shrink proof.
• the space dyed sweater fabric is cut and sewn and is surprisingly novel. It is 30% lighter in weight than a cotton sweater made to the same specifications. This is because the olefin specific gravity is .91 vs 1.38 for cotton or cotton polyester. This novel sweater will actually float in water.
• space dye or print dyeing yarn can be used.
• One skilled in the art will adjust the various machines to the specifications that I outlined above. Warp printing or package impregnation are two other common methods use to space dye yarns.
• Spun yarns are usually made into 18's, 20's, 24's, 28's, 30's, 36's, 40's, either plied or in single form.
• Continuous filament yarn is usually made into
• Pellets of olefin with a Melt Flow Index of 8-22 are intimately mixed and grafted with an olefin dye enhancement blend described above.
• This machine has three extruders that will separately feed a single spinneret. Barmag, Plantex, Rieter make such machines. One extruder is fed a mix of 95% olefin and 5% Dye enhancer, another is fed 97% olefin and 3% dye enhancer, and the third is fed 99% olefin and 1 % dye enhancer.
• a single white yarn with a dpf of 5.4 consisting of three separate levels of dye affinity is taken up on three-pound packages.
• the yarn at this stage has to be drawn and textured.
• the yarn is drawn 3:0 and false twist textured on conventional draw . twisting machinery known to those skilled in the art.
• the result is a continuous filament yarn having 300 ends of 1.8 dpf.
• One third of the yarn has a 5% additive, one third has 3% additive and one third has a 1 % additive.
• the yarn is knitted on a 30" rib knitting machine.
• the tubular cloth produced is a white greige tube, which is shipped to the dye house.
• the tube is dyed with a .005% owg disperse dye.
• the surprising result is a dyed fabric that simulates a tweed fabric having a deep, medium and a light blue tone. 1/3 of the yarn accepted one level of disperse dye, 1/3 of the yam accepted a second level of disperse dye, and 1/3 of the yarn accepted a third level of disperse dye.
• the fabric is opened, dried at a low temperature of 200 0 F and rolled for shipment.
• the fabric is cut and sewn into a full-fashioned ribbed spring coat with dress buttons.
• One skilled in the art would vary both the size of the extrusion and the grafted disperse dyeable compound to achieve the effect that they desire.
• a fabric containing tri-tone yarns would be ideal to space dye or print, as the printed yarn would dye into separate tones within tones at each strike of color letdown.
• the printed yarn would dye into separate tones within tones at each strike of color letdown.
• This invention enables the yarn spinner, the fabric maker and the dyer to create novel lightweight colored fabrics. It enables a fabric to be held until the last moment before dyeing and shipping to be manufactured in shades that match the current time of year and season.
• Olefin yarn is, made. according to the invention. It is enhanced to accept a deep solid shade of disperse dye.
• the size is 24/1 spun on the cotton spinning system taken up on three-pound cones. It contains a dyeable graft of 5% owg.
• the appropriate multiple ends are slashed and taken up on a weaving beam.
• the beam is set to feed a simple box loom.
• Olefin yarn made according to the invention containing 2.5% dyeable graft is made to feed the weft insertion on the box loom.
• the size is 24/1 spun on the cotton spinning system.
• a simple over and under woven fabric 60" wide is produced.
• one half of the yarn contains a 5% dye enhancer made according to the invention and one half contains a yam that has a 2.5% dye enhancer made according to the invention.
• the woven greige cloth is dyed in a jet dyer set at 25O 0 F with a Terasil Blue disperse dye using .005% on the weight of the goods.
• the warp or beamed yarn dyes a deep shade of blue and the weft yarn dyes to a medium shade of blue.
• the fabric is a two-tone tweed color.
• the fabric is dried in a relatively cool oven at 200 0 F to keep the temperature below the melt temperature of olefin.
• the fabric is tentered or held in a stretched position while it passes through drying oven. This "sets" the fabric so that it will not shrink in any further processing at a later time.
• the fabric is cut and sewn into a ladies jacket and skirt.
• the garment is a ladies suit made from 100% olefin fabric. This suit is easy care washable, stain resistant, and lightweight. It is 38% lighter than a similar suit made from polyester or wool /blends.
• a fabric is knitted or woven with one or more yarns containing differing dye levels.
• the fabric is dyed as per the examples above.
• Great cost savings result because the sheath comprises only 10% to 70% of the total composition.
• One skilled in the art would vary the percentages of the sheath and the dye enhancer to achieve the effect desired.
• a variation of the above is to use a sheath of non-dyeable olefin and a core of dyeable olefin.
• the result is a yarn with a clear outer shell with color in the core.
• One skilled in the art can manipulate this yarn or fiber to create the effect desired.
• Example IX Fabric knitted or Woven using Dveable Olefin Blended with .
• a novel and surprising effect is achieved when blending polyester and dyeable olefin fiber to make yarn.
• the resultant yarn has an outer cover consisting mostly of polyester and a core mostly of dyeable olefin. There is minor crossover in both the sheath and core.
• Olefin fiber is made according to the invention.
• the fiber is enhanced with the additive of this invention to accept a solid shade of disperse dye
• Pellets of olefin with a Melt Flow Index of 8-22 are extruded and intimately mixed with the blend using the invention's preferred mixture of PETG and Maleic Anhydride.
• the blend of 95% olefin and 5% PETG/Maleic is extruded into a staple mass using conventional staple extrusion equipment.
• the fiber dpf is 1.8 and is cut to 1.5".
• Approximat ⁇ ly 650 pounds of staple are produced and baled.
• the denier per filament is close to that of cotton and so is the staple length.
• Dye enhanced olefin staple fibers are blended together with polyester staple fibers having a 1.35 denier per filament cut to a 1.5" staple length at the cotton carding process and made into an intimate blend of roving containing 65% dyeable olefin and 35% polyester.
• the roving is made using conventional cotton equipment and is ring spun into a 28/1 cotton count then taken up on 3-pound packages.
• the yarn is twist plied into a 28/2 ply yarn. Both ends contain 65% dyeable olefin and 35% polyester.
• This yarn is then converted to a woven greige cloth on a conventional box loom using 40 ends per inch in the warp and 40 ends per inch in the fill.
• the fabric is woven to 67" width.
• the greige goods fabric is dyed in a conventional jet-dyeing machine ordinarily used to dye polyester.
• the temperature is kept at 25O 0 F to avoid damage to the olefin.
• a disperse dye Terasil Blue BRL at .005% owg is used with standard dye dispersion chemicals and water.
• the resultant woven fabric is a novel and pleasing bright shade of deep blue.
• the fabric is dried in a relatively cool oven. The temperature is kept below the melt temperature of olefin but is elevated to 255 0 F as the core of olefin is shielded by the sheath of polyester.
• the water flashes off leaving a dry bright fabric, which is rolled and wrapped for shipment. Drying time is greatly reduced in comparison to a cotton or cotton polyester blend because the olefin only holds limited amounts of water and only 35% of the fabric is polyester.
• a novel result is a fabric that shrinks in with to 61.5" after finishing. The fabric is then stable and does not shrink more than 1 % after washing. This effect makes the fabric a wash and wear easy care fabric.
• the woven dyed fabric is cut and sewn and is surprisingly novel. It is at least 20% lighter in weight than a polyester garment made to the same specifications. This is because the polyester/olefin specific gravity is 1.07 Vs 1.38 for polyester.
• the fabric has the soft feel of cotton yet is substantially lighter in weight. It is understood by one skilled in the art that different weight fabrics using various sizes of yarn can be produced in the same manner. In addition the yarn can be used to knit fabric using conventional knitting machines. i
• Woven, knitted or non-woven fabrics can be produced using this blend.
• micro denier polyester creates a soft fabric. 9.) The fabric will sew on any conventional sewing machine. 10.) The dyed fabric will not shrink more than 1-5%.
• Example X Fabric Woven or knitted using Dveable Olefin Blended with 5 Nylon
• the resultant yarn has an outer cover consisting mostly of nylon and a core mostly of dyeable olefin. There is minor crossover in both the sheath and core.
• the resultant yarn has a 0 sheath mostly of Nylon and a core mostly of dyeable olefin.
• Olefin fiber is made according to the invention.
• the fiber is enhanced to accept a solid shade of disperse dye.
• the blend of 95% olefin and 5% PETG/Maleic is extruded into a staple mass using conventional staple extrusion equipment.
• the fiber dpf is 1.8 and is cut to 1.5". 0 Approximately 650 pounds of staple are produced and baled.
• the denier per filament is close to that of cotton and so is the staple length.
• Dye enhanced olefin staple fibers are blended together with Nylon staple fibers having a 1.35 denier per filament cut to a 1.5" staple length 5 at the cotton carding process and made into an intimate blend of roving containing 65% dyeable olefin and 35% Nylon.
• the roving made using conventional cotton equipment is ring spun into a 28/1 cotton count and the yarn is taken up on 3-pound packages.
• the yarn is twist plied into a 28/2 ply yarn.
• This yarn is then converted to a woven greige cloth on a conventional box loom using 40 ends per inch in the warp and 40 ends per inch in the fill.
• the fabric is woven to 67" width.
• the greige goods fabric is dyed in a conventional jet-dyeing machine ordinarily used to dye fabric.
• the temperature is kept at 25O 0 F to avoid damage to the olefin.
• a disperse dye Terasil Blue BRL at .005% owg is used with standard dye dispersion chemicals and water.
• the resultant woven fabric is a novel and pleasing bright shade of deep blue.
• the fabric is dried in a relatively cool oven. The temperature is kept below the melt temperature of olefin but is elevated to 255 0 F as the core of olefin is shielded by the sheath of Nylon.
• the water flashes off leaving a dry bright fabric, which is rolled and wrapped for shipment. Drying time is greatly reduced in comparison to a cotton or cotton polyester blend because the olefin only holds limited amounts of water and only 35% of the fabric is nylon.
• the woven dyed fabric is cut and sewn and is surprisingly novel. It is at least 20% lighter in weight than a cotton garment made to the same specifications. This is because the Nylon/olefin specific gravity is .99 Vs 1.38 for cotton The fabric has the soft feel of cotton yet is substantially lighter in weight.
• One skilled in the art understands that different weight fabrics using various sizes of yarn can be produced in the same manner.
• Nylon is very easy to dye using an aqueous dye system.
• the fabrics made of nylon and olefin blends will print using any acid system commonly used to dye nylon or silk.
• the fabric can be printed using any aqueous dye system commonly used to print nylon, silk or polyester.
• Deeper dyeing Nylon can be used as the sheath.
• Cationic dyeing nylon can be used as the sheath.
• the fabric will sew on any conventional sewing machine.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Dispersion Chemistry (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
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• Knitting Of Fabric (AREA)
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• 2005
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