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
  • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
  • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
  • D02G3/04—Blended or other yarns or threads containing components made from different materials
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
  • D02G3/441—Yarns or threads with antistatic, conductive or radiation-shielding properties
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
  • D10B2201/01—Natural vegetable fibres
  • D10B2201/02—Cotton
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/02—Moisture-responsive characteristics
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2501/00—Wearing apparel
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/249921—Web or sheet containing structurally defined element or component

Definitions

• the present invention generally relates to fiber blends and yarns and fabrics produced therefrom. More particularly, the invention relates to fiber blends and yarns and fabrics produced therefrom, which have improved moisture management (water release rate, wicking, and drying time) properties.
• Fast drying fabrics comprising cellulosic yarns provide garment benefits in the areas of active sports, outdoor work, recreational activities, military and other uses for example, where the rate of perspiration is high.
• fabric is treated with a water resistant chemical to a degree that the entire fabric becomes water resistant or hydrophobic.
• a blend of cellulosic and synthetic yarns is incorporated into the fabric to provide improved water resistance and in some configurations, more rapid drying rates.
• these fabrics are typically treated with a hydrophobic chemical, or are blended with a synthetic fiber or hydrophobic treated yarn that does not absorb water, which reduces the overall ability of the fabric to absorb water compared to an untreated fabric.
• These fabrics therefore, do not absorb water to the degree of an untreated cellulosic fabric.
• these fabrics do not sufficiently absorb water and are not well suited for drying applications, such as towels, for example.
• a fiber blend that may be used in a fabric that has the appearance and feel of untreated cellulosic fabric, has a water weight gain similar to an untreated cellulosic fabric, is hydrophilic to provide wicking of sweat yet is fast drying.
• the fiber blends of the invention and the yarns, fabrics, garments and linens are directed toward these, as well as other, important ends.
• the invention relates generally to fiber blends whose hydrophobic fibers have both multiple staple lengths and multiple deniers are disclosed. Yarns, fabrics, garments, and linens comprising the fiber blends have improved moisture management properties, including faster water release rates, wicking, and drying times.
• One embodiment is directed to fiber blends, comprising:
• a hydrophilic component comprising at least one hydrophilic fiber; and about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of a hydrophobic component comprising:
• first synthetic hydrophobic fibers having a first composition
• first synthetic hydrophobic fibers have multiple staple lengths and multiple deniers
• a second embodiment is directed to fiber blends, comprising:
• a third embodiment is directed to fiber blends, comprising:
• Another embodiment is directed to yarns, comprising the fiber blends described herein.
• Yet another embodiment is directed to fabric, comprising the yarn described herein.
• a hydrophilic component comprising at least one hydrophilic fiber; and about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of a hydrophobic component comprising:
• first synthetic hydrophobic fibers having a first composition
• fiber means a unit of matter characterized by having a length at least 100 times its diameter or width and which has a definite preferred orientation of its crystal unit cells with respect to a specific axis.
• a fiber may be made of one or more continuous or very long filaments or shorter, cut portions or a combination thereof.
• the term "yarn,” as used herein, refers to any assembly of the hydrophobic and hydrophilic fibers in a continuous strand that can be made into a textile material.
• the term “yarn,” as used herein, encompasses spun yarns and sheathed filaments, as well as other possible embodiments.
• staple length refers to the average length of a group of fibers. Staple length depends on the origin of the fiber. Natural fibers (such as cotton or wool) have a range of lengths in each sample, so the staple length is an average. For synthetic fibers that have been cut to certain length, the staple length is the same for every fiber in the group.
• multiple staple lengths refers to fibers that have at least two different staple lengths, wherein the difference between any two staple lengths is at least about 5%, preferably about 10%, more preferably about 15%, even more preferably, at least about 20%, and yet even more preferably, at least about 25%.
• the term "denier,” as used herein, is a unit of measure for the linear mass density of fibers. It is defined as the mass in grams per 9000 meters of the fiber.
• the term “multiple deniers,” as used herein, refers to fibers that have at least two different deniers, wherein the difference between any two deniers is at least about 5%, preferably about 10%, more preferably about 15%, even more preferably, at least about 20%, and yet even more preferably, at least about 25%.
• a difference is at least about 1 %, preferably at least about 5%.
• polyacrylonitrile fiber refers to a manufactured fiber of polymer resin containing residues of
• modacrylic fiber refers to an acrylic synthetic fiber made from a polymer comprising primarily residues of acrylonitrile. Modacrylic fibers are spun from an extensive range of copolymers of acrylonitrile.
• the modacrylic fiber may contain the residues of other monomers, including vinyl monomer, especially halogen-containing vinyl monomers, such as but not limited to vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, and the like.
• the types of modacrylic fibers that can be produced within this broad category are capable of wide variation in properties, depending on their composition. Some examples of commonly available modacrylics are PROTEXTM, KANEKALONTM, and KANECARONTM by Kaneka Corporation, PYROTEXTM, and Formosa Plastics.
• nylon fiber refers to a manufactured fiber of aliphatic polyamides, including nylon-4,6, nylon-4,10, nylon-6, nylon-6,6, nylon-6,10, nylon-6,12, nyion-10,10, nylon-10,12, nylon-11, nylon-12, and the like.
• polyester fiber refers to a manufactured fiber of polymer resin containing ester functional groups in its main chain, such as such as polyethyleneterephthalate, polybutyleneterephthalate, poly(trimethylene terephthalate), copolymers thereof, and combinations thereof.
• fluoropolymer fibers refers to a manufactured fiber containing fluorocarbon-based polymer with at least one, but preferably multiple, strong carbon-fluorine bonds, including, but not limited to, polytetrafluoroethylene (PTFE), perfluoroalkoxy polymer (PFA), or fluorinated ethylene-propylene (FE.P).
• PTFE polytetrafluoroethylene
• PFA perfluoroalkoxy polymer
• F.P fluorinated ethylene-propylene
• aramid fiber refers to a manufactured fiber in which the fiber-forming substance is a long-chain synthetic polyamide in which at least 85% of the amide linkages, (-CO-NH-), are attached directly to two aromatic rings, including, but not limited to, para-aramid (p-aramid) and meta-aramid (m- aramid).
• para-aramids include, but are not limited to, (poly(p-phenylene terephthalamide), e.g., KEVLAR® (E.I. du Pont de Nemours and Company), TWARON® (Teijin Twaron BV), and TECHNORA by Teijin Company.
• KEVLAR is a para-aramid fiber having a very high tenacity of between 28 and 32 grams/denier and outstanding heat resistance.
• meta-aramids include, but are not limited to, (poly(m-phenylene isophthalamide), such as NOMEX® (E.I. du Pont de Nemours and Company) and CONEX® (Teijin Twaron BV).
• the structural fiber is p-aramid, microdenier p-aramid.
• Such structural fibers feature excellent thermal stability and are virtually non-flammable. These fibers have a very high resistance to heat and are resistant to melting, dripping and burning at a temperature of at least 700°F.
• melamine fiber is a manufactured fiber in which the fiber-forming substance is a synthetic polymer composed of at least 50% by weight of a crossiinked non-thermoplastic melamine polymer of melamine units joined by methylene and dimethylene ether linkages. In the polymerization reaction, methylol derivatives of melamine react with each other to form a three-dimensional structure. This structure is the basis for the fiber's heat stability, solvent resistance, and flame resistance.
• antistatic Fiber refers to a fiber, when incorporated into a fabric or other material, eliminates or reduces static electricity. Suitable fibers include, but are not limited to, metal fibers (steel, copper or other metal), metal-plated polymeric fibers, and polymeric fibers incorporating carbon black on the surface and/or in the interior of the fiber, such as those described in US- A-3,803,453, US-A-4.035,441 , US-A-4,107,129, and the like. Antistatic carbon fiber is a preferred antistatic fiber.
• One example of such conductive fiber is NEGASTAT® produced by E.I.
• du Pont de Nemours and Company a carbon fiber comprising a carbon core of conductive carbon surrounded by non-conductive polymer cover, either nylon or polyester.
• RESISTAT® made Shakespeare Conductive Fibers LLC, a fiber where the fine carbon particles are embossed on the surface of a nylon filament.
• the yarns of both such fibers are available in a denier of at least 40.
• a steel wire is available under the names BEKINOX and BEKITEX from Bekaert S.A. in a diameter as small as 0.035 millimeter.
• Another antistatic fiber is the product X-static made by Noble Fiber Technologies, a nylon fiber coated with a metal (silver) layer. The X-static fibers may be blended with other fibers, such as modacrylics, in the process of yarn spinning.
• the term "garment” refers to any article of clothing or clothing accessory worn by a person, including, but not limited to shirt, pants, underwear, outer wear, footwear, headwear, swimwear, belts, gloves, headbands, and wristbands, especially those used as protective wear or gear.
• the term "linen" refers to any article used to cover a worker or seating equipment used by workers, including, but not limited to sheets, blankets, upholstery covering, vehicle upholstery covering, and mattress covering.
• the term "intimate blend,” when used in conjunction with a yarn, refers to a statistically random mixture of the staple fiber components in the yarn.
• the fiber blends of the invention have hydrophobic fibers having both multiple staple lengths and multiple deniers within a single fiber composition for both single and multiple hydrophobic fiber compositions.
• Yarns, fabrics, garments, and linens comprising the fiber blends have improved moisture management properties, including faster water release rates, wicking, and drying times.
• the invention is directed to fiber blends, comprising:
• a hydrophilic component comprising at least one hydrophilic fiber; and about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of a hydrophobic component comprising:
• first synthetic hydrophobic fibers having a first composition
• first synthetic hydrophobic fibers have multiple staple lengths and multiple deniers
• a second embodiment is directed to fiber blends, comprising:
• a third embodiment is directed to fiber blends, comprising:
• At least a portion of said modacrylic fibers, at least a portion of said nylon fibers, or at least a portion of both of said modacrylic fibers and said nylon fibers have multiple staple lengths and multiple deniers.
• Suitable hydrophilic fibers include at least one polymer selected from the group consisting of cellulose, cellulose derivative (such as cotton, viscose, linen, rayon, fire-resistant rayon, lyocel!, or a combination thereof), wool, and copolymers thereof, and combinations thereof.
• the hydrophilic fiber comprises cotton or fire-resistant rayon, or a combination thereof.
• the hydrophilic fiber is a cellulose derivative, including but not limited to, cotton, viscose, linen, rayon, or a combination thereof.
• the hydrophilic fiber is cotton, especially cotton that has not been treated with a fugitive fire resistant treatment.
• Suitable hydrophobic fibers may include at least one polymer selected from the group consisting of polypropylene, polyester (such as polyethyleneterephthalate, polybutyleneterephthalate, poly(trimethylene terephthalate)), polyphenylene oxide, polylactide, nylon, polyacrylonitrile, polybenzimidazole, aramid, fluoropolymer, and copolymers thereof, and combinations thereof.
• the hydrophobic fiber comprises polyester, polyacrylonitrile or copolymer thereof, nylon, or a combination thereof. More preferably, the hydrophobic fiber is polyester or a combination of modacrylic and nylon.
• said hydrophilic fibers are cellulose, cellulose derivative, wool, or a combination thereof.
• said hydrophilic fiber is cotton or rayon.
• said first synthetic hydrophobic fibers are fibers selected from the group consisting of polypropylene, polyester, polyphenylene oxide, polylactide, nylon, polyacrylonitrile, polybenzimidazole, aramid, fiuoropolymer, and copolymers thereof.
• said at least one second synthetic hydrophobic fibers are present.
• said at least one second synthetic hydrophobic fibers are present and said at least one second synthetic hydrophobic fibers are fibers selected from the group consisting of polypropylene, polyester, polyphenylene oxide, polylactide, nylon, polyacrylonitrile, polybenzimidazole, aramid, fiuoropolymer, and copolymers thereof.
• said first synthetic hydrophobic fibers are fibers selected from the group consisting of poly(ethylene terephthalate), nylon, and modacrylic.
• said at least one second synthetic hydrophobic fibers are present and said at least one second synthetic hydrophobic fibers are fibers selected fibers selected from the group consisting of poly(ethylene terephthalate), nylon, and modacrylic.
• said hydrophobic component is a single color.
• At least a portion of said first synthetic hydrophobic fibers comprise:
• first group of fibers having the same staple length and multiple deniers; and a second group of fibers having the same denier and multiple staple lengths; wherein a fiber in said first group may be a fiber in said second group.
• said first group of fibers and said second group of fibers are substantially the same color.
• At least a portion of said first synthetic hydrophobic fibers comprise:
• first group of fibers having a first staple length and a first denier
• second group of fibers having a second staple length and a second denier; wherein said first staple length is different than said second staple length; and wherein said first denier is different than said second denier.
• said first group of fibers and said second group of fibers are substantially the same color.
• said hydrophilic component is present at a level of about 10% by weight to about 15% by weight, based on the total weight of the fiber blend;
• hydrophobic component is present at a level of about 85% by weight to about 90% by weight, based on the total weight of the fiber blend.
• said first synthetic hydrophobic fibers comprise:
• said first synthetic hydrophobic fibers comprise: about 10% by weight to about 90% by weight, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first staple length;
• first staple length is different from said second staple length; and about 0% by weight to about 80% by weight, based on the total weight of the first synthetic hydrophobic fibers, of at least one fiber having an additional staple length different than said first staple length, second staple length, and any said additional staple length, if present.
• said first synthetic hydrophobic fibers comprise:
• said first synthetic hydrophobic fibers comprise:
• said first synthetic hydrophobic fibers comprise: about 20 weight % to about 80 weight %, based on the total weight of the first synthetic hydrophobic fibers, of a fiber having a first denier;
• said first synthetic hydrophobic fibers comprise:
• said first synthetic hydrophobic fibers comprise:
• said fiber blend is substantially intimately blended.
• Another embodiment is directed to yarns, comprising the fiber blends described herein.
• said yarn is a spun yarn.
• the yarn may optionally contain at least one antistatic fiber.
• the antistatic fibers(s) are present at about 0.1-2.5% by weight, based on the total weight of the fabric.
• Yet another embodiment is directed to fabric, comprising the yarn described herein.
• said fabric meets the requirement for flame resistance, as set forth in American Society for Testing and Materials Standard Performance Specification ASTM F1506.
• said fabric has a water release rate at least about 5%, preferably at least about 10%, greater than a comparative fabric, as said fabric dries from 20% by weight water to 1% by weight water, when tested in accordance with a modified version of the provisional AATCC Gravimetric Drying Test Method (AATCC/MM TS-05); and
• said comparative fabric is compositionally identical to said fabric and whose hydrophobic fibers are not both of multiple staple lengths and multiple deniers.
• said fabric has a water release rate at least about 5%, preferably at least about 10%, greater than a comparative fabric, as said fabric is dried from a condition of wet (padded) to less than 1% by weight water, when tested in accordance with a modified version of the provisional AATCC Gravimetric Drying Test Method (AATCC/MM TS-05); and
• said comparative fabric is compositionally identical to said fabric and whose hydrophobic fibers are not both of multiple staple lengths and multiple deniers.
• said fabric has a drying time at least about 5%, preferably at least about 10%, faster than a comparative fabric from 20% by weight water to 1% by weight water in a controlled environment of 70°F and 55% relative humidity (+A 5% relative humidity), when tested in accordance with a modified version of the provisional AATCC Gravimetric Drying Test Method (AATCC/ASTM MM TS-05); and
• said comparative fabric is compositionally identical to said fabric and whose hydrophobic fibers are not both of multiple staple lengths and multiple deniers.
• a hydrophilic component comprising at least one hydrophilic fiber; and about 85% by weight to about 100% by weight, based on the total weight of the fiber blend, of a hydrophobic component comprising:
• first synthetic hydrophobic fibers having a first composition
• first synthetic hydrophobic fibers have multiple staple lengths and multiple deniers.
• the fiber blends, yarns, and fabrics may contain other components and treatments.
• the fabric may contain anti-microbial and/or anti-odor components, such as, for example, triciosan, silver, and the like.
• the fabrics, garments, and linens may also be treated with a stain release agent or water repellant on the outside surface of the fabric to reduce overall absorbency of the warp yarn, thereby further improving moisture management.
• Suitable stain release agents and water repellants include conventional f!uoropolymers and silicone polymers (such as EPIC by Nextec and DWR from Xeromax).
• the yarns of hydrophobic and optional hydrophilic fibers can be made into a textile material or fabric by conventional means, such as weaving and knitting. Non- woven fabrics may also be made from the blended fibers. Other fibers may be incorporated into the fabric to obtain desired properties.
• the fabric may contain about 5% by weight to about 10% by weight, based on the total weight of the fabric, of a continuous elastomeric filament, such as those products sold under the trade names of Lycra (Invista), Elaspan (Invista), Acepora (Taekwang), Creora (Hyosung), ROICA and Dorlastan (Asahi Kasei), Linel (Fillattice), and ESPA (Toyobo), incorporated into the fabric to provide stretch.
• the fabric may contain about 0.1% by weight to about 2.5% by weight, based on the total weight of the fabric, of an antistatic fiber to eliminate or reduce static electricity.
• the fabric may contain at least one structural fiber selected from the group consisting of aramid polymer, melamine polymer, and combinations thereof.
• the structural fibers are present at about 5-30%, by weight, based on the total weight of the fabric.
• the structural component is present at about 20-30%, by weight, based on the total weight of the fabric.
• the structural component is aramid polymer, such as m-aramid polymer or p-aramid polymer.
• the fabrics may be dyed and finished in a conventional manner as described in references such as T. Ishida, An Introduction to Textile Technology, published by Osaka Senken Ltd., Osaka, Japan (1991) and J. H. Marvin, Textile Processing, Volume 1, South Carolina State Department of Education (1973), the disclosures of which are herein incorporated by reference.
• Example 1 Two 100% polyester yarns were spun with following denier and staple
• a fabric knitted from Yarn A (invention) (Fabric A) (invention) and a fabric knitted from Yarn B (Fabric B) (comparative) were dyed and finished in the same manner. These fabrics were evaluated for their hand/softness and drying time performance as detailed below:
• drying times including wet pickup, total drying time (total to 1% moisture), dry time in comfort zone (20% to 1% moisture), water release rate (WRR) (total to 1% moisture), and WRR in comfort zone (20% to 1% moisture), were measured for Fabric 1 (invention) and Fabric 2 (comparative), in accordance with the AATCC/ASTM Moisture Management Technical Supplement 05 (AATCC/ASTM MM TS-5) gravimetric drying test procedures.
• the blotted wet sample was attached to the top of the wire loop using the clips, such that the sample hung down within the wire loop.
• the weight of the sample was recorded to establish a wet weight.
• the balance was coupled to a data acquisition system comprising Lab View software. Weight readings were automatically recorded every 15 seconds by the computer.
• the test was complete once the sample weight had reached a designated stopping moisture level versus the conditioned dry weight. The stopping moisture level was approximately 2%.
• the test was ended by stopping data acquisition in Lab View. The data file was saved for that sample. Calculation and Interpretation
• Total drying time is the time it takes the specimen to reach the stopping weight.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Woven Fabrics (AREA)
• Professional, Industrial, Or Sporting Protective Garments (AREA)
• Knitting Of Fabric (AREA)
• Nonwoven Fabrics (AREA)

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• 2014
  • 2014-11-04 AU AU2014361936A patent/AU2014361936A1/en not_active Abandoned
  • 2014-11-04 CN CN201480001458.7A patent/CN104903499B/zh active Active
  • 2014-11-04 US US14/760,379 patent/US20150354097A1/en not_active Abandoned
  • 2014-11-04 JP JP2016535638A patent/JP2017501313A/ja active Pending
  • 2014-11-04 IN IN2796KON2014 patent/IN2014KN02796A/en unknown
  • 2014-11-04 EP EP14869606.5A patent/EP3080342A4/en not_active Withdrawn
  • 2014-11-04 MX MX2016007579A patent/MX2016007579A/es unknown
  • 2014-11-04 WO PCT/US2014/063824 patent/WO2015088672A1/en active Application Filing
  • 2014-11-04 CA CA2930568A patent/CA2930568A1/en not_active Abandoned

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