Yarn for fabric and fabric

Abstract

Existing synthetic yarns are susceptible to high levels of heat absorption. It is desirable to address this by composing a yarn for use in a fabric that has a lower level of heat absorption and with a relatively lower environmental impact. The invention provides, a multifilament yarn for use in the composition of a fabric to be incorporated into furniture, shading, screening and fittings, apparel, shoes or other general textile applications, the yarn comprising a polymeric content of at least approximately 80%, a tenacity of at least approximately 2 grams per denier (g / d), UltraViolet (UV) additive content of approximately 0.0-1.0%, an Infrared (IR) reflective pigment content of approximately 0.5-4.0%, a dispersive additive content of approximately 0.0 to 0.8%, and an IR reflective additive content of approximately 0.0 to 1.0% all of which are incorporated in the yarn during the yarn extrusion process; and wherein the yarn is solution dyed during a yarn extrusion manufacturing process. The invention also provides a fabric comprised of said yarn. Said yarn and fabric have lower heat absorption properties and are more environmentally friendly relative to existing commonly used yarns.

Description

[0001] The present application claims priority from Australian provisional application 2023904176 filed on 21 December 2023, and Australian provisional application 2024903768 filed on 15 November 2024, the contents of which are to be considered to be incorporated into this specification by this reference. Technical Field

[0002] The invention relates to a yarn and a fabric formed from the yarn, specifically, a yarn and a fabric suitable for use both indoors and outdoors, the fabric having a use as a component of furniture and fixtures such as blinds, cushions, canopies and shade cloth, as well apparel, shoes, and other general textile applications Background of Invention

[0003] The following discussion of background art is included to explain the context of the present invention. A reference herein to a matter which is given as prior art is not to be taken as an admission that the matter was known or that the information it contains was part of the common general knowledge as at the priority date of any of the claims.

[0004] For thousands of years humans have covered structuresand furniture for aesthetic and functional purposes. Prior to the development of synthetic materials, natural materials such as woven reeds, grasses and animal hides were used as outdoor furniture covers, or as key components of outdoor furniture and apparel. Such materials were utilised due to their availability and durability, whilst others were used to portray class and prestige.

[0005] Over time, fabrics have been developed and optimised specifically for outdoor use. A key turning point in fabric development was during the industrial revolution where new weaving techniques and machinery led to the production of more versatile and durable fabrics. Initially, there was an increase in demand and popularity for canvas following the industrial revolution.

[0006] Canvas, a plain-woven fabric, was initially made from hemp. It has evolved to be predominantly made from cotton and is coated with various waterproofing solutions to enhance its weather resistance.

[0007] In the mid-20th century, the development of synthetic yarns such as acrylic, polyester, and nylon, revolutionized the outdoor furniture industry and outdoor apparel industry. These yarns offered improved durability, resistance to fading, and enhanced moisture resistance compared to natural yarns. Acrylic fabrics gained popularity due to their vibrant colours and ability to retain their colour even when exposed to sunlight for long durations. The evolution of synthetic yarns has resulted in the development of a blended canvas. Blended canvases are made from a combination of cotton and synthetic yarns, which allow for enhanced durability and water resistance, thus making blended canvases an ideal and suitable fabric for outdoor furniture and fixtures, and for use in apparel often worn or applied outdoors.

[0008] Synthetic yarns and resulting fabrics have been further developed to enhance performance, in particular, resistance to UV degradation, durability, and heat absorption and dissipation. These, amongst others, are essential considerations manufacturers make in the development of yarns for outdoor fabrics and furniture.

[0009] Where these synthetic yarn-based fabrics are exposed to sunlight they absorb heat. Specifically plastic articles, including synthetic fibres, heat up when exposed to sunlight because the base polymeric structure along with the pigments, which absorb infrared wavelengths from the sun and convert them into heat energy. The darker the pigment, the warmer it becomes when exposed to the sunlight, with a black pigment being the highest heat absorber.

[0010] The amount of heat absorbed can be unbearable, for example, on a clear summer day. For example, the fabric of a tent, a chair, a mat, a hat, or a marquee, will absorbs a great amount of radiant heat on a clear summer day, making the fabric unbearable to touch and uncomfortable to use. The fabric often becomes hotter than its surrounding environment, resulting in heat transfer to the surrounding environment through conduction and / or convection.

[0011] Mitigating heat absorption is an important consideration when designing fabrics which are exposed to sunlight. One such measure employed to mitigate heat absorption is to provide apertures throughout the fabric to facilitate ventilation, which has limited effectiveness. Another measure includes the use of reflective coatings which can be expensive, harmful to the environment, and which often degrade over time. In the current market, outdoor fabrics are predominantly manufactured from canvas or woven yarns, most commonly synthetic yarns such as polyester, PVC, acrylic, nylon, or polyolefin. The versatility of synthetic yarns and their colour fastness has seen outdoor fabrics evolve to reflect changing design trends and consumer preferences. Manufacturers now offer a wide variety of patterns, colours, and textures to suit different outdoor decor styles.

[0012] Whilst fabric and yarn technology have come a long way since the industrial revolution, fabrics still have a limited useful life due to degradation of the fabric / yarn. Where a fabric has outlasted a fashion trend, or has degraded and is due for replacement, it is disposed of by a user and usually ends up in landfill. To reduce the amount of fabric that ends up in landfill, measures have been developed and implemented to extend the fabric's life. These methods include, re-painting / dying, periodic application of protective films and regular maintenance. Whilst efforts to extend the fabric life are noble, they are costly and, in some instances, harmful to the environment. It is often more cost effective to replace the fabric than to repair, re-paint or recoat.

[0013] With no simple solution to repurpose synthetic outdoor fabrics, their disposal is problematic. A limitation of such fabrics originates in their synthetic and blended / composite makeup, which makes them costly and resource intensive to recycle. Existing recycling processes require polymer separation, which is a complex, resource intensive and unreliable process. In most instances, synthetic-based yarn fabrics are sent to landfill or illegally dumped, thus resulting in adverse environmental effects.

[0014] The fabric manufacturing industry is aware of disposal and recyclability issues. The industry is averse to entirely redesigning the yarn and fabric makeup for a few reasons, some of which include preserving performance existing characteristics, or the manufacturing and optimisation of machinery tailored for specific fabric and yarn makeups. Rather, improvements to ingredients used in the manufacturing of fabrics have been made to reduce the 4 environmental impact a fabric has, particularly once disposed. For example, environmentally harmful additives such as toxic inks and pigments have been replaced with inks and pigments that are not toxic. This allows a coloured / printed fabric to be washed or incinerated without releasing toxic chemicals, and for the disposed fabric to be used in a waste-energy stream. Another innovation has been to use a water-based coating which is biodegradable. Once disposed in landfill the water-based coating does not contaminate the soil or any adjacent water streams.

[0015] As synthetic yarns and fabrics continue to evolve, manufacturers face the challenge of developing aesthetically pleasing yarns and fabrics that are increasingly versatile whilst preserving base line performance characteristics of predecessor fabrics, all the while seeking a lower adverse environmental impact to their manufacture, use and disposal. While fabrics and yarns may be developed and tested for experimental purposes on a small scale, significant challenges lie in developing improved fabrics at a reasonable manufacturing cost all the while minimising environmental adverse effects.

[0016] It is desirable to create versatile, comfortable, durable, and aesthetically pleasing fabric solutions whilst minimising the negative environmental effect resulting from the disposal of current fabrics. Summary of Invention

[0017] The present invention seeks to provide a versatile yarn which enhances in-use comfort, is strong enough to withstand a variety of stresses and conditions, and which can be aesthetically tailored. In one form of the invention there is provided a multifilament yarn for use in the composition of a fabric to be incorporated into furniture and fittings, the yarn comprising: - a polypropylene content of at least approximately 80%, - a denier of at least approximately 100D, - a tenacity of at least approximately 2 grams per denier (g / d), - UltraViolet (UV) additive content of approximately 0.0-1.0%, an IR reflective pigment content of approximately 0.5-4.0%, a dispersive additive content of approximately 0.0 to 0.8%, and an IR reflective additive content of approximately 0.0 to 1.0% all of which are incorporated in the yarn during the yarn extrusion process; and wherein the yarn is solution dyed during a yarn extrusion manufacturing process.

[0018] At a denier of at least 100D, the yarn can be woven or knitted to form a fabric which can be used in a variety of furniture, fittings, fixtures, apparel or other textile applications. The yarn tenacity provides the yarn and the subsequently knitted or woven fabric sufficient strength with stand stress and force the fabric may be subjected to, for example, at a range above 2 g / d, a fabric made of the yarn of the present invention can support the mass of a person or an object when used in the form a suspension chair or a suspension table, or any other piece of furniture or fitting required to support mass. Additionally, its tenacity gives it sufficient strength to withstand external elements when in the form of an umbrella canopy, or any item to remain predominantly outdoors, or under consistent mechanical stress. The yarn is versatile and can be used to form a woven or knitted fabric with a wide variety of end uses both indoor and outdoor. The denier and tenacity of the yarn not only contribute to a fabric's properties, but they allow the yarn to be used in a knitting or weaving manufacturing process without issue. The specified tenacity of at least 2grams per denier and a net denier of approximately at least 100D allows the yarn to have adequate strength whilst also maintaining a level of flexibility to ensure its versatility during manufacturing, and its end use as fabric.

[0019] The inclusion of the combination of an ultraviolet additive, an IR pigment, a dispersive additive, and an IR reflective additive allows for the yarn to be used on tactile surfaces without absorbing heat. For non-tactile surfaces, the yarn's heat reflective properties serve to increase comfort and reduce the wear and tear of the yarn, thus prolonging its life while providing a comfortable surrounding environment. In an embodiment, the UV additive is comprised of Hindered Amines Light Stabilsers (HALS). The inclusion of these additives and pigments during the extrusion manufacturing process serves to integrate the additives into the polymer matrix of the yarn, thus ensuring the longevity of the yarn's heat resistant capabilities as the additives and pigments are unlikely to leech. Additionally, as the yarn is solution dyed during the fibre manufacturing process, there is no risk of colour run-off or paint degradation. Rather, being solution dyed, the yarn has enhanced colour preservation in comparison to surface dyed yarns which are prone to fading, degradation, peeling and run-off. In this respect, the colour is 'locked-in' to the polymer matrix.

[0020] The yarn is predominantly made up of polypropylene, thus reducing the complexity around the recycling of a fabric made predominantly of the yarn, either knitted or woven. Being predominantly polypropylene, complex polymer separation techniques are not required to recycle the yarn / fabric. Further, as the yarn is solution dyed as opposed to surface dyed, there is no risk of toxic dye run off. This not only simplifies the recycling process, but also makes the yarn safer to use in a domestic environment, and desirable for applications with direct skin contact.

[0021] A fabric made of the yarn of the present invention can be entirely recycled at a relatively low cost. With the yarn being solution dyed, and capable of being either knitted or woven gives it the yarn both a function and aesthetic versatility, making it suitable for plethora of fabric manufacturing techniques and end uses / products.

[0022] While the yarn is predominantly made of polypropylene, it is possible that it contains trace amounts of other polymers to enhance its strength. The small amounts of other polymer / s may not necessarily alter the simplified recycling process; however, it may result in a lower quality recycled material. To counter this, in an embodiment, the yarn may be polypropylene homopolymer so as to ensure a relatively higher quality recyclate.

[0023] In developing a knitted or woven fabric there is a balance between workability, and UV coverage. Once the yarn is beyond a certain thickness it may be unable to be knitted with ease, or unable to be knitted at all. If it is woven at a high thickness, it may result in a coarse looking fabric with compromised UV blocking, as the resulting fabric will appear porous. If the yarn thickness falls below a certain value, despite being easier to work with while knitting or weaving, the end fabric may not provide sufficient UV block or water tightness at a standard weight / density, and in the case of a woven fabric a higher density may be required to achieve an adequate UV block or water tightness. Therefore, in an embodiment, the yarn denier is between approximately 100D and 1000D. The yarn denier can be chosen depending on the end use of the fabric into which it will be woven or knitted into to. In a preferred embodiment, the yarn denier is between 400D and 600D.

[0024] In an embodiment, the yarn comprises approximately 72 to 288 fibers per filament, and preferably approximately 144 fibers per filament. The number of filaments per fibers can be adjusted to create a yarn with a specific denier. Alternatively, the denier of each individual filament / fiber can be adjusted, or both can be adjusted. In this respect, in an embodiment the denier of each filament of the yarn may be approximately 1.0D and up to at least 8.0D.

[0025] The weight of the yarn is an important factor, particularly when the yarn is used to form a fabric for use in applications where weight is important, for example, a portable marquee or umbrella cover, a blind or clothing. In an embodiment the fabric comprises a weight of approximately 100 to 600 grams per square metre (GSM).

[0026] Cases where the yarn is to form a mould and mildew resistant fabric, the yarn may in an embodiment incorporate an antimicrobial additive. Antimicrobial additives such as Microban™ are comprised of silver ion, or zinc oxide, composites which are inherently antimicrobial. This serves to slow or entirely stop mould and mildew from growing or forming on the yarn. The antimicrobial additive may be applied post extrusion, however, for longevity it is incorporated into the yarn during the extrusion manufacturing process. In such an embodiment, the yarn may be comprised of up to 0.5% by wt antimicrobial additive.

[0027] Although polypropylene is inherently hydrophobic, its hydrophobicity can be enhanced. This is particularly desirable in instances where the yarn is to be used to form a fabric for use as an outdoor seat cover, or a suspension seat. Therefore, in a further embodiment, the yarn may also comprise a hydrophobic surface treatment. The treatment may be applied after the extrusion process, however, to allow for the hydrophobic properties to be long lasting, the treatment may be incorporated during the extrusion manufacturing process. The surface treatment may be any one of a Teflon™ finish, or a silicone solution, or zinc oxide nanoparticles. Given the polypropylene's inherent hydrophobicity the total hydrophobic surface treatment content can be relatively modest so as to not adversely affect other material properties. In an embodiment, the content of the surface treatment additive is approximately 0.5% to approximately 2% and preferably approximately 1% by wt.

[0028] The aesthetic of the yarn can be manipulated to make it appear like a natural fibre. This can be achieved through several methods, and in one form of the invention, the yarn may be texturised. The yarn texturization process is a dedicated process which occurs after the yarn has been extruded. Texturising techniques can include bulking (where thermoplastic yarns are twisted, heat set and untwisted), crimping and coiling, amongst others.

[0029] As previously noted, the yarn of the invention in any one or a combination of the above embodiments may be used to form a fabric through traditional textile conversion processes including, but not limited to, weaving, warp knitting, and tricot knitting

[0030] In one form of the invention, there is provided a knitted fabric for shading applications, comprised partially or entirely of the multifilament yarn as described in the preceding paragraphs. In one embodiment, the yarn of the knitted fabric comprises a denier of approximately 450D, a dpf of approximately 3.1. The fabric is comprised of a 12-gauge knit pattern and a weight of 310 gsm, wherein the UV block of the fabric is between approximately 90 to 100%. This fabric may be manufactured on a compound or latch needle warp knitting machine having two guide bars being a first (GB1), and a second (GB2), guide bar, wherein the guide bars follow the following knit pattern to manufacture the fabric: GB110 / 01 / / , GB2 01 / 34 / / .

[0031] Such a fabric may be used as an umbrella or a shade cloth or a marquee cover and have a UV block of approximately 90 to 100%.

[0032] In a further alternative embodiment of the invention, the knitted fabric is comprised partially or entirely of a multifilament yarn having a denier of approximately 800 to 1000D, a dpf of approximately 6.6, a tenacity of at least 6.0g / D. The fabric is comprised of a 6-gauge knit pattern and a weight of 340 gsm, wherein the UV block of the fabric is at least 80%. The fabric may be manufactured on a compound or latch needle warp knitting machine having four guide bars being a first (GB1), a second (GB2), a third (GB3), and a fourth (GB4) guide bar wherein the guide bars follow the following knit pattern to manufacture the fabric: GB110 / 01 / / , GB2 23 / 21 / 10 / 12 / / , GB3 10 / 12 / 23 / 21 / / , GB4 00 / 44 / / .

[0033] Where the fabric is not entirely comprised of the yarn of the present invention, GB4 may run a monofilament High Density Polyethylene (HDPE) or Polypropylene (PP) yarn of approximately 600D. The HDPE yarn is used to provide the fabric with enhanced properties such as strength and stiffness. The fabric may be a suspension fabric in which a degree of flexibility is required to allow for comfort and durability, particularly where the suspension fabric is to be a suspension seat and back cover / wrap. In such an embodiment, the UV block may be relatively lower to that of an umbrella and may be at approximately at least 80%.

[0034] In a further form of the invention there is a provided a woven fabric comprised of the multifilament yarn according to any form or embodiment of the invention as previously discussed. In one embodiment the multifilament yarn comprises a denier of approximately 600 D, and a dpf of approximately 4.2. The fabric is comprised of a weave pattern of 19x15 yarns / cm and a weight of 220 gsm, wherein the UV block of the fabric is approximately at least 98%. Such a fabric may be suitable as a cushion cover of an outdoor couch. However, given the density of the weave pattern, the fabric may be significantly less breathable than a knitted fabric. However, it is envisaged that the heat reflective properties of the yarn make this fabric superior to existing woven cushion covers for outdoor couches.

[0035] In a further form of the invention there is a provided tricot knitted fabric comprised of the multifilament yarn according to any form or embodiment of the invention as previously discussed. In one embodiment the multifilament yarn comprises a denier of approximately 150 D, and a dpf of approximately 3.2. The fabric can be knitted to any desirable pattern, with a weight range from 50 to 500gsm. Such a fabric may be suitable as an outer layer for a shoe, or other general textile applications

[0036] The yarn of the present invention exhibits relatively lower infrared wavelength absorption, and thus limits the build-up of heat / temperature after exposure to sunlight or similar light sources when compared to conventional fibres and fabrics. This provides and higher level of comfort as well as prolonging the life of the yarn. Further, being predominantly polypropylene, the relatively heat resistant yarn can be recycled with relative ease, and without the need for complex polymer separation. The use of polypropylene as the main ingredient allows for ease of fabrication, high abrasion resistance, tear and fray resistant, and enhanced durability and resilience allowing the yarn and resulting fabric to have some stretch.

[0037] In addition to its enhanced recyclability, the yarn of the present invention is not susceptible to runoff / leeching of colour or surface coating as all colours and hydrophobic coatings, and antimicrobial additives are incorporated into the makeup of the yarn during the extrusion process. There are challenges associated with incorporating these additives during the extrusion manufacturing process as their inclusion in the polymer matrix can adversely affect the other properties such as strength and durability of the yarn. The present invention is directed to not only the incorporation and combination of these additives into a yarn, but to the actual quantity of each additive, the quantity ranges along with yarn dimensions and any corresponding ranges, which in combination yield a versatile and relatively environmentally friendly yarn suitable for forming a fabric for use in indoor and outdoor settings.

[0038] Whilst Polyproplylene yarn has been broadly referenced in this Summary of Invention, alternate polymeric materials can also be applicable. Replacement synthetic fibres such as, but not limited to, Polyethylene Terephthalate (PET or Polyester), Polyamide (Nylon) or PolyAcrylonitrile (Acrylic), can also be applicable to this invention.

[0039] Where the terms "comprise", "comprises", "comprised" or "comprising" are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other features, integers, steps or components, or group thereto. Detailed Description

[0040] The present invention relates to a yarn and a fabric comprised partially or entirely of the yarn.

[0041] The yarn is predominantly comprised of polypropylene. The properties of the yarn are such that any woven or knitted fabric comprising the yarn can be used in a variety of settings across a variety of products such as an outdoor umbrella, an outdoor or indoor cushion cover, an outdoor or indoor couch cover, a pet bed, a chair cover, a suspension chair seating surface, a storage bag, a carry bag, a sports bag, a privacy screen, a shade cloth, a marquee cover, a picnic or beach blanket, clothing, shoes or any other conceivable product or fixture.

[0042] It is to be appreciated that the yarn properties such as denier, tenacity, polypropylene content, weave or knit pattern, and additive content can be tailored for a particular use or purpose. For example, the yarn requirements for an umbrella differ to the yarn requirements for a clothing, shoe or suspension chair. However, there are limitations to the inclusion of additivesand pigments. Inclusion of additives into the extrusion manufacturing process reduces the total polypropylene content in the extruded yarn. A reduction in polypropylene content can adversely affect the strength and performance properties of the yarn, however, the inclusion of the additives improves other performance aspects of the yarn such as heat resistance, hydrophobicity, and antimicrobial properties.

[0043] In this respect, the yarn of the present invention has been formulated to account for different uses and for the inclusion of additives in the extrusion manufacturing process. The formulation has been carefully developed to provide a yarn that is capable of being used in a manufacturing process without breaking, and to also provide a versatile yarn that can be used to form fabrics for a wide range of uses without significantly compromising the innate properties of polypropylene.

[0044] According to the invention the yarn is a multifilament yarn formed by an extrusion manufacturing process. While the yarn can be a monofilament and formed by other means, the inventors found a multifilament yarn extruded yarn to be easier to mass manufacture and one that performs at a higher standard.

[0045] The multifilament yarn is comprised of at least approximately 80% by wt polypropylene with an overall denier of at least approximately 100D. The high polypropylene content gives the yarn properties unique to polypropylene. These properties include flexibility, durability, chemical resistance, and light weight. The yarn is a polypropylene homopolymer. This significantly simplifies the recycling process of the yarn, or a fabric made entirely of the yarn, as complex polymer separation is not required. In alternative embodiments it is possible for the yarn to include other polymers in the yarn makeup.

[0046] The denier of the yarn can be increased to cater to different purposes as will be discussed in the proceeding paragraphs, and it is to be appreciated that a minimum denier of approximately 100D is required to develop a yarn that performs to a minimum standard for fabric manufacture. In this respect, the yarn is comprised of a minimum tenacity of approximately 2 grams per denier (g / d) to withstand stresses during a weave or knit manufacturing process, whilst also satisfying minimum strength requirements of a fabric for both indoor, outdoor and personal use.

[0047] Key advantages of the multifilament yarn include softness, pliability and a high strength to weight ratio. The yarn can be comprised of an UltraViolet (UV) additive content of approximately 0.0-1.0%, an IR reflective pigment content of approximately 0.5-4.0%, a dispersive additive content of approximately 0.0 to 0.8%, and an IR reflective additive content of approximately 0.0 to 1.0%. Each of these additives are incorporated in the yarn during the extrusion manufacturing process. This in essence 'locks' the heat reflective capability into the yarn polymer matrix, making the heat reflective capability an inherent property of the yarn.

[0048] The alternative to incorporating the additives into the yarn polymer matrix during the extrusion manufacturing process is to coat the extruded yarn with additive and pigment layers which may impart a degree of heat reflectivity. While a heat reflective coating may be initially effective, such a coating has a limited useful life before degrading. The degradation of a coating may result in noxious or toxic run-off if the coating is comprised of noxious or toxic chemicals. Additionally, the recoating process is costly, and it is often more cost effective to replace an entire fabric instead of recoating it.

[0049] In comparison to the traditional process of coating a fabric, the heat reflective recipe of additives and pigments of the present invention are not expected to leach out or diminish in performance over time. Further, the inclusion of infrared reflective pigments and / or additives in the polymer matrix of the yarn allow for the sector of IR wavelengths that carry heat to be reflected when the yarns are exposed to sunlight, or an equivalent light source, thus reducing the surface temperature of the yarn / fabric. The UV additive in combination with the IR reflective pigment, the dispersive additive and the IR reflective additive reduce the heat absorption of the yarn. In comparison to a yarn that does not have this combination of pigments and additives incorporated into its polymer matrix, the yarn of the present invention remains cooler to touch and emits less radiant / convective heat making it cooler to be around. The benefits of this combination are set out in PCT / AU2023 / 050477 the contents of which are incorporated herein by this reference. In corresponding PCT / AU / 2023050477 application, the fabric comprising a similar recipe of additives and pigments to that disclosed in the present application remains approximately 20% cooler than a fabric without heat resistant properties when exposed to sun light over a six hour period.

[0050] The UV additive incorporated in the yarn can be any suitable additive. In one embodiment the UV additive is Hindered amines light stabilizers (HALS). Additionally, any one or a combination of the following IR reflective pigments and additives can be used: ColanyalTM Oxide Yellow BV531 and Titanium Dioxide, blended with additional pigments to create a Beige fabric colour.

[0051] The IR reflective pigment used in the yarn makeup is not restricted to Colanyal™ Oxide Yellow BV531. In alternative embodiments the IR reflective pigment can be altered to provide a different yarn colour. For example, Colanyl™ Scarlet GO532 and / or Colanyl™ Oxide Red G531 are used to give the yarn a red colour; and Colanyl™ Oxide Blue is used to give the yarn a blue colour. The Colanyl™ additives are proprietary additives and colours developed by Clariant AG which is owned by Heubach GmbH. These IR reflective pigments can be mixed and matched to obtain a desired colour. Thus, in a further alternative aspect, a combination of IR reflective pigments is used to obtain a desired colour. Further, any other suitable IR reflective pigment may be used, for example, titanium dioxide, mica, and silicon dioxide all have a pigmentation effect, and may be used alone or in combination with each other and the ColanylTM pigments to obtain a desirable colour. It is to be appreciated that the list of IR reflective pigments is not exhaustive. Other branded IR reflective pigments, or other IR reflective pigments not listed may be used.

[0052] The IR reflective additive used may be any one of titanium dioxide, or mica, or silicon dioxide, or a combination thereof. It is to be appreciated that additives such as titanium dioxide, mica, and silicon dioxide have a pigmentation effect. As a result, in certain embodiments, the IR reflective additives are used in place of the IR reflective pigments noted above, or in combination with those IR reflective pigments, or in combination with any other suitable IR reflective pigment or additive. It is to be appreciated that the list of IR reflective additives is not exhaustive. Other branded IR reflective additives not listed may be used.

[0053] It is also to be appreciated that the yarn of the present invention is solution dyed during the extrusion manufacturing process. Like the heat resistant ingredients noted in the previous paragraphs, the solution dye is locked into the yarn polymer matrix, thus eliminating any colour leeching or run-off. In this respect, the yarn has improved colour fastness in comparison to a surface dyed or coated yarn, and the colour of the yarn of the present invention is expected to last longer than that of a surface coated yarn. Additionally, a UV stabiliser can be incorporated into the yarn, and may form part of the heat resistant additives and pigments, and / or the solution or dye, or may be a separate component added during the manufacturing process. The UV stabiliser protects the yarn from long-term degradation due to UV light exposure, where required

[0054] The heat resistant properties of the yarn of the present invention allow it to be used in fabrics which are to be exposed to sun light and subject to human or animal touch. The heat resistant properties give such fabrics a relatively lower surface temperature (compared to fabrics without the same properties), making them relatively cooler touch, enhancing the users experience. Such fabrics are often found in apparel, shoes, on tables, sofas, chairs, tents, surface rugs, and may be desirable for use on steering wheels, tools, and clothing.

[0055] Depending on the end use of the yarn, the denier can be increased from approximately 100D up to approximately 1000D. For example, if the denier is to be used to form a knitted fabric for an umbrella, the desirable yarn denier is between approximately 400D to 600D. Such a denier is sufficiently large to give a knitted fabric strength to withstand forces generated from wind and rain, whilst also allowing for a knit pattern and density to provide sufficient UV blocking and water repellence properties (depending on the fabric application).

[0056] Where a yarn is used to form a woven cushion fabric for an indoor or outdoor couch, the denier range is between approximately 500D and 800D. This denier range is optimal for polypropylene as it results in the formation of an aesthetically pleasing knitted or woven fabric at a cost-effective density while also providing a high UV block rating. In instances the yarn is to be used to form a knitted fabric for a suspension chair back and / or a suspension chair seat, the fabric has enhanced strength and resilience, and a polypropylene yarn having a higher denier range of approximately 800D to 1000D is used. Yarn of this denier is subjected to a coarse knitting process to produce a fabric that can withstand the mass and compressive forces it will be subjected to through chair use by humans and animals. Where a yarn is used to form a fabric for a shoe outer, the denier range is between approximately 100D and 300D. This denier range is optimal for polypropylene as it results in the formation of pliable and breathable knitted or woven fabric

[0057] With a desired denier range of between approximately 100D and up to 1000D, the yarn can comprise approximately 72 to 288 fibers per filament (fbf) with a denier of each filament (dpf) being at least approximately 1.0D and up to at least approximately 8.0D. Yarn prototypes have been manufactured at 144 fbf, with a maximum denier of approximately 7.0D dpf.

[0058] The weight of the yarn is an important consideration, particularly where a fabric made of the yarn is to form a structural component of furniture or a fixture, or if the fabric is to be supported by structural components such as umbrella arms, or if the fabric is to be used in an apparel application. The weight of the fabric is dictated by several factors such as the material of the yarn (generally polypropylene in this case), the denier and the fibers per filament. With the variable ranges noted in the preceding paragraphs, the extruded yarn is tailored to produce fabrics that have a weight within the range of approximately 100 and up to 600 grams per square metre (gsm). While the fabric can have a weight above or below this range, it was found that a weight within this range provided was capable of forming a fabric(woven, or knitted or other) that could cater to a wide range of requirements whilst also being versatile enough to have a variety of uses such as shade cloth, blind, clothing, furniture fabric, or a protective synthetic blanket.

[0059] In certain environments, in particular those requiring higher levels of hygiene, it is desirable to use fabrics that are either easily cleaned and can to an extent resist the growth of mould and mildew. In this respect, the yarn of the present invention can incorporate antimicrobial properties in its polymer matrix. This is achieved through the inclusion of an antimicrobial additive during the yarn extrusion process. The weight content of the antimicrobial additive can vary between approximately 0.1% and 1.0% wt of the yarn, depending on the required antimicrobial resistance. Antimicrobial properties are desirable in most outdoor fabrics, in particular those exposed to humidity, water, or human and animal touch. One such example is a pet bed or pet mat where antimicrobial properties are desirable to help ensure the health and safety of pets who are prone to licking a wide range of surfaces and refuse.

[0060] Most antimicrobial additives comprise silver ion, or zinc oxide, composites, and in the yarn of the present invention the antimicrobial additive that is included is known as Microban™. Other brands and formulations may be used in place of Microban™. Such additives are known to provide a degree of odour control while resisting the growth of microorganisms like bacteria, mould, and mildew.

[0061] Another fabric characteristic that is desirable, for outdoor furniture or general textile application uses is hydrophobicity. For such applications, the yarn of the present application incorporates a hydrophobic surface treatment in its polymer matrix, whereby the surface treatment is incorporated during the extrusion manufacturing process. The surface treatment can be any number of solutions or finishes such as Teflon™, or a silicon solution, or any suitable solution that enhances hydrophobicity. The yarn is configured to have a hydrophobic surface treatment content of approximately between 0.5% wt and up to 2.0% wt. A content of 1.0% wt was found to provide sufficient hydrophobicity and stain resistance for a fabric made predominantly of the yarn of the present invention.

[0062] A synthetic yarn has a distinct look compared to a natural yarn. In fabrics where aesthetic appearance of the yarn and resulting fabric are of importance, a synthetic yarn can be manipulated to have a certain aesthetic and / or texture. In this respect, it is often desirable for a synthetic yarn texture to resemble that of a natural yarn. To achieve this, the yarn of the present invention can undergo a texturization process after it has been extruded. There exist several different texturization processes some of which include 'false twisting', 'direct texturing', 'air jet texturing', 'twisting', and 'box stuffing'. Any one or number of texturization processes can be used to texturise the yarn of the present invention, and in one preferred form air jet texturing is used. This involves texturing a yarn by applying a stream of air that entangles some of the filaments in the flat yarn. Air jet yarn texturing gives a synthetic yarn a similar texture to a conventionally spun yarn, particularly with respect to the yarn's hairiness, and does not provide any strength to the yarn.

[0063] With polypropylene being the main ingredient in the yarn of the present invention, the yarn has inherent moisture wicking capabilities. Polypropylene has moisture wicking properties and unlike other polymers such as polyester, polypropylene can dry quickly. This makes the yarn of the present invention ideal for forming fabrics that will involve regular and prolonged human contact such as clothing, shoes, chair / cushion fabrics, beach blankets, and picnic blankets.

[0064] It is to be appreciated that the moisture wicking properties of a fabric are not just dictated by the yarn material, the configuration of the yarn within a fabric is important. Moisture wicking properties of a fabric depend on two primary factors being capillary pressure and permeability. Capillary pressure is the force responsible for the movement of moisture as it is pulled away from a person's skin through. This is caused by the force of surface tension between the liquid and the walls of a narrow gap or pore within the fabric and / or yarn. This overcomes the forces between the molecules in the liquid so that moisture moves into empty gaps until the force evens out. Permeability is a measurement of a fabric's ability to transport moisture through itself, and is determined by gap / aperture sizes within the fabric, which are dictated by yarn denier, weave / knit patterns and density. Fabrics with a higher density / weight (typically due to a smalleryarn denier), tend to comprise a tighter knit / weave and have smaller gaps through which liquids can move through. Factors influencing permeability include the yarn twist, the contact angle between fabric and a liquid, the knit and weave pattern and density, and the texture of the yarn (surface roughness). In this respect, there is a balance to be achieved between UV block and moisture wicking capabilities.

[0065] It is appreciated that there exist applications in which moisture wicking is not desirable. For example, where a fabric is used to provide shade in the form of a shade cover, a blind or a marque cover, moisture wicking properties are not needed and or are not desirable. Rather, hydrophobicity is required in these applications, and it is envisaged that yarns for use in fabrics for these types of applications will have a hydrophobic surface treatment content at or above approximately 1.0% by wt, and / or a knit / or weave pattern which does not enhance or encourage moisture wicking. Fabric Examples

[0066] As previously noted, the yarn of the present invention is quite versatile and can be used to form a fabric for use in a wide range of applications.

[0067] In an example, the yarn of the present invention is used to form a knitted fabric for an umbrella canopy. In this respect the fabric is entirely comprised of the yarn of the present invention. The yarn of the knitted fabric comprises a denier of approximately 450D, a dpf of approximately 3.1. The fabric is formed through a 12-gauge knit pattern and has a weight of 310 gsm. The knit pattern and yarn denier provide a fabric UV block of between approximately 90 to 100%. The fabric is manufactured on a compound or latch needle warp knitting machine having two guide bars being a first (GB1), and a second (GB2), guide bar. The guide bars follow the following knit pattern to manufacture the fabric: GB110 / 01 / / , GB2 01 / 34 / / .

[0068] Being a knitted fabric, it inherently has apertures (porous) due to the knit pattern. Such apertures are sufficiently small so as to allow the fabric to have a relatively high UV block rating (UPF) whilst also allowing the fabric to be breathable. Breathability is a desirable feature in fabrics used to provide shade (e.g., an umbrella or marquee cover). Breathability of a fabric facilitates allows air flow from and through the fabric. In the context of a shade fabric, it encourages ventilation through to the shaded area, making the shaded area relatively more tolerable than if it were covered by a non-porous / non-breathable fabric.

[0069] The yarn of the fabric is solution dyed, and is comprised of heat reflective ingredients, antimicrobial additives (Microban™), and a silicon surface treatment solution for enhanced hydrophobicity and stain resistance, as set out in the preceding paragraphs. In this respect, the fabric is entirely Per- and polyfluoroalkyl substances (PFAS) free. This allows the fabric to be recycled with relative ease as no complex polymer separation is required to isolate the different polymers. The yarn of the fabric is also texturised to give it a matte aesthetic.

[0070] In an alternative embodiment, the hydrophobic surface treatment may be a Teflon™ finish which would introduce trace amounts of PFAS. It is envisaged that the fabric will be recyclable with the inclusion of PFAS without polymer separation, however, the quality of recyclate may differ to that of a fabric without a PFAS additive.

[0071] In another example, the yarn of the present invention is used to form a woven fabric for use as a cushion cover. The woven fabric is comprised entirely of the multifilament yarn of the invention, the yarn having a denier of approximately 600D, a dpf of approximately 4.2. The fabric is comprised of a weave pattern of 19x15 yarns / cm and a weight of 225 gsm. This arrangement provides a UV block of approximately at least 98%, with a comparatively low breathability compared to the knitted fabric of the first example.

[0072] The yarn of the fabric is solution dyed and is comprised of heat reflective ingredients as described in the preceding paragraphs. The heat reflective capabilities of the fabric make it relatively more comfortable to sit on, to touch and to be around. The yarn of the fabric also includes antimicrobial additives (Microban™), and a silicon surface treatment solution for enhanced hydrophobicity and stain resistance, both of which have been described in preceding paragraphs. The enhanced hydrophobicity of the yarn reduces the moisture wicking capabilities of the fabric. The yarn of the fabric is also texturised to give the fabric a matte aesthetic.

[0073] Like the fabric of the first example, this cover fabric is PFAS free. In this respect, the fabric is entirely recyclable with relative ease as no complex polymer separation is required to isolate the polypropylene.

[0074] In an alternative embodiment, the hydrophobic surface treatment may be a Teflon™ finish which would introduce trace amounts of PFAS. It is envisaged that the fabric will be recyclable with the inclusion of PFAS without polymer separation, however, the quality of recyclate may differ to that of a fabric without a PFAS additive.

[0075] In another example, the yarn of the present invention is used to form a knitted fabric for use as a suspension surface in a suspension chair. The woven knitted fabric is comprised of the multifilament yarn according to the invention. The yarn has a denier of approximately 800-1000D, a dpf of approximately 6.6, a tenacity of at least 6.0g / D. The fabric is comprised of a 6-gauge knit pattern and a weight of 340 gsm. The relatively larger yarn denier provides the fabric with enhanced strength; however, the fabric is more porous to facilitate breathability. In this respect, the UV block of the fabric is at least 80%, which is lower than that of the knitted and woven fabric examples discussed in the preceding paragraphs. The fabric is manufactured on a compound or latch needle warp knitting machine having four guide bars being a first (GB1), a second (GB2), a third (GB3), and a fourth (GB4) guide bar wherein the guide bars follow the following knit pattern to manufacture the fabric: GB110 / 01 / / , GB2 23 / 21 / 10 / 12 / / , GB3 10 / 12 / 23 / 21 / / , GB4 00 / 44 / / .

[0076] To enhance the strength and flexibility of the fabric, the fabric in an embodiment includes a yarn that is different to that of the present invention. For example, GB4 may run a monofilament High-density polyethylene (HDPE) or Polypropylene (PP) yarn of approximately 600D. The HDPE yarn is used to provide the fabric with enhanced properties such as stiffness and strength. Alternatively, the fabric is made entirely of the yarn of the present invention.

[0077] The yarn of the fabric is solution dyed and is comprised of heat reflective ingredients as described in the preceding paragraphs. This makes the fabric relatively comfortable to sit on, to touch and to be around. The yarn of the fabric also includes antimicrobial additives (Microban™), and a silicon surface treatment solution for enhanced hydrophobicity and stain resistance. The relatively porous structure of the yarn provides the fabric with enhanced hydrophobicity and moisture wicking capabilities. The yarn of the fabric is also texturised to give the fabric a matte aesthetic.

[0078] The fabric having a silicon based hydrophobic solution does not have any PFAS. In an alternative embodiment, the hydrophobic surface treatment may be a Teflon™ finish which would introduce trace amounts of PFAS.

[0079] It is appreciated that the combination of a HDPE yarn in addition to the polypropylene yarn of the invention increases the recyclability difficulty of the fabric. Separation of the HDPE and the polypropylene polymers will be required. In embodiments where the fabric is made entirely of the yarn of the present invention, the fabric is entirely recyclable with relative ease, and will merely require shredding and pelletisation. Washing is optional and depends on the condition of the fabric.

[0080] In another example, the yarn of the present invention is used to form a tricot knitted fabric comprised of the multifilament yarn according to any form or embodiment of the invention as previously discussed. In one embodiment the multifilament yarn comprises a denier of approximately 150 D, and a dpf of approximately 3.2. The fabric can be knitted to any desirable pattern, with a weight range from 50 to 500gsm. Such a fabric may be suitable as an outer layer for a shoe. The yarn of the present invention exhibits relatively lower infrared wavelength absorption, and thus limits the build-up of heat / temperature after exposure to the sun light or similar light sources when compared to conventional polypropylene yarns. Further, being predominantly polypropylene, the relatively heat resistant yarn can be recycled with relative ease, and without the need for complex polymer separation. The use of polypropylene as the main ingredient allows for ease of fabrication, high abrasion resistance, tear and fray resistant, and enhanced durability and resilience allowing the yarn and resulting fabric to have some stretch.

[0081] In addition to its enhanced recyclability, the yarn of the present invention is not susceptible to runoff / leeching of colour or surface coating as all colours and hydrophobic coatings, and antimicrobial additives are incorporated into the makeup of the yarn during the extrusion process. There are challenges associated with incorporating these additives during the extrusion manufacturing process as their inclusion in the polymer matrix can adversely affect the other properties such as strength and durability of the yarn. The present invention is directed to not only the incorporation and combination of these additives into a yarn, but to the actual quantity of each additive, the quantity ranges along with yarn dimensions and any corresponding ranges, which in combination yield a versatile and relatively environmentally friendly yarn suitable for forming a fabric for use in indoor and outdoor settings.

[0082] Whilst Polyproplylene yarn has been broadly referenced in these fabric samples, alternate polymeric materials can also be applicable. Substitute synthetic fibres such as, but not limited to, Polyethylene Terephthalate (PET or Polyester), Polyamide (Nylon) or PolyAcrylonitrile (Acrylic), can also be applicable to this invention. It is to be understood that various alterations, modifications and / or additions may be introduced into the construction and arrangement of the parts previously described without departing from the spirit or ambit of this invention.

Claims

1. A multifilament yarn for use in the composition of a fabric to be incorporated into furniture, shading, screening and fittings, apparel, shoes or other general textile applications, the yarn comprising:- a polymeric content of at least approximately 80%,- a tenacity of at least approximately 2 grams per denier (g / d),- UltraViolet (UV) additive content of approximately 0.0-1.0%, an Infrared (IR) reflective pigment content of approximately 0.5-4.0%, a dispersive additive content of approximately 0.0 to 0.8%, and an IR reflective additive content of approximately 0.0 to 1.0% all of which are incorporated in the yarn during the yarn extrusion process;and wherein the yarn is solution dyed during a yarn extrusion manufacturing process.

2. The multifilament yarn according to claim 1, wherein the yarn is a polypropylene homopolymer.

3. The multifilament yarn according to claim 1 or 2, wherein the yarn denier is at least approximately 100D, or between approximately 100D and approximately 1000D, and preferably 400D to 800D.

4. The multifilament yarn according to any one of claims 1 to 3, wherein the UV additive is comprised of Hindered amines light stabilizers (HALS).

5. The multifilament yarn according to any one of claims 1 to 4, wherein the yarn comprises approximately 72 to 288 fibers per filament.

6. The multifilament yarn according to claim 5, wherein the yarn comprises approximately 144 fibers per filament (fpf).

7. The multifilament yarn according to any one of claims 1 to 6 wherein a denier of each filament (dpf) of the yarn is approximately at least 1.0D and up to at least approximately 8.0D.

8. The multifilament yarn according to any one of claims 1 to 7, comprising an antimicrobial additive.

9. The multifilament yarn according to claim 8, wherein the yarn comprises 0.1 to 1% antimicrobial additive by weight, wherein the additive is incorporated into the yarn during the extrusion manufacturing process.

10. The multifilament yarn according to claim 9, wherein the yarn comprises 0.2% antimicrobial additive.

11. The multifilament yarn according to any one of claims 1 to 10, comprising a hydrophobic surface treatment incorporated during the yarn extrusion manufacturing process.

12. The multifilament yarn according to claim 11, wherein the content of the surface treatment is 0.5% to 2% and preferably 1% by wt.

13. The multifilament yarn according to any one of claims 1 to 12, wherein the yarn is texturized.

14. The multifilament yarn according to claim 1, wherein the yarn is polyester, nylon, acrylic or any other synthetic polymer.

15. A knitted fabric comprised of the multifilament yarn of any one of claims 1 to 14.

16. The knitted fabric of claim 15, comprising a weight of approximately 100 to 600 grams per square meter (GSM).

17. The knitted fabric of claim 15 or 16, wherein the multifilament yarn comprises a denier of approximately 450D, a dpf of approximately 3.1, a 12-gauge knit pattern and the fabric comprises a weight of 310 gsm, wherein the UV block of the fabric is between approximately 90 to 100%.

18. The knitted fabric of claim 17, wherein the fabric is manufactured on a compound or latch needle warp knitting machine having two guide bars being a first (GB1), and a second (GB2), guide bar, wherein the guide bars follow the following knit pattern to manufacture the fabric:- GB110 / 01 / / ,- GB2 01 / 34 / / .

19. The knitted fabric of claim 15 or 16, wherein the multifilament yarn comprises a denier of approximately 800-1000D, a dpf of approximately 6.6, a tenacity of at least 6.0g / D, a 6-gauge knit pattern and the fabric comprises a weight of 340 gsm, wherein the UV block of the fabric is at least 80%.

20. The knitted fabric of claim 19, wherein the fabric is manufactured on a compound or latch needle warp knitting machine having four guide bars being a first (GB1), a second (GB2), a third (GB3), and a fourth (GB4) guide bar wherein the guide bars follow the following knit pattern to manufacture the fabric:-  GB110 / 01 / / ,-  GB2 23 / 21 / 10 / 12 / / ,-  GB3 10 / 12 / 23 / 21 / / ,-  GB4 00 / 44 / / wherein on GB4 there is a monofilament yarn of approximately 600D.

21. The knitted fabric of claim 19 and 20, wherein the fabric is as a suspension fabric.

22. A woven fabric comprised of the multifilament yarn of any one of claims 1 to 14.

23. The woven fabric of claim 22, comprising a weight of approximately 100 to 600 grams per square meter (GSM).5       24. The woven fabric according to claim 22 or 23, wherein the multifilament yarn comprisesa denier of approximately 600D, a dpf of approximately 4.2, a weave pattern of 19x15 yarns / cm and a weight of 225 gsm, wherein the UV block of the fabric is approximately at least 98%.10       25. A fabric comprised of the multifilament yarn of any one of claims 1 to 14, wherein thefabric comprises a weight of approximately 100 to 600 grams per square meter (GSM).