Composite yarn comprising at least two individual elastic filaments and plurality of inelastic elements

Abstract

A composite yarn (100) comprising at least two individual elastic filaments (101) and a plurality of inelastic elements (103) wherein the inelastic elements (103) comprise a plurality of inelastic filaments and / or a bundle of inelastic filaments; the individual elastic filaments (101) and the inelastic filaments (103) are connected to each other by interlacing.

Description

[0001] This application is a divisional application of the invention application with application number CN202080029536.X and title “Composite yarn comprising at least two single elastic yarns and multiple non-elastic elements” filed by Shangke Textile Enterprise Industry and Trade Co., Ltd. on April 17, 2020. Technical Field

[0002] The present invention relates to an elastic yarn, in particular to a composite elastic yarn. The yarn of the present invention is particularly suitable for producing fabrics for highly elastic garments such as leggings and similar garments. Background Art

[0003] Elastic fiber or spandex filaments and yarns are known in the art and have been widely used in the textile industry for the production of elastic yarns and fabrics. Elastic fiber filaments are produced by extruding a polymer through a spinneret having multiple extrusion units. Before the filaments leave the extruder, a certain number of solid individual filaments or strands are coalesced to produce a bundle of filaments of the desired number, i.e., the desired thickness. Thus, each bundle of elastic fiber (spandex) filaments is composed of many smaller individual fibers, which adhere to each other due to the natural stickiness of their surfaces.

[0004] Bundled elastic filaments are used to make yarn.It is known to produce elastic yarn by combining a single bundle of elastic filaments with a plurality of substantially inelastic (or substantially non-stretchable) polyester filaments.

[0005] These types of elastic yarns can present some problems when used to produce high-stretch fabrics. The main problem with such fabrics is known as "elastane breakage" or "elastane slippage," where the elastic yarn can break and retract into the interior of the fabric, particularly at the seamed edge areas, primarily in the hip and crotch regions of the garment.

[0006] This problem may arise, for example, when sewing with an overlock or fold seam, or when performing a dry scraping process, or when washing in an industrial washing machine, or when drying in a tumble dryer for domestic washing.

[0007] WO2008130563 discloses a composite yarn having a core comprising at least one elastic performance filament and at least one inelastic control filament. A fiber sheath, preferably formed from spun staple fibers, surrounds the core filaments along substantially their entire length. Most preferably, the at least one elastic performance filament comprises spandex and / or lastol.

[0008] Such yarns are used in cotton sheaths, which are undesirable for the present invention. Summary of the Invention

[0009] The object of the present invention is to solve the problems mentioned above and to provide a yarn which, when used in highly elastic garments, is not affected (or at least is less affected) by elastic yarn breakage and "slippage".

[0010] According to one or more of the accompanying technical solutions, the present solution achieves this and other objects.

[0011] One aspect of the invention relates to composite yarns, fabrics, articles and processes according to the independent claims, while preferred aspects are recited in the dependent claims.

[0012] According to one aspect, the composite yarn comprises at least two single elastic filaments and a plurality of inelastic elements. The inelastic elements may be different inelastic fibers or different bundles of inelastic fibers. The single elastic filaments and the inelastic filaments are connected by interlacing.

[0013] Thus, intertwining (entanglement) serves to couple individual elastic filaments and non-elastic elements that are typically substantially separate elements prior to intertwining.

[0014] As mentioned above, elastic filaments are "individual," meaning they are not part of a continuous, connected bundle of the same elastic yarn. Indeed, it is well known that for elastic textile elements, a number of filaments can be bundled together to create a desired thickness. For example, spandex yarn is known to be a bundle of filaments, as spandex yarn can be composed of multiple smaller, individual filaments that adhere to each other due to the natural stickiness of its surface. In contrast, "individual elastic filament" refers to a monofilament "yarn."

[0015] The individual filaments are “elastic” in that they can be stretched to an extent (as elongation at break) in the range of between 50% and 1000% according to DIN 53820 Part 2.

[0016] The inelastic element is "inelastic" because its elongation at break is less than that of a single elastic thread, preferably less than 75% of that of a single elastic thread, more preferably less than 50% of that of a single elastic thread. Typically, according to DIN ISO 2062, the elongation at break of an inelastic element is between 5% and 100%.

[0017] In the claimed solution, there are at least two, and preferably more than two, individual elastic strands: they behave and move (and therefore may break) not as a single element, but rather retain a certain degree of independence even when intertwined with non-elastic elements. This fact provides better resistance to stress, especially since it can be limited to damage only to some of the elastic strands. According to a preferred aspect, to help maintain the aforementioned independence of behavior, the individual elastic strands are not coupled to each other before intertwining. In other words, according to a preferred aspect, the elastic strands remain separate before intertwining. They can be fed into the mixing device close to each other, so that they can touch each other, but they are not twisted against each other.

[0018] Preferably, the composite yarn is essentially composed of a single elastic filament and a non-elastic element as described above. In particular, according to a preferred aspect, the composite yarn as described above is not used as the core of the core-sheath composite yarn. In other words, the composite yarn is not covered by a sheath of staple fibers.

[0019] According to one aspect, the composite yarn is composed of elastic strands and inelastic filaments.

[0020] All of the elastic filaments of the yarn may be single elastic filaments. However, in addition to single elastic filaments, the composite yarn may also include elastic filaments that are part of a bundle of elastic connecting filaments. In other words, embodiments of the present invention may be provided with single elastic filaments or with bundles of connected elastic filaments.

[0021] In preferred embodiments, there are more than two elastic threads. Embodiments of the present invention may in fact be provided with at least three elastic threads, or at least five elastic threads, or at least ten elastic threads.

[0022] Exemplary and preferred embodiments provide for 2 to 22 individual elastic filaments.

[0023] As a general concept, the number and count of inelastic elements are not limited. However, preferably, the total count of the inelastic elements is equal to or greater than the total count of the elastic elements. In other words, the weight percentage of the inelastic elements in the composite yarn is preferably equal to, or more preferably, greater than, the weight percentage of the elastic elements in the composite yarn. In the final yarn, the elastic filaments may comprise between 5% and 50% of the final composite yarn weight.

[0024] Furthermore, according to one aspect, the number of inelastic elements in the composite yarn is greater than the number of elastic filaments in the final yarn.

[0025] According to one aspect, each of the non-elastic elements comprises at least one polyester filament and / or polyamide filament, and / or polyester copolymer, and / or polyamide copolymer.

[0026] The object of the present invention is also a fabric, preferably a woven fabric, comprising a composite yarn according to one or more of the above aspects, and also an article, preferably a garment, comprising such a fabric.

[0027] Furthermore, the present invention relates to a process for producing a composite yarn, comprising the steps of: providing a plurality of inelastic elements, each elastic element being selected from a single filament or a bundle of filaments; providing at least two separate individual elastic filaments; interlacing the individual elastic filaments and the inelastic elements; and collecting the composite yarn obtained by the interlacing step. Preferably, the interlacing is performed by air-jet interlacing.

[0028] By using a plurality of bundles of coalesced elastic filaments and a plurality of inelastic filaments, and by intertwining them into entanglement points, or knots, a final yarn with no or very little elastic slip can be obtained; this elastic yarn can also be used practically as such without further treatment. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Exemplary and non-limiting embodiments will now be described with reference to the following drawings, in which:

[0030] - Figure 1 is a schematic diagram of a portion of a composite yarn according to an embodiment of the present invention;

[0031] - Figure 2 Is used for production Figure 1 A schematic diagram of a possible arrangement of composite yarns is shown;

[0032] - Figure 3 Yes Figure 2 A schematic diagram of an interlacing device used in the device shown;

[0033] - Figure 4 is a diagram of a garment made of fabric, which in turn consists of Figure 1 The composite yarn shown;

[0034] - Figure 5 is a schematic cross-sectional view of three monofilaments;

[0035] - Figure 6 Schematic diagram of a bundle of continuously connected elastic threads. DETAILED DESCRIPTION

[0036] The composite yarn 100 includes at least two individual elastic filaments 101 .

[0037] Figure 5 As described above, providing a single elastic thread is similar to providing Figure 6In contrast to the continuously connected filaments in the bundle B schematically shown in FIG, all filaments behave like a single element. In contrast, as will be described below, even when intertwined, the individual elastic filaments (monofilaments) retain a certain degree of movement independence from one another, in particular at a certain distance from the connection point P provided by the intertwining.

[0038] Preferably, the number of elastic threads is equal to or greater than 2, and preferably equal to or greater than 3, more preferably equal to or greater than 7, even more preferably equal to or greater than 10, and at most 50.

[0039] Some embodiments of the present invention are provided with a plurality of individual elastic filaments numbering between 2 and 50.

[0040] The single elastic filament is preferably an elastomeric filament, ie, a filament that can be repeatedly stretched to at least twice its original length at room temperature and will be immediately forced to recover to approximately its original length after the stretching force is removed. According to one aspect, the elastic filament 101 is a polyurethane filament, such as a spandex filament.

[0041] The count of each elastic thread 101 is preferably between 2 and 100 deniers, more preferably between 10 and 100 deniers, and more preferably between 10 and 70 deniers.

[0042] Composite yarn 100 includes a plurality of inelastic elements 103. In the illustrated embodiment, inelastic elements 103 are part of a bundle of inelastic filaments. Consequently, in the illustrated embodiment, the inelastic elements correspond to the inelastic filaments. Different embodiments may provide for the inelastic elements to be a bundle of connected (e.g., bonded) inelastic filaments. The count of each inelastic filament is lower than the count of elastic filament 101. Preferred inelastic filaments have a count between 0.5 and 3 denier.

[0043] Generally, the composite yarn 100 includes a plurality of inelastic elements 103, wherein the inelastic elements may be single inelastic filaments or bundles of inelastic filaments.

[0044] The non-elastic element 103 is preferably a single filament (monofilament) of partially oriented yarn (POY, pre-oriented yarn) known in the art. Preferred yarns for the non-elastic element 103 are selected from polyester yarns and polyamide (nylon) yarns, or yarns made of polyester or polyamide copolymers. The non-elastic yarn is preferably a textured yarn.

[0045] The non-elastic element 103 may also comprise a filament that is a bicomponent filament, such as a PBT / PTT or PET / PTT or PET / PTMT bicomponent filament.

[0046] Elastic filaments 101 and inelastic elements 103 are connected to each other at a plurality of points P by interlacing to provide a final composite yarn 100. As a result, in the final composite yarn 100, a portion of a single elastic filament 101 is not connected to the elastic element 103 (i.e., between two subsequent connection points P), and this portion can behave in a manner that is substantially independent of each other. As described above, to help provide this independence, it is preferred that the elastic filaments 101 be fed to the interlacing device as independent filaments, or at least in an untwisted state, as shown in the figure.

[0047] As mentioned above, the inelastic element comprises (or contains) inelastic threads. The number and / or total count of the inelastic threads are preferably greater than the number and / or total count of the elastic threads, respectively, even though, as mentioned above, the count of one inelastic thread of the yarn is preferably less than the count of one elastic thread of the yarn.

[0048] In other words, the volume percentage of the inelastic filaments in the final composite yarn is greater than (or in the worst case is equal to) the volume percentage of the elastic filaments in the final composite yarn, and / or the weight percentage of the inelastic filaments in the final composite yarn is greater than (or in the worst case is equal to) the weight percentage of the elastic filaments in the final composite yarn. Preferably, the interlacing is provided by air-jet interlacing.

[0049] The composite yarn 100 is typically used to provide a fabric 200, preferably a woven fabric. One aspect of the present invention relates to an article 300, typically a garment, comprising such a fabric 200. According to a possible embodiment, Figure 2 In the embodiment shown, in the process of producing the composite yarn according to the present invention, the inelastic element 103 is provided by one or more sources 1, such as one or more bobbins. In the embodiment shown, a single source 1 provides a bundle of separate inelastic elements (ie, inelastic filaments) 103.

[0050] Each source of inelastic yarns may have yarns of a different count / denier and in the final product all yarns may be present in different count / denier combinations such as 40D / 4F (4 yarns of 40 denier) + 30D / 3F (3 yarns of 30 denier).

[0051] The non-elastic element 103 may be passed through a guide 3 (eg, a tube) and drawn by a drawing device (stretching device) 2 (eg, one or more drawing rollers).

[0052] Prior to interlacing, each elastic filament may be stretched using different levels of draft (draw rate).

[0053] The non-elastic element 103 may also be heat treated, for example, by a heating element 4, possibly followed by a cooling element 5, such as a heating chamber and a cooling chamber through which the non-elastic element 103 passes. The temperature of the first heating element may be between 180 and 210° C.

[0054] Sensor(s) 6 may be provided to verify if the non-elastic element breaks during the process, in order to monitor and avoid them from being removed from the source 1. A further sensor 7 may be provided to verify the tension of the non-elastic element 103.

[0055] The elastic thread 101 can be drawn from one or more associated sources 11. For example, in the embodiment shown, a single source 11 (e.g., a single bobbin) can be provided in a known manner with a plurality of individual elastic threads 101. As a result, for at least a portion of their paths, the individual elastic threads 101 and the inelastic element 103 follow different and independent paths.

[0056] Then, the non-elastic element 103 and the single elastic thread 101 are connected together at a plurality of connection points P by an interlacing device 8, preferably an air-jet interlacing device.

[0057] As mentioned above, the intertwining device provides a plurality of connection points P between the filaments of the final yarn. Specifically, as is known, intertwining provides a plurality of connection points P (knots) between the filaments 101, 103 of the final yarn. There are some known methods and testing machines to measure the number of tangles per meter of yarn, that is, to measure the number of knots, for example by evaluating the change in yarn thickness. As an example, in the ITEMAT+ conducted by Textechno H.Stein (Moenchengladbach, DE; https: / / www.textechno.com), in the "entanglement test", the yarn is passed between two cylinders at a predetermined elongation to evaluate the number of entanglements. At each entanglement point, there is an entanglement point or knot of the elastic and non-elastic filaments, which still exists when the yarn is tensioned or stretched, and they can be sensed by the testing machine in the otherwise smooth yarn.

[0058] Preferably, when tested using a similar machine and when stretched at an elongation of 6.0%, the yarn according to the present invention has at least 50 connection points (i.e., knots) per meter, more preferably at least 80 connection points / knots per meter, and even more preferably at least 100 entanglement points / knots per meter. A suitable number of knots is in the range of up to 120 knots / meter, for example 80 to 120 knots / meter.

[0059] According to a preferred aspect, the non-elastic elements 103 are oversupplied to the intertwining device 8 preferably by a percentage between 1.2% and 7.0%.

[0060] Before entanglement, the elastic filaments 101 may be passed together through a drafting device 9, such as a drafting roller. Preferably, the stretching ratio applied by the drafting device 9 (applied simultaneously to the elastic filaments 101 and the inelastic element 103) is greater than the stretching ratio applied to the inelastic element 103 by the drafting device 2 (located upstream of the drafting device 9). Specifically, the stretching ratio applied by the drafting device 9 may be between 1.5 and 1.8 greater than the stretching ratio applied by the drafting device 2.

[0061] Preferably, the stretch ratio of the elastic thread 101 is between 1.1 and 6.9, more preferably between 2 and 6, and even more preferably between 3 and 5. With respect to the inelastic element 103, the stretch ratio is preferably less than 6, more preferably less than 5, and even more preferably less than 4. In addition, the elastic thread 101 is preferably more stretched than the inelastic element 103.

[0062] Additionally, the non-elastic element 103 may be textured by the texturing device 10 before it is attached to the elastic wire 101. Any suitable texturing device may be used, such as a friction disc device.

[0063] After interlacing a composite yarn is formed, in which the individual elastic filaments 101 and the inelastic elements 103 are connected by interlacing.

[0064] Further finishing processes may be performed, such as heat treatment by means of a heating chamber 16 and / or further drawing by means of one or more drawing devices 13 and / or application of a finishing agent, such as oil or similar elements, by means of a finishing device 14 .

[0065] The composite yarn 100 is finally collected on the collecting element 15; the composite yarn 100 is usually wound on a bobbin.

[0066] In one embodiment, during the production process, essentially no additional yarns, rovings, slivers or similar textile elements are added to the composite yarn 1, and therefore the composite yarn 1 is used in the following form, that is, essentially comprising a single elastic yarn 101 (and possibly bundled elastic yarns) and non-elastic elements 103 as yarns to manufacture a fabric, in particular a woven fabric 200, for an article 300 such as clothing.

Claims

1. A composite yarn (100) comprising at least two individual elastic filaments (101) and a plurality of inelastic elements (103), wherein: The non-elastic element (103) comprises a plurality of non-elastic threads and / or bundled non-elastic threads; The single elastic thread (101) and the non-elastic element (103) are connected to each other by interlacing.

2. The composite yarn (100) according to claim 1, characterized in that The composite yarn is essentially composed of elastic filaments (101) and the non-elastic elements (103) coupled by interlacing.

3. The composite yarn (100) according to claim 1 or 2, characterized in that Each of the non-elastic elements includes at least one polyester filament and / or polyamide filament.

4. The composite yarn (100) according to any one of the preceding claims, characterized in that The composite yarn comprises a large number of entanglement points: greater than 50 entanglement points per meter, more preferably greater than 80 entanglement points per meter, most preferably greater than 100 entanglement points per meter, preferably up to 150 entanglement points per meter.

5. The composite yarn (100) according to any one of the preceding claims, characterized in that The non-elastic filaments (101) are drawn, preferably with a draw ratio between 1.1 and 6.9, more preferably 2 to 6, even more preferably 3 to 5.

6. The composite yarn (100) according to any one of the preceding claims, characterized in that The stretching ratio of the non-elastic element (103) is 1.6, more preferably less than 5, even more preferably less than 4.

7. The composite yarn (100) according to any one of the preceding claims, characterized in that The stretching ratio of the non-elastic element (103) is smaller than the stretching ratio of the elastic thread (101).

8. The composite yarn (100) according to any one of the preceding claims, characterized in that The non-elastic element (103) is textured.

9. The composite yarn (100) according to any one of the preceding claims, characterized in that The non-elastic element (103) comprises a bicomponent filament, which is preferably selected from PET / PTT, PBT / PTT, and PET / PTMT.

10. The composite yarn (100) according to any one of the preceding claims, characterized in that The composite yarn comprises at least three elastic filaments (101), preferably at least five elastic filaments (101), more preferably at least ten elastic filaments, more preferably a number of between 2 and 50 elastic filaments (101).

11. The composite yarn according to any one of the preceding claims, characterized in that The count of said elastic thread (101) is comprised between 2 and 100 deniers, preferably comprised between 10 and 100 deniers.

12. Composite yarn (1) according to any one of the preceding claims, characterized in that The composite yarn further comprises at least one bundle of elastic filaments intertwined with the non-elastic element (103), or wherein the elastic filaments consist of a single elastic filament.

13. A fabric (200), preferably a woven fabric, comprising the composite yarn according to any one of the preceding claims.

14. An article (300), preferably a garment, comprising the fabric (200) according to claim 12.

15. A process for producing a composite yarn (100), comprising the steps of: a. Providing a plurality of inelastic elements (103), wherein the inelastic element (103) comprises a plurality of inelastic wires or bundled inelastic wires; b. Providing at least two separate single elastic wires (101); c. preferably entangle the single elastic fiber (101) and the non-elastic element (103) by air jet entanglement; d. Collecting the composite yarn (100) obtained through the interlacing step.

16. The process of claim 15, wherein Between steps c and d, no additional yarn, roving or sliver is added to the composite yarn (100).

17. The process according to claim 15 or 16, characterized in that The process includes the step of texturing the non-elastic element (103).

18. The process according to any one of claims 15 to 17, characterized in that Said non-elastic element (103) is preferably overfed during said step c) by a percentage between 1.2% and 7.0%.

19. A composite yarn obtainable by the process according to any one of claims 15 to 18.

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