Dyed yarn retaining elongation properties

Abstract

A dyed yarn having a staple fiber core yarn and a bicomponent filament yarn in an outer sheath surrounding the staple fiber core yarn is described. The bicomponent filament includes two polymers having different shrinking properties during dyeing process. An undyed yarn is wound on a perforated tube in a controlled way so that a tension of the undyed yarn wound on the perforated tube is varying. A percent elongation of the dyed yarn is proximate to a percent elongation of the undyed yarn. The percent elongation of the dyed yarn being between 20 – 30 %. A fabric made using the dyed yarn is also described.

Description

DYED YARN RETAINING ELONGATION PROPERTIESBACKGROUND

[0001] The present embodiments relate to a dyed yam that retains its elongation properties, a method of preparing a dyed yam to retain elongation properties, and fabric articles made using the dyed yam.

[0002] Combination yams incorporating bicomponent filaments can have different shrinking percentages during the dyeing process that cause damage to the dyed yam. As a result, the elongation properties of the dyed yam are reduced compared to the elongation properties of the combination yam prior to dyeing.

[0003] There exists a need in the art for a dyed yam that retains its elongation properties after the dyeing process and fabric articles, including sportwear and other garments, made using such yams.SUMMARY

[0004] In one aspect, the disclosure provides a dyed yam having a staple fiber core yam, and a bicomponent filament yam in an outer sheath surrounding the staple fiber core yam. The bicomponent filament includes two polymers having different shrinking properties during dyeing process. An undyed yam is wound on a perforated tube in a controlled way so that a tension of the undyed yam wound on the perforated tube is varying. A percent elongation of the dyed yam is proximate to a percent elongation of the undyed yam. The percent elongation of the dyed yam being between 20 - 30 %.

[0005] In another aspect, the disclosure provides a fabric having a face side including a first yam. The first yam including a first dyed yam having a staple core yam and a bicomponent filament yam in an outer sheath surrounding the staple core yam. The bicomponent filament including two polymers having different shrinking properties during dyeing process. A a first undyed yam is wound on a perforated tube in a controlled way so that a tension of the first undyed yam winded on the perforated tube is varying. A percent elongation of the first dyed yam is proximate to a percent elongation of the first undyed yam. The percent elongation of the first dyed yam being between 20 - 30 %. The fabric also having a back side including a second yam. The second yam including a second dyed yam having a staple core yam and a bicomponent filament yam in an outer sheath surrounding the staple core yam. The bicomponent filament including two polymers having different shrinking properties during dyeing process. A second undyed yam is wound on a perforated tube in a controlled way so that a tension of the second undyed yam winded on the perforated tube is varying. A percent elongation of the second dyed yam is proximate to a percent elongation of the second undyed yam. The percent elongation of the first dyed yam being between 20 - 30 %.

[0006] In another aspect, the disclosure provides a method of preparing an undyed combination yam for a dyeing process. The method includes winding the undyed combination yam around a tube of a spool at a first tension until the undyed combination yam reaches a first thickness at a first boundary. The method further includes continuingto wind the undyed combination yarn around the tube of the spool over the first thickness of the undyed combination yam at a second tension until the undyed combination yam reaches a second thickness at a second boundary. The method also includes continuing to wind the undyed combination yam around the tube of the spool over the first thickness and the second thickness of the undyed combination yam at a third tension until the undyed combination yam reaches a third thickness at a third boundary.

[0007] Other systems, methods, features and advantages of the disclosure will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the disclosure, and be protected by the following claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The disclosure can be better understood with reference to the following drawings and description. Throughout the drawings, reference numbers may be re-used to indicate correspondence between referenced elements. The drawings are provided to illustrate example embodiments described herein and are not intended to limit the scope of the disclosure. Sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes and sizes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility.

[0009] FIG. 1 is a representative view of an example embodiment of a combination yam including a core yam surrounded by a bi-component filament yam;

[0010] FIG. 2A is a schematic view of an example embodiment of forming a combination yam with a bi-component filament yam surrounding the core yam;

[0011] FIG. 2B a schematic view of an example embodiment of forming a combination yam with two bi-component filament yams surrounding the core yam;

[0012] FIG. 3 is a representative view of an undyed combination yam on a spool;

[0013] FIG. 4 is a schematic view of an example embodiment of a portion of a yarn spooling machine;

[0014] FIG. 5 is a representative view of an example embodiment of a method of applying a first tension during the process of spooling yam onto a spool;

[0015] FIG. 6 is a representative view of an example embodiment of a method of applying a second tension during the process of spooling yam onto a spool;

[0016] FIG. 7 is a representative view of an example embodiment of a method of applying a third tension during the process of spooling yam onto a spool;

[0017] FIG. 8 is a representative view of an example embodiment of a yam spool carrier for dyeing a batch of yam;

[0018] FIG. 9 is a representative view of an example embodiment of dyeing a batch of yam using one or more dyeing processes;

[0019] FIG. 10 is a representative view of an example embodiment of a woven fabric incorporating at least one dyed combination yam; and

[0020] FIG. 11 is a representative view of an example embodiment of a knit fabric incorporating at least one dyed combination yam.DETAILED DESCRIPTION

[0021] Elongation refers to a fundamental property of textile materials and components that measures their ability to stretch or lengthen under tension. Elongation properties of materials and components affect the performance and behavior of fabrics incorporating those materials and components in various applications, including apparel, garments, and other fabric products.

[0022] Elongation, also known as elongation at break or stretchability, represents the percentage increase in the length of a yam or fabric when subjected to a specific amount of tensile force or stress. Elongation is typically measured by comparing the original length of the material to its extended length after the application of tension. Elongation is generally expressed as a percentage and is a measure of the material's elasticity or ability to recover its original shape after being stretched.

[0023] Combination yams incorporating filaments of different materials can have different shrinking percentages during the dyeing process that cause damage to the dyed yam. As a result, the elongation properties of the dyed yam are typically reduced compared to the elongation properties of the combination yam prior to the dyeing process.

[0024] Combination yams prepared for dyeing using a method that retains the elongation properties of the undyed yam after the dyeing process are described herein. Fabric articles, including sportwear and other garments, made using such yams are also described herein. The techniques of the present embodiments provide a method of preparing undyed combination yams prior to the dyeing process that allows the elongation or stretch properties of the various yam component materials in the combination yams to be retained after dyeing is completed.

[0025] In the following description, details are set forth to provide an understanding of the application. In some instances, certain structures, techniques, and methods have not been described or shown in detail in order not to obscure the application. In the context of the present disclosure, various terms are used in accordance with what is understood to be the ordinary meaning of those terms.

[0026] For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. It will be understood that each of these directional adjectives may be applied to garments or articles of clothing, as well as individual components of the article of clothing or garment. Directional terms such as “top”, “bottom”, “front”, “back”, “upper”, “lower”, “outer” and “inner” are used in the following description for the purpose of providing relative reference only, and are not intended to suggest any limitations on how any article or garment is to be positioned during use, or to be mounted in an assembly or relative to an environment. The use of the word “a” or “an” when used herein in conjunction with the term “comprising” may mean “one”, but it is also consistent with the meaning of “one or more”, “at least one” and “one or more than one”. Any element expressed in the singular form also encompasses its plural form. Any element expressed in the plural form also encompasses its singular form. The term “plurality” as used herein means more than one, for example, two or more, three or more, four or more, and the like.

[0027] Referring now to FIG. 1 , an example embodiment of a combination yam 100 is shown. In this embodiment, combination yam 100 includes a core yam 102 that is surrounded by a bicomponent filament yam 104 forming an outer sheath 106 that extends along a length of core yam 102. In some embodiments, bicomponent filament yam 104 may be spun, wrapped, or twisted around core yam 102 along a length of core yam 102 to form combination yam 100.

[0028] In some embodiments, core yam 102 may be a staple fiber yam. Staple fiber is a non-continuous fiber of relatively short length. In one embodiment, the staple fiber may be a natural staple fiber, including but not limited to cotton, wool, cashmere, rabbit fur, hemp, flax, linen, coconut, pineapple, acetate, silk, protein fibers, regenerated cellulosic fibers, and / or any blend combination thereof. In other embodiments, the stable fiber may be a synthetic cellulose stable fiber, including but not limited to viscose, modal, lyocell, and / or any blend combination thereof. In still other embodiments, the staple fiber may be a synthetic staple fiber or filament, including but not limited to acrylic, nylon, polyester, polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET),elastane, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and / or any blend combination thereof.

[0029] In an example embodiment, bicomponent filament yam 104 may be formed by a synthetic material that includes acrylic, nylon, polyester, polypropylene, elastane, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), polyethylene (PE), polytrimethylene terephthalate (PTT), and / or any blend combination thereof. In one embodiment, bicomponent filament yam 104 may be formed by a synthetic bicomponent filament that includes but is not limited to polyethylene terephthalate (PET) and nylon. In some embodiments, bicomponent filament yarn 104 may be formed from at least two different synthetic materials that may have different properties. In one embodiment, bicomponent filament yarn 104 may be formed from a combination or blend of polyethylene terephthalate (PET) and polyethylene (PE), a combination or blend of polyethylene terephthalate (PET) and polytrimethylene terephthalate (PTT), a combination or blend of polyethylene terephthalate (PET) and nylon, a combination or blend of polyethylene (PE) and nylon, or a combination or blend of polytrimethylene terephthalate (PTT) and nylon.

[0030] In one embodiment, bicomponent filament yarn 104 may be formed from polyethylene terephthalate (PET) and nylon having different deniers and filaments. In an example embodiment, bicomponent filament yarn 104 made of PET and nylon may have a denier in a range of 30D - 75D and a number of filaments in a range of 24-72 filaments for both PET and nylon. In one embodiment, bicomponent filament yarn 104 made of PET and nylon has a denier of 30D and 24 filaments for both PET and nylon. In another embodiment, bicomponent filament yarn 104 made of PET and nylon has a denier of 50D and 36 filaments for both PET and nylon. In still another embodiment, bicomponent filament yarn 104 made of PET and nylon has a denier of 75D and 72 filaments for both PET and nylon.

[0031] The different synthetic materials forming bicomponent filament yam 104 may have different shrinking percentages during the dyeing process. In some cases, the different synthetic materials forming bicomponent filament yam 104 may be associated with different dyeing temperatures and / or durations. As a result, when dyeing combination yam 100, which includes core yam 102 and bicomponent yam 104 formed of different synthetic materials, some of the filaments may break or be damaged, thus limiting the resulting elongation properties of dyed combination yam 100 compared to its original elongation properties prior to the dyeing process (i.e. , undyed combination yam 100).

[0032] Referring now to FIG. 2A, an example embodiment of combination yam 100 including core yam 102 and bicomponent filament yam 104 surrounding core yam 102 to form outer sheath 106 extending along the length of combination yam 100 is shown. In one embodiment, bicomponent filament yam 104 may be spun, wrapped, or twisted around core yam 102 using any one of a single or double spinning process or a vortex spinning process to produce combination yam 100.

[0033] In another embodiment, combination yam 100 may include core yam 102 that has two bicomponent filament yams surrounding core yam 102 to form outer sheath 106 extending along the length of combination yam 100. Referring now to FIG. 2B, in this embodiment, combination yam 100 has a first bicomponent filament yam (e.g., bicomponent filament yam 104) that is spun, wrapped, or twisted along a length of core yam 102 and also a second bicomponent filament yam 200 that is spun, wrapped, or twisted to surround core yam 102 along a length of combination yam 100. In some cases, first bicomponent filament yam 104 and second bicomponent filament yam 200 may be made of the same materials. In other cases, first bicomponent filament yam 104 and second bicomponent filament yam 200 may be made from different materials, including different blends or combinations of similar materials, such as blends or combinations with different ratios of the same materials.

[0034] For example, in one embodiment, first bicomponent filament yam 104 and second bicomponent filament yam 200 may be made from a synthetic materialthat that includes acrylic, nylon, polyester, elastane, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), polyethylene (PE), polytrimethylene terephthalate (PTT), and / or any blend combination thereof.

[0035] In some embodiments, combination yam 100, including core yam 102 and at least one of bicomponent filament yam 104 and second bicomponent filament yam 200 may be dyed after forming combination yam 100. Referring now to FIG. 3, undyed combination yam 100 is shown wrapped on a spool 300. In some embodiments, undyed combination yam 100 may be wrapped or spooled around a tube 302 to form spool 300 of undyed combination yam 100. For example, spool 300 may be formed using a yam spinning or spooling machine, as would be known to one of ordinary skill in the art.

[0036] According to the techniques of the present embodiments, a method of preparing undyed combination yams for dyeing is described that retains the elongation properties of the materials forming the undyed combination yam after the dyeing process is completed. For example, in some cases, the elongation properties of the dyed combination yam may be within 10% or less of the original elongation properties of the undyed yam prior to being dyed.

[0037] Referring now to FIG. 4, a schematic view of an example embodiment of a portion of a yam spooling machine 400 is shown. In an example embodiment, yam spooling machine 400 may include at least a computer 402 having one or more processors for executing instructions that control yam spooling machine 400. In an example embodiment, computer 402 controls a tensioner 404 of yam spooling machine 400 to apply a variable amount of tension to combination yam 100 as it is being spooled or wound onto tube 302 to form spool 300. As will be described in more detail below, application of variable tension during the spooling of combination yam 100 onto tube 302 prepares undyed combination yam 100 for the dyeing process in a manner that allows combination yam 100 to retain its elongation properties after the dyeing process is completed.

[0038] As shown in FIG. 4, tensioner 404 controls the application of tension on combination yam 100 as it is spooled or wound onto tube 302. In this embodiment, tube 302 includes an outer surface 406 having a plurality of perforations 408 that extend from outer surface 406 to an interior 410 of tube 302. Plurality of perforations 408 in tube 302 allow dye to penetrate combination yam 100 from interior 410 and the exterior of spool 300 when spool 300 is placed into a vat of dye during the dyeing process (as shown in FIG. 9).

[0039] In an example embodiment, combination yam 100 is spooled or wound around tube 302 by rotating or spinning tube 302 in a counter clockwise direction 412 using yam spooling machine 400 so as to wrap or wind combination yam 100 around outer surface 406 of tube 302. It should be understood that counter clockwise direction 412 is shown for purposes of illustration and combination yam 100 may be wrapped or wound onto tube 302 by rotating in either a clockwise or counter clockwise direction.

[0040] During the process of spooling or winding combination yam 100 around tube 302, tensioner 404 is controlled by computer 402 of yam spooling machine 400 to vary the tension applied to combination yam 100 in a specific sequence to prepare undyed combination yam 100 for the dyeing process in a manner that retains the elongation properties after dyeing. FIGs. 5, 6, and 7 illustrate the method of preparing undyed combination yam 100 during spooling or winding by applying variable tension in a specific sequence so that the dyed combination yam retains the elongation properties of undyed combination yam 100.

[0041] Referring now to FIG. 5, a first step 500 in the method of preparing undyed combination yam 100 during spooling or winding is shown. In some embodiments, first step 500 of the method of preparing undyed combination yam 100 may be implemented using computer 402 and tensioner 404 of yam spooling machine 400 to vary the tension applied to combination yam 100 in a specific sequence to prepare undyed combination yam 100 for the dyeing process in a manner that retains the elongation properties after dyeing. As shown in FIG. 5, computer 402 of yam spooling machine 400controls tensioner 404 to apply a first tension 502 to undyed combination yam 100 as it is being wound onto perforated tube 302 of spool 300.

[0042] In this embodiment, undyed combination yam 100 winds or spools around outer surface 406 of perforated tube 302 of spool 300 while tensioner 404 applies first tension 502 to undyed combination yam 100. In an example embodiment, first step 500 may be implemented until undyed combination yam 100 reaches a first thickness T1 around outer surface 406 of perforated tube 302 of spool 300 associated with a first portion. That is, as shown in FIG. 5, first tension 502 is applied by tensioner 404 to undyed combination yam 100 until undyed combination yam 100 reaches first thickness T1 extending from outer surface 406 to a first boundary 504.

[0043] Referring next to FIG. 6, a second step 600 in the method of preparing undyed combination yam 100 during spooling or winding is shown. In some embodiments, second step 600 of the method of preparing undyed combination yam 100 may be implemented using computer 402 and tensioner 404 of yam spooling machine 400 to vary the tension applied to combination yam 100 in a specific sequence to prepare undyed combination yam 100 for the dyeing process in a manner that retains the elongation properties after dyeing. As shown in FIG. 6, computer 402 of yam spooling machine 400 controls tensioner 404 to apply a second tension 602 to undyed combination yam 100 as it is being wound onto perforated tube 302 of spool 300.

[0044] In this embodiment, undyed combination yam 100 winds or spools around a portion of undyed combination yam 100 that has already been wound onto outer surface 406 of perforated tube 302 of spool 300 (e.g. , the portion extending first thickness T1 from outer surface 406) while tensioner 404 applies second tension 602 to undyed combination yam 100. In an example embodiment, second step 600 may be implemented until undyed combination yam 100 reaches a second thickness T2 from the portion extending first thickness T 1 from outer surface 406 of perforated tube 302 of spool 300 associated with a second portion. That is, as shown in FIG. 6, second tension 602 is applied by tensioner 404 to undyed combination yam 100 until undyed combination yam 100 reaches second thickness T2 from first boundary 504 to a second boundary 604.

[0045] Referring next to FIG. 7, a third step 700 in the method of preparing undyed combination yam 100 during spooling or winding is shown. In some embodiments, third step 700 of the method of preparing undyed combination yam 100 may be implemented using computer 402 and tensioner 404 of yam spooling machine 400 to vary the tension applied to combination yam 100 in a specific sequence to prepare undyed combination yam 100 for the dyeing process in a manner that retains the elongation properties after dyeing. As shown in FIG. 7, computer 402 of yam spooling machine 400 controls tensioner 404 to apply a third tension 702 to undyed combination yam 100 as it is being wound onto perforated tube 302 of spool 300.

[0046] In this embodiment, undyed combination yam 100 winds or spools around a portion of undyed combination yam 100 that has already been wound onto outer surface 406 of perforated tube 302 of spool 300 (e.g. , the portion extending first thickness T1 from outer surface 406 and second thickness T2 from first boundary 504) while tensioner 404 applies third tension 702 to undyed combination yam 100. In an example embodiment, third step 700 may be implemented until undyed combination yam 100 reaches a third thickness T3 from the portion extending second thickness T2 from first boundary 504 associated with a third portion. That is, as shown in FIG. 7, third tension 702 is applied by tensioner 404 to undyed combination yam 100 until undyed combination yam 100 reaches third thickness T3 from second boundary 604 to a third boundary 704.

[0047] In some embodiments, third boundary 704 may represent the entire thickness of spool 300 of undyed combination yam 100 after the winding or spooling process has been completed. In an example embodiment, first thickness T1 from outer surface 406 of perforated tube 302 of spool 300 to first boundary 504 may be referred to as the first portion or an inside portion of spool 300 and may represent approximately 25- 30% of the total overall thickness of undyed combination yam 100 wound or spooled on perforated tube 302 of spool 300. Second thickness T2 from first boundary 504 to second boundary 604 may be referred to as the second portion or a middle portion of spool 300 and may represent 30-40% of the total overall thickness of undyed combination yam 100 wound or spooled on perforated tube 302 of spool 300. Third thickness T3 from secondboundary 604 to third boundary 704 may be referred to as the third portion or an outside portion of spool 300 and may represent 30-40% of the total overall thickness of undyed combination yam 100 wound or spooled on perforated tube 302 of spool 300. Together, the total overall thickness of undyed combination yam 100 wound or spooled on perforated tube 302 of spool 300 may be represented by the sum of first thickness T 1 , second thickness T2, and third thickness T3.

[0048] In some embodiments, the value of the actual overall total thickness may vary based on the dimensions of the yam or spool or may be based on the type of yam winding or spooling machine (e.g., yam spooling machine 400). By representing the relationships between the applied tensions (e.g., first tension 502, second tension 602, and third tension 702) to proportional thicknesses of each of the inside portion, middle portion, and outside portion of spool 300, the techniques of the present embodiments may be applied to different types and varieties of yams and may be implemented using different sized spools and types of winding or spooling machines.

[0049] According to the techniques of the present embodiments, the specific sequence of varying the tension applied to combination yam 100 to prepare undyed combination yam 100 for the dyeing process in a manner that retains the elongation properties after dyeing includes reducing tension to the combination yam 100 as the amount of combination yam 100 wound on perforated tube 302 of spool 300 increases. That is, in the present embodiments, first tension 502 applied by tensioner 404 to undyed combination yam 100 is the largest amount of tension. As combination yam 100 builds up on tube 302 (e.g., to first thickness T1), the amount of tension applied by tensioner 404 is reduced to second tension 602, which is a smaller amount of tension than first tension 502. Similarly, as combination yam 100 continues to build up on tube 302 (e.g., to second thickness T2), the amount of tension applied by tensioner 404 is reduced again to third tension 702, which is a smaller amount of tension than first tension 502 and second tension 602.

[0050] In some embodiments, the reduction in tension between each step in the sequence (e.g. , from first tension 502 in first step 500 to second tension 602 in secondstep 600 and from second tension 602 in second step 600 to third tension 702 in third step 700) may be within a range of 10-20%. For example, in one embodiment, the tension applied by tensioner 404 is controlled by computer 402 so that first tension 502 is reduced by 10% to second tension 602 and second tension 602 is reduced by 11 % to third tension 702. That is, each step in the sequence reduces tension applied to combination yam 100 by approximately 10-11 %.

[0051] In another embodiment, the reduction is tensions between each step in the sequence is reduced by a larger percentage. For example, the tension applied by tensioner 404 is controlled by computer 402 so that first tension 502 is reduced by 17% to second tension 602 and second tension 602 is reduced by 20% to third tension 702. That is, in this embodiment, each step in the sequence reduces tension applied to combination yam 100 by approximately 17-20%.

[0052] In other embodiments, the tension applied to combination yam 100 during the winding or spooling process may be reduced by a larger or smaller amount. In some cases, the reduction in tension may be based on the materials forming the combination yam 100 (e.g., the materials of core yam 102, bicomponent filament yam 104, and / or bicomponent filament yam 200). With this arrangement, the elongation properties of undyed combination yam 100 may be retained after the dyeing process is completed.

[0053] In some embodiments, the transitions between each level or amount of tension (i.e., from first tension 502 to second tension 602 and from second tension 602 to third tension 702) may be gradual. That is, computer 402 may control tensioner 404 to gradually decrease tension from first tension 502 to second tension 602 as undyed combination yam 100 approaches first boundary 504. Similarly, computer 402 may control tensioner 404 to gradually decrease tension from second tension 602 to third tension 702 as undyed combination yam 100 approaches second boundary 604. With this arrangement, the tension applied by tensioner 404 of yam spooling machine 400 may be gradually varied in a specific sequence during the winding or spooling of combinationyarn 100 onto spool 300 to prepare undyed combination yam 100 for the dyeing process in a manner that retains the elongation properties after dyeing.

[0054] In other embodiments, the transitions between each level or amount of tension (i.e., from first tension 502 to second tension 602 and from second tension 602 to third tension 702) may be performed in a step-like manner. That is, computer 402 may control tensioner 404 to decrease tension from first tension 502 to second tension 602 once undyed combination yam 100 reaches first boundary 504. Similarly, computer 402 may control tensioner 404 to decrease tension from second tension 602 to third tension 702 once undyed combination yam 100 reaches second boundary 604. With this arrangement, the tension applied by tensioner 404 of yam spooling machine 400 may be varied in a specific sequence during the winding or spooling of combination yam 100 onto spool 300 to prepare undyed combination yam 100 for the dyeing process in a manner that retains the elongation properties after dyeing.

[0055] With this arrangement, the reduction in tension applied to combination yam 100 during the winding or spooling process causes fewer broken filaments to combination yam 100 after the dyeing process is completed. By reducing the breakage to combination yam 100 during the dyeing process using the preparation method described herein, the dyed combination yam retains elongation properties that are proximate to the elongation properties of undyed combination yam 100. In one embodiment, the elongation properties of the dyed combination yam are within 90% or more of the initial elongation properties of undyed combination yam 100.

[0056] Additionally, in some embodiments, the winding or spooling speed of yam spooling machine 400 may also be controlled by computer 402 during the winding or spooling of combination yam 100 around tube 302 of spool 300 while the tension is being varied. In an example embodiment, the winding or spooling speed (e.g., the rotational rate of combination yam 100 winding or spooling around tube 302) may be increased as the tension is reduced during the winding or spooling process. That is, during first step 500 when tensioner 404 is applying first tension 502 to combination yam 100, yam spooling machine 400 may rotate tube 302 of spool 300 at a first rate. Whentensioner 404 applies second tension 602 to combination yarn 100 during second step 600, the rotational speed of tube 302 of spool 300 may be increased to a second rate. Similarly, when tensioner 404 applies third tension 702 to combination yam 100 during third step 700, the rotational speed of tube 302 of spool 300 may be further increased to a third rate.

[0057] In one embodiment, the first rate is smaller than the second rate and the third rate and the second rate is smaller than the third rate. In an example embodiment, the difference between the first rate and the second rate may be larger than the difference between the second rate and the third rate. In other words, the initial change in rotational rate at which combination yam 100 is being wound or spooled around tube 302 of spool 300 is largest between the first rate and the second rate when transitioning from first tension 502 to second tension 602. For example, in one embodiment, the increase in rotational speed from the first rate to the second rate is approximately 38-50% and the increase in rotational speed from the second rate to the third rate is approximately 9-11 %. In other embodiments, the increase in the rotational rate may be larger or smaller, for example, depending on the selection of materials forming combination yam 100, as described above with regard to the applied tension.

[0058] Referring now to FIG. 8, an example embodiment of a yam spool carrier 800 for dyeing a batch of yam is shown. In some embodiments, undyed combination yam 100 wound or spooled on one or more spools, including a plurality of spools prepared in a similar manner as spool 300, are dyed in a batch using a package dyeing process. The plurality of spools are stacked on perforated rods in a rack 802 and immersed in a tank 900, as shown in FIG. 9.

[0059] FIG. 9 illustrates an example embodiment of package dyeing a batch of yam using one or more dyeing processes. In this embodiment, yam spool carrier 800 including a plurality of spools of undyed combination yam 100 prepared as described above in reference to spool 300 is immersed within an interior 902 of tank 900. In an example embodiment, dye 904 is forced outward through the perforated rods in rack 802 and flows through plurality of holes 408 in perforated tube 302 of spool 300 (as shown inFIG. 4) to dye undyed combination yarn 100. In some embodiments, the dyeing process may include different dyeing temperatures and / or durations. For example, in one embodiment, the dyeing process may include a first dyeing stage having a first temperature (e.g., 130 degrees Celsius) that is maintained for a first duration (e.g., 40 minutes) for dyeing a first material included in combination yam 100. The dyeing process may further include a second dyeing stage having a second temperature (e.g. , 60 degrees Celsius) that is maintained for a second duration (e.g., 60 minutes) for dyeing a second material included in combination yam 100.

[0060] In this example dying process, the first temperature and the second temperature are different and the first duration and the second duration are also different due to the differences in the materials in combination yam 100 that are to be dyed during each stage of the dyeing process. These variations in the temperatures and / or durations during the dyeing process are typically the cause of broken or damaged filaments in combination yams. As noted above, these broken or damaged filaments limit the elongation properties of the combination yam after dyeing. The method of preparing the combination yam for dyeing using the specific sequence of varying tension, however, allows the dyed combination yam to retain elongation properties that are proximate to the elongation properties of the undyed combination yam 100. In one embodiment, the elongation properties of the dyed combination yam are within 90% or more of the initial elongation properties of undyed combination yam 100.

[0061] For example, Table 1 below illustrates the elongation percentage retained after yam dyeing for an example embodiment of a combination yam including bicomponent filaments.Table 1

[0062] As shown in Table 1 , undyed combination yarn 100 has an initial elongation percentage of 27.27 prior to dyeing. After dyeing, dyed combination yam 100 has an elongation percentage of 25.335. The difference in elongation properties between the undyed and dyed combination yam in this example is 1 .935, which represents a minor reduction in elongation properties of the dyed combination yam of approximately 7%. That is, dyed combination yam 100 is within approximately 93% of the initial undyed elongation percentage of undyed combination yam 100. In this example embodiment, the elongation properties of the dyed combination yam are within 93% of the initial elongation properties of undyed combination yam 100. In other embodiments, the elongation properties of the dyed combination yam may be between 95% to 90% of the initial elongation properties of undyed combination yam 100. In still other embodiments, elongation properties of more than 95% of the initial elongation properties of undyed combination yam 100 may be retained using the method of preparation described herein.

[0063] In some embodiments, combination yam 100 including core yam 102 and bicomponent yam 104 and / or bicomponent yam 200 may be incorporated into a fabric. For example, FIGs. 10 and 11 illustrate example embodiments of different types of fabrics that may be made using a combination yam that has been dyed using the method of preparation according to the techniques described herein. Referring first to FIG. 10, a representative view of an example embodiment of a woven fabric 1000 incorporating at least one dyed combination yam is shown.

[0064] In this embodiment, woven fabric 1000 includes a plurality of yams, including warp yams 1002 and weft yams 1004. In one embodiment, at least one weft yam 1004 of woven fabric 1000 includes a weft dyed combination yam having a staple fiber core yam and a bicomponent filament yam in an outer sheath surrounding the staple fiber core yam. In some embodiments, at least one warp yam 1002 of woven fabric 1000 includes a warp dyed combination yam having a staple fiber core yam and a bicomponent filament yam in an outer sheath surrounding the staple fiber core yam. In some cases,the dyed combination yarn may form a portion of a face side of woven fabric 1000 and / or a portion of a back side of woven fabric 1000. In some embodiments, the at least one weft yam may further include an elastane material and the at least one warp yam may further include an elastane material.

[0065] Additionally, in some embodiments, one or more treatments may be applied to the fabric including the combination yam. For example, in one embodiment, woven fabric 1000 at least one of the face side and the back side may be brushed. Because the method of preparation of spooling the undyed combination yam described herein reduces the broken or damaged filaments in the dyed combination yam, the brushed face side and / or back side of woven fabric 1000 may be a smoother surface than a fabric made using a combination yam that has not been prepared according to the techniques described herein.

[0066] FIG. 11 is a representative view of an example embodiment of a knit fabric 1100 incorporating at least one dyed combination yam. As shown in FIG. 11 , knit fabric 1100 includes a first layer 1102 which is the layer next to the skin A (inner or back layer) of the wearer and a second layer 1104 which correspond to the layer of knit fabric 1100 facing the exterior B (outer or face layer) and away from the skin A of the wearer. As illustrated in Fig. 11 , in one embodiment, a connecting yam 1106 may bind together first fabric layer 1102 and second fabric layer 1104 to tighten knit fabric 1100 together.

[0067] In an example embodiment, first fabric layer 1102 may include a first yam 1108 and second fabric layer 1104 may include a second yam 1110. In other embodiments, first fabric layer 1102 may further include a third yam knitted together with first yarn 1108 to form the next to skin A (inner or back layer) first fabric layer 1102. In one embodiment, first yarn 1108 and / or the third yarn may include a dyed combination yarn (e.g., combination yarn 100) prepared for dyeing according the method of preparation described herein. In some cases, the third yarn may include an elastane material, resulting in first fabric layer 1102 being a composite blend of a synthetic polymer plated with an elastane.

[0068] In an example embodiment, second fabric layer 1104 may further include a fourth yam knitted together with second yam 1110 to form (outer or face layer) second fabric layer 1104 facing towards outside B. In one embodiment, second yarn 1110 and / or the fourth yarn may include a dyed combination yarn (e.g., combination yarn 100) prepared for dyeing according the method of preparation described herein. In some cases, the fourth yarn may include an elastane material, resulting in second fabric layer 1104 being a composite blend of a synthetic polymer plated with an elastane.

[0069] In some embodiments, connecting yam 1106 binding together first fabric layer 1102 and second fabric layer 1104 may be a single strand or multiple strands. In one embodiment, connecting yam 1106 is an elastane yam. In other embodiments, connecting yam 1106 may be a synthetic polymer such as for example a nylon, a polyester, a polypropylene, an acrylic, a polyacrylic or a combination thereof. Alternatively, connecting yam 1106 as described herein may include a natural fiber such as for example a cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose or a combination thereof. In some cases, connecting yam 1106 may have a zig-zag structure (an overlap) between first fabric layer 1102 and second fabric layer 1104. The zig-zag structure may include a lapping back and forth between first fabric layer 1102 and second fabric layer 1104 in order to connect them together as shown in FIG. 11. As described herein, in some embodiments, knit fabric 1100 is made with a knitting construction that includes a weft knitted or a warp knitted structure. For example, knit fabric 1100 may be a single jersey plated construction a double jersey plated construction for example or Tricot warp knit plated structure.

[0070] It should be understood that the fabrics described herein incorporating a combination yam prepared for dyeing using the method of preparation with varying tension described herein may be used for any type of articles of apparel including shirts, headwear, coats, jackets, pants, underwear, gloves, socks, and footwear.

[0071] While various embodiments of the disclosure have been described, the description is intended to be exemplary, rather than limiting and it will be apparent tothose of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the disclosure. Accordingly, the disclosure is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Claims

CLAIMS1. A dyed yarn having: a staple fiber core yam; and a bicomponent filament yam in an outer sheath surrounding the staple fiber core yam, the bicomponent filament comprising two polymers having different shrinking properties during dyeing process; wherein an undyed yam is wound on a perforated tube in a controlled way so that a tension of the undyed yam wound on the perforated tube is varying; and wherein a percent elongation of the dyed yam is proximate to a percent elongation of the undyed yam, the percent elongation of the dyed yam being between 20 - 30 %.

2. The dyed yam of claim 1 , wherein the undyed yam wound on the perforated tube has a first tension value on an inside of the perforated tube and has a second tension value in an outside of the perforated tube, the first tension value being different than the second tension value, a difference between the first tension value and the second tension value allowing retention of percent elongation of the dyed yam.

3. The dyed yam of claim 2, wherein the first tension value is greater than the second tension value.

4. The dyed yam of claim 3, wherein the tension of the undyed yam on the perforated tube gradually decreases from the first tension value toward the second tension value.

5. The dyed yam of claim 3, wherein the undyed yam wound on the perforated tube has a third tension value in a middle of the perforated tube.

6. The dyed yarn of claim 1 , wherein the bicomponent filament yam in the outer sheath comprises a synthetic filament.

7. The dyed yam of claim 6, wherein the synthetic bicomponent filament is made of a material that includes acrylic, nylon, polyester, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and / or any blend combination thereof.

8. The dyed yam of claim 6, wherein the synthetic bicomponent filament is polyethylene terephthalate (PET) and polyethylene (PE), polytrimethylene terephthalate (PTT), polyethylene terephthalate (PET) and nylon, polytrimethylene terephthalate (PTT) and nylon, or polyethylene (PE) and nylon.

9. The dyed yam of claim 1 , wherein the staple fiber core yam comprises a natural staple yam.

10. The dyed yam of claim 9, wherein the staple fiber core yam is made of a material that includes cotton, modal, acetate, silk, wool, lyocell, protein fibers, regenerated cellulosic fibers, and / or any blend combination thereof.11 . The dyed yam of claim 10, wherein the staple fiber core yam is made of a micro modal.

12. The dyed yam of claim 9, wherein the staple fiber core yam further comprises a synthetic filament or staple.

13. The dyed yam of claim 1 , wherein the bicomponent filament yam in an outer sheath comprises two filaments of bicomponent filament yam spun around the staple core yam.

14. A fabric comprising: a face side comprising a first yam, the first yam comprising a first dyed yam having a staple core yam and a bicomponent filament yam in an outer sheath surrounding the staple core yam, the bicomponent filament comprising two polymers having different shrinking properties during dyeing process, wherein a first undyed yam is wound on a perforated tube in a controlled way so that a tension of the first undyed yam winded on the perforated tube is varying, and wherein a percent elongation of the first dyed yam is proximate to a percent elongation of the first undyed yam, the percent elongation of the first dyed yam being between 20 - 30 %; and a back side comprising a second yam, the second yam comprising a second dyed yam having a staple core yam and a bicomponent filament yam in an outer sheath surrounding the staple core yam, the bicomponent filament comprising two polymers having different shrinking properties during dyeing process, wherein a second undyed yam is wound on a perforated tube in a controlled way so that a tension of the second undyed yam winded on the perforated tube is varying, and wherein a percent elongation of the second dyed yam is proximate to a percent elongation of the second undyed yam, the percent elongation of the first dyed yam being between 20 - 30 %.

15. The fabric of claim 14, wherein the fabric is knitted.

16. The fabric of claim 15, further comprising a connecting yam connecting the face side and the back side.

17. The fabric of claim 16, wherein the connecting yam comprises an elastane material.

18. The fabric of claim 17, wherein the connecting yam is a filament of elastane.

19. The fabric of claim 15, wherein the fabric is double jersey knitted fabric, single jersey knitted fabric, tricot knitted fabric, interlock knitted fabric.

20. The fabric of claim 14, wherein at least one of the face side and the back side are brushed.

21. The fabric of claim 14, wherein the fabric is woven.

22. The fabric of claim 21 , further comprising: a weft yam comprising a weft dyed yam having a staple fiber core yam and a bicomponent filament yam in an outer sheath surrounding the staple fiber core yam; and a warp yam comprising a warp dyed yam having a staple fiber core yam and a bicomponent filament yam in an outer sheath surrounding the staple fiber core yam.

23. The fabric of claim 21 , wherein at least one of the face side and the back side are brushed.

24. The fabric of claim 22, wherein the weft yam further comprises an elastane material and the warp yam further comprises an elastane material.

25. A method of preparing an undyed combination yam for a dyeing process, the method comprising: winding the undyed combination yam around a tube of a spool at a first tension until the undyed combination yam reaches a first thickness at a first boundary; continuing to wind the undyed combination yam around the tube of the spool over the first thickness of the undyed combination yam at a second tension until the undyed combination yam reaches a second thickness at a second boundary; and continuing to wind the undyed combination yam around the tube of the spool over the first thickness and the second thickness of the undyed combination yam at a third tension until the undyed combination yam reaches a third thickness at a third boundary.

26. The method according to claim 25, wherein the first tension is greater than the second tension and the second tension is greater than the third tension.

27. The method according to claim 25, wherein the first boundary is associated with an inner portion of the spool, wherein the second boundary is associated with a middle portion of the spool, and the third boundary is associated with an outer portion of the spool.

28. The method according to claim 25, wherein the tension is varied gradually from the first tension to the second tension and from the second tension to the third tension.

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