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

Abstract

To provide yarns that are not affected (or are only slightly affected) by breaking of elastic yarns and sliding of the elastic yarns from a seam to the interior of a fabric, especially on the sewing edge area on both of hips side and crotch of a high-elasticity garment, in the garment.SOLUTION: There is provided a composite yarn (100) comprising at least two single 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, and the single elastic filaments (101) and the inelastic filaments (103) are connected to each other by intermingling.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to elastic yarns, and in particular composite elastic yarns. The yarns of the present invention are particularly useful in the manufacture of fabrics for highly elastic garments, such as jeggings and similar garments. [Background technology]

[0002] Elastane or spandex filaments and yarns are well known in the art and have been widely used in the textile field to produce elastic yarns and fabrics. Elastane filaments are produced by extruding a polymer through a spinneret with several extrusion cells. Before the filaments leave the extruder, a certain amount of solid single filaments or strands are bonded together to produce a bundle of filaments with the desired count, i.e., the desired thickness. Thus, each bundle of elastane (spandex) filaments is composed of many smaller fibers that are bonded together by the inherent tackiness of their surfaces.

[0003] Bundles of elastane filaments are used to make yarns. It is known to produce elastic yarns by combining a single bundle of elastane filaments with a plurality of substantially inelastic (or substantially instretchable) polyester filaments.

[0004] Several problems are observed when these types of elastic yarns are used to manufacture highly elastic fabrics. The main problems with this type of fabric are known as "elastane breakage" and "elastane slippage", i.e., the breaking of the elastic yarns and the slippage of the elastic yarns from the seam into the interior of the fabric, especially in the edge regions of both the waist and crotch of the garment.

[0005] These problems can occur, for example, when sewing with overlock or folded seams, during dry scraping processes, when laundering in industrial washing machines, when drying in tumble dryers, or when laundering at home.

[0006] The '691 patent discloses a composite yarn having a filamentary core with at least one elastic control filament and at least one inelastic control filament. A fibrous sheath formed from spun staple fibers preferably surrounds the filamentary core over substantially its entire length. The at least one elastic control filament most preferably comprises spandex and / or lustole filaments.

[0007] This type of yarn provides a cotton sheath, which is not desirable for the present invention. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] International Publication No. 2008 / 130563 Summary of the Invention [Problem to be solved by the invention]

[0009] The object of the present invention is to solve the above-mentioned problems and to provide a yarn which is not (or is less) susceptible to elastic yarn breakage and "slippage" when used in highly elastic garments. [Means for solving the problem]

[0010] These objects are solved by one or more claims of the present invention.

[0011] An aspect of the invention relates to composite yarns, fabrics, articles and processes as set out in the independent claims, while preferred aspects are set out in the dependent claims.

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

[0013] Thus, twisting is used to join single elastic filaments and inelastic elements which, prior to twisting, were substantially separate elements.

[0014] As mentioned above, the elastic filaments are "single", i.e., they are not part of the same elastic bundle of continuously connected filaments. In fact, it is known that in the case of elastic fiber elements, a certain amount of filaments can be bundled together to produce a desired thickness. It is known that spandex yarns, for example, are bundles of filaments, since they can be composed of several smaller individual filaments that adhere to each other by the natural tackiness of their surface. In contrast to this, "single elastic filament" means a "yarn" of a monofilament.

[0015] A single elastic filament is "elastic" because according to DIN 53820 part 2 it can be stretched from 50% to 1000% (as elongation at break).

[0016] Inelastic elements are "inelastic" because they have an elongation at break that is preferably less than 75%, more preferably less than 50%, than a single elastic filament. Typically, inelastic elements have an elongation at break of between 5% and 100% according to DIN ISO 2062.

[0017] In the claimed solution, there are at least two, preferably three or more single elastic filaments. They do not behave or move like a single element (which would cause them to break), but they maintain a certain independence from each other, even when they are twisted with non-elastic elements. This fact provides a better resistance to stresses, in particular limiting damage to only a portion of the elastic filaments. According to a preferred embodiment, in order to help maintain the independence of the above-mentioned behavior, the single elastic filaments should not be bonded to each other before twisting. In other words, according to a preferred embodiment, the elastic filaments should be kept separate before twisting. They can be fed close to each other into the twisting device, so that they may come into contact with each other, but they do not twist with each other.

[0018] Preferably, the composite yarn consists essentially of the above-mentioned single elastic filaments and inelastic elements. In particular, according to a preferred embodiment, the above-mentioned composite yarn is not used as the core of a core-sheath yarn, in other words, the composite yarn is not covered by a sheath of, for example, staple fibers.

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

[0020] All of the elastic filaments that make up the yarn can be single elastic filaments. However, a composite yarn can include elastic filaments that are part of a bundle of elastically connected filaments in addition to single elastic filaments. In other words, embodiments of the invention can include single elastic filaments and can also include bundles of connected elastic filaments.

[0021] In preferred embodiments, there are three or more elastic filaments, and embodiments of the invention may in fact comprise at least three elastic filaments, or at least five elastic filaments, or at least ten elastic filaments.

[0022] Exemplary and preferred embodiments include between 2 and 22 single elastic filaments.

[0023] As a general concept, the number and yarn count of the inelastic elements are not limited. However, it is preferable that the total yarn count of the inelastic elements is equal to or greater than the total yarn count of the elastic filaments. In other words, the weight ratio of the inelastic elements in the composite yarn is preferably equal to, and more preferably greater than, the weight ratio of the elastic filaments in the composite yarn. In the resulting yarn, the elastic filaments can be 5% to 50% by weight of the resulting composite yarn.

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

[0025] Further according to one aspect of the invention, each inelastic element comprises at least one polyester filament, and / or polyamide filament, and / or polyester copolymer, and / or polyamide copolymer.

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

[0027] The invention further relates to a method for producing a composite yarn, comprising the steps of providing a plurality of inelastic elements, each inelastic element being selected from an inelastic filament or a bundle of inelastic filaments, providing at least two separate single elastic filaments, twisting the single elastic filaments and the inelastic elements, and collecting the composite yarn obtained by the twisting step, the twisting being preferably performed by air jet twisting.

[0028] By using multiple bundles of bonded elastic filaments and multiple inelastic filaments and twisting them together at entanglement points or knots, a resulting yarn with no or very little slippage of elastane can be obtained, which can also be used as is without further processing.

[0029] Exemplary, non-limiting embodiments of the present invention are described with reference to the following figures. [Brief description of the drawings]

[0030] [Figure 1] FIG. 2 is a schematic diagram of a portion of a composite yarn according to one embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic diagram of an apparatus capable of producing the composite yarn shown in FIG. [Diagram 3] FIG. 3 is a schematic diagram of a twisting device that can be used in the apparatus shown in FIG. 2. [Figure 4] FIG. 2 is a schematic diagram of a garment obtained using a fabric containing the composite yarn shown in FIG. 1 continuously. [Diagram 5] FIG. 2 is a schematic cross-sectional view of three single elastic filaments. [Figure 6] FIG. 1 is a schematic cross-sectional view of a bundle of continuously connected elastic filaments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] The composite yarn 100 is composed of at least two single elastic filaments 101 .

[0032] Three single elastic filaments (monofilaments) are shown diagrammatically in Figure 5. As mentioned above, providing single elastic filaments differs from the bundle of continuously connected filaments B shown diagrammatically in Figure 6, in which all filaments behave as a single element. In contrast, even when twisted, the single elastic filaments (monofilaments) retain a degree of independent movement from each other, particularly at a distance from the connection point P provided by the twisting, as will be explained in more detail below.

[0033] The number of single elastic filaments is 2 or more, preferably 3 or more, more preferably 7 or more, even more preferably 10 or more up to 50.

[0034] Some embodiments of the invention include between 2 and 50 single elastic filaments.

[0035] The single elastic filament is preferably an elastomeric filament, i.e., a filament that can be repeatedly stretched at room temperature to at least twice its original length, and immediately and forcefully returns to approximately its original length upon removal of tension. According to one embodiment of the invention, the single elastic filament 101 is a polyurethane filament, such as an elastane filament.

[0036] The count of each single elastic filament 101 is 2 to 100 denier, preferably 10 to 100 denier, and more preferably 10 to 70 denier.

[0037] The composite yarn 100 comprises a plurality of inelastic elements 103. In the above-mentioned embodiment, the inelastic elements 103 are part of a bundle of inelastic filaments. As a result, in the above-mentioned embodiment, the inelastic elements correspond to the inelastic filaments. In a different embodiment, the inelastic elements can be a bundle of connected (e.g. bonded) inelastic filaments. The count of each inelastic filament is smaller than the count of the single elastic filament 101. The preferred inelastic filaments have a count of 0.5 to 3 denier.

[0038] Generally, the composite yarn 100 includes a plurality of inelastic elements 103, which can be single inelastic filaments or bundles of inelastic filaments.

[0039] The inelastic elements 103 are preferably single filaments (monofilaments) of partially oriented yarn (POY) as known in the art. The filaments of the inelastic elements 103 are preferably selected from polyester filaments and polyamide (nylon) filaments or filaments made of polyester or polyamide copolymers. The inelastic filaments are preferably textured filaments.

[0040] The inelastic element 103 may also include bicomponent filaments, such as PBT / PTT or PET / PTT or PET / PTMT bicomponent filaments.

[0041] The single elastic filament 101 and the inelastic elements 103 are connected to one another at multiple points P by twisting to form the resulting composite yarn 100. As a result, in the resulting composite yarn 100, there are portions of the single elastic filament 101 that are not connected to the inelastic elements 103 (i.e., between two subsequent connection points P), and the portions can behave substantially independently of one another. As mentioned above, to facilitate such independence, the single elastic filament 101 is preferably fed to the twisting device as an independent filament, or at least in an untwisted state, as shown.

[0042] As mentioned above, the inelastic element 103 comprises (or is composed of) inelastic filaments. As mentioned above, the number and / or total count of the inelastic filaments is preferably greater than the number and / or total count of the elastic filaments, respectively, even if the count of the single inelastic filament of the yarn is preferably smaller than the count of the single elastic filament of the yarn.

[0043] In other words, the volume % of the inelastic filaments in the resulting composite yarn is greater than (at worst equal to) the volume % of the elastic filaments in the resulting composite yarn and / or the weight % of the inelastic filaments in the resulting composite yarn is greater than (at worst equal to) the weight % of the elastic filaments in the resulting composite yarn. Preferably, the twisting is performed by air jet twisting.

[0044] The composite yarn 100 is typically used to provide a fabric 200, preferably a woven fabric. One aspect of the invention relates to an article 300, typically a garment, comprising such a fabric 200. According to a possible embodiment, as shown in Figure 2, in the manufacturing process of the composite yarn according to the invention, the inelastic elements 103 are provided by one or more sources 1, for example one or more bobbins. According to the illustrated embodiment, a single source 1 provides a bundle of separate inelastic elements (i.e. inelastic filaments) 103.

[0045] Each source of inelastic filaments may have different filament count / denier, resulting in a different overall filament count / denier combination in the final product, such as 40D / 4F (40 denier with 4 filaments) + 30D / 3F (30 denier with 3 filaments).

[0046] The inelastic element 103 passes through a guide 3, for example a tube, and can then be drafted by a drafting means 2, for example one or more drafting rollers.

[0047] Each elastic filament can be stretched to a different level of draft ratio before being twisted.

[0048] The inelastic element 103 can also be subjected to a heat treatment, for example by a heating element 4 followed by a cooling element 5, for example a heating and cooling chamber through which the inelastic element 103 passes. The temperature of the initial heating element 4 can be between 180 and 210°C.

[0049] A sensor 6 can be provided to verify if breakage of the inelastic element occurs during this process, thereby monitoring and preventing further withdrawal of the inelastic element from the source 1. A further sensor 7 can be provided to verify the tension of the inelastic element 103.

[0050] The single elastic filament 101 is drawn from one or more associated sources 11. As in the illustrated embodiment, a single source 11 (e.g., a single bobbin) may supply, in a known manner, a plurality of single elastic filaments 101. As a result, for at least some of these paths, the single elastic filament 101 and the inelastic elements 103 travel along different and separate paths.

[0051] The inelastic element 103 and the single elastic filament 101 are then connected together at a number of connection points P by a twisting device 8, preferably an air jet twisting device.

[0052] As mentioned above, the twisting device provides a number of connection points P between the filaments of the resulting yarn. In particular, as is known, twisting provides a number of connection points P (knots) between the filaments 101, 103 of the resulting yarn. There are known methods and testers for measuring the number of entanglements, i.e. knots, per meter of yarn, for example by evaluating the change in the thickness of the yarn. As an example, in the "Interlace Test" of ITEMAT+ by Textechno H. Stein, Moenchengladbach, DE (https: / / www.textechno.com), the yarn is passed between two cylinders at a given elongation to evaluate the number of twist points. At each twisting point, an entanglement, or knot, of the elastic and inelastic filaments is provided, which remains even when the yarn is pulled or stretched. Alternatively, in smooth yarns, a tester can sense,

[0053] When tested on the same machine, when stretched by 6.0%, the yarn according to the invention preferably has at least 50 connection points (i.e. knots) per meter, more preferably at least 80 connection points / knots per meter, even more preferably at least 100 entanglements / knots per meter. A suitable number of knots per meter is up to 120, for example 80-120.

[0054] According to a preferred embodiment, the inelastic elements 103 are overfed to the twisting device 8, preferably by a ratio of 1.2% to 7.0%.

[0055] Before being twisted, the single elastic filaments 101 may pass together through a drafting device 9, e.g. a drafting roller. Preferably, the draft of the drafting device 9 (applied to both the single elastic filaments 101 and the inelastic elements 103) is greater than the draft applied to the inelastic elements 103 by the drafting device 2 (located upstream of the drafting device 9). In particular, the draft applied to the drafting device 9 may be 1.5 to 1.8 times greater than the draft applied by the drafting device 2.

[0056] The draft of the single elastic filament 101 is preferably 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 elements 103, the draft is preferably less than 6, more preferably less than 5, and even more preferably less than 4. Furthermore, the single elastic filament 101 is preferably drafted less than the inelastic elements 103.

[0057] Additionally, the non-elastic element 103 may be textured by a texturing device 10 prior to connection with the single elastic filament 101. Any suitable texturing device may be used, such as a friction disc device.

[0058] After twisting, a composite yarn is formed, in which the single elastic filaments 101 and the inelastic elements 103 are connected by twisting.

[0059] Further finishing processes may be performed, such as heat treatment by a heating chamber 16, and / or further drafting by one or more drafting devices 13, and / or application of a finishing agent, such as oil or a similar substance, by a finishing device 14.

[0060] The composite yarn 100 is finally collected in a yarn collection element 15. Typically, the collected composite yarn 100 is wound on a bobbin.

[0061] In one embodiment, substantially no further yarns, rovings, slivers or similar fibrous elements are added to the composite yarn 100 during this manufacturing process, so that it can be used in a form essentially including single elastic filaments 101 (and possibly bundles of elastic filaments) and inelastic elements 103 as a yarn for manufacturing fabrics, particularly woven fabrics 200, for articles 300 such as garments. [Explanation of symbols]

[0062] 1 Source 2 Draft device 3 Guide 4 heating elements 5 Cooling Elements 6, 7 Sensors 8 Twisting device 9 Draft device 10 Texture adding device 11 Source 13 Draft device 14 Finishing Equipment 15 Yarn collection elements 16 Heating Chamber 100 Composite Yarn 101 Single Elastic Filament 103 Inelastic Elements 200 Fabric (woven) 300 Articles (clothing) B. A bundle of continuously connected filaments P Connection Point

Claims

1. A composite yarn (100) comprising two or more single elastic filaments (101) and a plurality of inelastic elements (103), The inelastic element (103) comprises a plurality of inelastic filaments and / or a bundle of inelastic filaments; The composite yarn (100) is characterized in that the single elastic filament (101) and the inelastic filament (103) are connected to each other by twisting.

2. 2. The composite yarn (100) of claim 1, wherein the single elastic filaments (101) are drafted at different draft ratios prior to being twisted with the inelastic elements (103).

3. 3. A composite yarn (100) according to claim 1 or 2, characterized in that it consists essentially of said single elastic filament (101) and said inelastic elements (103), which are joined by twisting.

4. 4. The composite yarn (100) according to any one of claims 1 to 3, characterized in that each said inelastic element comprises at least one polyester filament and / or polyamide filament.

5. 5. The composite yarn (100) according to any one of claims 1 to 4, characterized in that it comprises more than 50 entanglement points per meter, more preferably more than 80 entanglement points per meter, most preferably more than 100 entanglement points per meter, preferably up to 150 entanglement points per meter.

6. The composite yarn (100) according to any one of claims 1 to 5, characterized in that the single elastic filaments (101) are preferably drafted at 1.1 to 6.9, more preferably at 2 to 6, and even more preferably at 3 to 5.

7. 7. The composite yarn (100) according to any one of claims 1 to 6, characterized in that the draft of the inelastic elements (103) is less than 6, more preferably less than 5, even more preferably less than 4.

8. 8. The composite yarn (100) according to any one of claims 1 to 7, characterized in that the draft of the inelastic elements (103) is smaller than the draft of the single elastic filaments (101).

9. The composite yarn (100) according to any one of the preceding claims, characterized in that the inelastic elements (103) are textured.

10. 10. The composite yarn (100) according to any one of claims 1 to 9, characterized in that the inelastic elements (103) preferably comprise bicomponent filaments selected from PET / PTT, PBT / PTT, PET / PTMT.

11. 11. The composite yarn (100) according to any one of claims 1 to 10, characterized in that it comprises at least 3 single elastic filaments (101), preferably at least 5 single elastic filaments (101), more preferably at least 10 single elastic filaments (101), even more preferably between 2 and 50 single elastic filaments (101).

12. A composite yarn (100) according to any one of the preceding claims, characterized in that said single elastic filaments (101) have a count between 2 and 100 denier, more preferably between 10 and 100 denier.

13. 13. The composite yarn (100) according to any one of claims 1 to 12, further comprising at least a bundle of elastic filaments twisted with said inelastic elements (103), or said elastic filaments consist of a single elastic filament.

14. A fabric (200), preferably a woven fabric, comprising the composite yarn according to any one of claims 1 to 13.

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

16. a. providing a plurality of inelastic elements (103) comprising a plurality of inelastic filaments or bundles of inelastic filaments; b. Providing at least two separate single elastic filaments (101); c. twisting said single elastic filament (101) and said inelastic element (103), preferably by air jet twisting; and d. collecting the composite yarn (100) obtained by said twisting step.

17. 17. The method of claim 16, characterized in that no further yarns, or rovings, or slivers are added to the composite yarn (100) between steps c and d.

18. Method for producing a composite yarn (100) according to any one of claims 16 or 17, characterized in that it comprises a step of imparting texture to the inelastic elements (103).

19. A method for producing a composite yarn (100) according to any one of claims 16 to 18, characterized in that in step c, the inelastic elements (103) are overfed, preferably by a proportion of 1.2% to 7.0%.

20. 20. A method for producing a composite yarn (100) according to any one of claims 16 to 19, characterized in that the single elastic filaments (101) are drafted at different draft ratios before being twisted with the inelastic elements (103).

21. A composite yarn obtainable by the process according to any one of claims 16 to 20.

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