Yarns and textiles for cut resistant denim

Abstract

A denim textile may be manufactured using a warp yarn and a weft yarn that give the denim textile cut-resistant properties. The warp and weft yarns may both have a first covering layer which is made from Ultra-High Molecular Weight Polyethylene (UHMWPE). The UHMWPE may provide cut-resistant properties to each of the warp yarn and weft yarn. Each of the warp yarn and weft yarn may also have a second covering of nylon. The nylon may give the denim textile a softer, more comfortable texture and flexibility, and may serve to impart a specific color on the denim textile. The weft yarn may additionally have a cotton, polyester and rayon fibers blended core that may also include spandex and / or other stretch fibers, which may collectively give the denim additional softness and flexibility. The resulting denim textile is expected to meet various ANSI test requirements for cut resistance and durability.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure claims priority to U.S. Provisional Application 63 / 743,052, filed on Jan. 8, 2025, and entitled “YARNS AND TEXTILES FOR CUT RESISTANT DENIM”, which is incorporated by reference in its entirety.BACKGROUND

[0002] In some work environments, industrial workers require their clothing to be cut resistant. Denim is a preferred clothing material for some industrial workers due to its versatility, durability, comfort, and low maintenance. Denim and twill are textile materials that have been used for decades in workwear bottoms. When it comes to providing cut resistant clothing made from denim material, the market has not provided many solutions that are designed for achieving flexibility of the material, comfort, and high cut resistance. Historically, denim has been produced from the use of spun cotton yarns and twill. Denim textiles woven from cotton and twill are not designed to provide high level of cut resistance. Workers often wear articles of clothing made from denim that are not cut resistant, only to supplement their clothing with an additional layer of PPE that is cut resistant. In other cases, workers may wear denim articles of clothing that are not cut resistant and not supplement with additional PPE. This creates a safety hazard, as statistics historically show that most injuries are caused through careless behavior such as removing PPE during the work process. Considering this issue, the industry is in an endless pursuit to provide the most comfortable, high flexibility cut-resistant denim, while ensuring that clothing made from such denim remains highly protective.BRIEF SUMMARY

[0003] A textile for use in making protective garments comprises a first composite yarn and a second composite yarn. The first composite yarn includes a first core yarn comprising nylon filaments, a first covering yarn comprising ultra-high molecular weight polyethylene (UHMWPE), and a second covering yarn comprising nylon filaments. The second composite yarn includes a second core yarn comprising a blend of cotton, polyester and rayon fibers, a third covering yarn comprising UHMWPE, and a fourth covering yarn comprising nylon filaments.

[0004] In some embodiments, the nylon filaments of the first core yarn comprise one or more ply strands of 72-filament, 140 Denier nylon, wherein the one or more ply strands are selected from 1-ply, 2-ply, 3-ply, or 4-ply. In some embodiments, the first covering yarn comprises 200 filaments of 400 Denier UHMWPE. In some embodiments, the second covering yarn comprises one or more ply strands of 72-filament, 140 Denier nylon, wherein the one or more ply strands are selected from 1-ply, 2-ply, 3-ply, or 4-ply. In some embodiments, the blend of cotton, polyester and rayon fibers of the second core yarn comprises approximately 68% cotton, approximately 18% polyester, and approximately 14% rayon. In some embodiments, the third covering yarn comprises 200 filaments of 400 Denier UHMWPE. In some embodiments, the fourth covering yarn comprises one or more ply strands of 72-filament, 140 Denier nylon, wherein the one or more ply strands are selected from 1-ply, 2-ply, 3-ply, or 4-ply. In some embodiments, the first composite yarn and the second composite yarn are woven in a three-by-one left-hand twill configuration. In some embodiments, the textile is formed as any one or more of a pair of pants, a jacket, a shirt, or a glove. In some embodiments, the UHMWPE does not protrude through a surface of the textile after washing. In some embodiments, the textile achieves a level of cut resistance equivalent to at least ANSI Level A4. In some embodiments, the second core yarn further comprises one or more stretch fibers, wherein the blend of cotton, polyester and rayon fibers wraps around the stretch fibers by a ring spinning process.

[0005] A method for producing a textile comprises manufacturing a first composite yarn including a first core yarn of nylon filaments, a first covering yarn of UHMWPE, and a second covering yarn of nylon filaments; manufacturing a second composite yarn including a second core yarn of cotton, polyester and rayon fibers, a third covering yarn of UHMWPE, and a fourth covering yarn of nylon filaments; and weaving the first and second composite yarns into the textile. In some embodiments, the textile has a three-by-one left-hand twill configuration.

[0006] In some embodiments, the method further comprises forming the textile as any one or more of a pair of pants, a jacket, a shirt, or a glove. In some embodiments, the UHMWPE does not protrude through a surface of the textile after washing. In some embodiments, the textile achieves a level of cut resistance equivalent to at least ANSI Level A4. In some embodiments, the second core yarn further comprises one or more stretch fibers, wherein the blend of cotton, polyester and rayon fibers wraps around the stretch fibers by a ring spinning process.

[0007] A method for producing protective garments comprises providing a textile comprising a first composite yarn and a second composite yarn, wherein the first composite yarn includes a nylon core, UHMWPE covering, and nylon covering, and the second composite yarn includes a polyester-cotton core, UHMWPE covering, and nylon covering; and constructing a garment from the textile.

[0008] In some embodiments, the method further comprises washing the textile to pre-shrink it, wherein the UHMWPE does not protrude through a surface of the textile after pre-shrinking.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is an elevated view of an example first yarn (Warp Yarn) which may be incorporated into a denim textile.

[0010] FIG. 1A is a front perspective and partial detail view of an example first covering yarn of the example first yarn (Warp Yarn) illustrated in FIG. 1.

[0011] FIG. 1B is a front perspective and partial detail view of an example second covering yarn of the example first yarn (Warp Yarn) illustrated in FIG. 1.

[0012] FIG. 2 is an elevated view of an example second yarn (Weft Yarn) which may be incorporated into a denim textile.

[0013] FIG. 2A is a front perspective and partial detail view of an example first covering yarn of the example second yarn (Weft Yarn) illustrated in FIG. 2.

[0014] FIG. 2B is a front perspective and partial detail view of an example second covering yarn of the example second yarn (Weft Yarn) illustrated in FIG. 2.

[0015] FIG. 2C is an elevated view of an example second yarn (Weft Yarn) which may be incorporated into a stretch denim textile.

[0016] FIG. 3A is flow diagram of an example method for preparing a covered yarn.

[0017] FIG. 3B is flow diagram of an example method for preparing a covered yarn for stretch denim.

[0018] FIG. 4 is an elevated partial front detail view of the example first yarn illustrated in FIG. 1, showing a partial construction of the example first yarn.

[0019] FIG. 5 is an illustration of an example loom weaving assembly for manufacturing a denim textile in accordance with one or more embodiments.

[0020] FIG. 6A is a top plan view illustrating an example weaving pattern diagram of the example denim textile in accordance with one or more embodiments.

[0021] FIG. 6B is a top plan view illustrating another example weaving pattern diagram of the example denim textile in accordance with one or more embodiments.DETAILED DESCRIPTION

[0022] Reference will now be made in detail to examples of yarns and textiles for cut resistant denim, which are illustrated in the accompanying drawings. While the present disclosure includes descriptions of certain examples, it is understood that they are not intended to limit the coverage of this disclosure. On the contrary, this disclosure is intended to cover alternatives, modifications, and equivalents. Furthermore, in this disclosure, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments. However, it is understood that such embodiments may be practiced without these specific details. In other instances, well known methods, procedures, and components have not been described in detail so as not to unnecessarily obscure aspects of the disclosed embodiments.

[0023] Generally speaking, various embodiments provide for a denim textile for use in clothing and a method to produce denim textiles that are thinner, lighter, and more comfortable while maintaining high levels of cut resistance, towards increasing worker safety by reducing the likelihood of removal of cut-resistant clothing articles during work. The denim textile may be manufactured with a composite yarn comprising ultra-high molecular weight polyethylene (“UHMWPE”) that is advantageous over products currently in the cut resistant clothing market. Instead of using an older spun yarn technology (which may feel scratchier than heavy cotton), embodiments disclosed herein include cut resistant clothing products produced from UHMWPE via a process called filament spinning to create filament yarns.

[0024] Filament extruding technology has enabled the creation of new products made from extruded filaments. In particular, filament extrusions may be spun to produce yarns for use in the creation of textiles. Textiles made from extruded filaments as disclosed herein may achieve better ratings for cut resistance and durability testing than conventional denim materials. In some embodiments, UHMWPE is an extruded filament which may have a linear density that is higher than conventional yarn materials. The UHMWPE may also have better durability and cut resistance properties. UHMWPE may be used in the fabrication of denim textiles to impart cut resistance properties to a denim textile and overcome limitations of conventional cut resistant materials which traditionally may not be added to denim.

[0025] In conventional cut resistant textiles, metal, fiberglass, basalt, or any other type of cut resistant fiber may be traditionally spun into a yarn, and the resulting yarn used to impart cut resistant properties to a textile. However, when attempting to add metal, fiberglass, basalt, or other conventional cut resistant fibers to denim textiles, the shrinkage of the denim yarn / material during the manufacturing wash process creates an issue with the resulting textile due to the differential shrinkage between the traditional cut resistant fibers and the fibers being blended with the cut resistant fibers (like cotton, polyester, etc.).

[0026] Specifically, denim textiles are traditionally known to shrink by around ten percent after a denim garment washing process. In denim constructions, if metal, glass, or basalt is used as the cut resistant fiber, such a fiber would not shrink at the same shrinkage rate of the surrounding denim textile yarn. As a result, the glass, metal, or basalt fibers would poke through the denim and hit the skin of a wearer of the garment, causing irritation or an uncomfortable wearing experience. Glass, metal, or basalt may continue to irritate the skin and may worsen over subsequent washes, which may further shrink surrounding denim textile yarns.

[0027] In some embodiments, the manufacture of denim garments involves a wash process performed to pre-shrink the garments before selling commercially. In a first operation, the denim garments are constructed in an oversized configuration to account for anticipated shrinkage. The denim garments are then washed to shrink the garments to a proper size. In some embodiments, a stone washing process may produce a stone washed look and may also shrink the garment to an actual wearing size. Without washing a denim garment during the manufacture of the garment, the garment would tend to shrink around ten percent in both the length and width directions after consumer purchase, producing an undesirable fit.

[0028] The materials as described in this specification utilizing UHMWPE yarn may shrink at a same or substantially similar shrinkage rate along with the rest of the materials used in the construction of a denim textile. Because the UHMWPE filaments shrink compatibly with the nylon, rayon, cotton, and polyester fibers in the denim construction, the pre-shrinking wash process can effectively prioritize the occurrence of substantially all shrinkage before the garment reaches the consumer. This is a technical improvement over the conventional cut resistant fibers, such as metal, fiberglass, basalt, and other abrasive cut resistant yarns, that tend to protrude through the textile surface in such a way that they might cause irritation to the person wearing the cut-resistant denim. This protrusion was particularly pronounced after washing the textiles made with the conventional cut resistant fibers, as the conventional cut-resistant fibers typically did not shrink compatibly with the other fibers in the denim construction. Therefore, the materials as described in this specification utilizing UHMWPE yarn may be more comfortable and / or less irritable than conventional cut resistant fibers such as metal, glass, basalt, and other abrasive cut resistant yarns.

[0029] The materials as described in this specification are also able to obtain an ANSI Level 6 cut resistant performance that greatly exceeds conventional denim textiles in the market today. By adjusting the Denier of certain yarns, such as the UHMWPE covering yarns, the construction may achieve even higher levels of cut resistance, including ANSI Level A7, A8, and A9. These yarns, and textiles comprising the yarns, achieve added flexibility and comfort as well as cut resistance, which in turn may decrease the need, want, or desire for workers to remove cut-resistant clothing before work is completed. This may translate into greater worker safety across a workforce which is required to use cut-resistant clothing. The present disclosure creates a denim or twill construction that may elevate the cut level from above A2 and easily achieve A4, A5, A6, and higher. Furthermore, the construction of the denim of the present disclosure can be manipulated, changed, or modified to obtain any different level ANSI cut rewsistance in order to provide a wearer the most comfortable experience with the right level of protection.Warp Yarn

[0030] FIG. 1 of the drawings discloses a first yarn (“Warp Yarn 10”) to be used in manufacturing a denim textile for use in cut-resistant clothing. In some embodiments, Warp Yarn 10 features a core 12 around which is wrapped a first covering layer 14. A second covering layer 16 is wrapped around first covering layer 14. In some embodiments, core 12 may include or be made from 2-ply ends of 72 filament, 140 Denier nylon. Although the exemplary drawing as shown in FIG. 1 may not illustrate 72 such filaments of the 140 Denier nylon, it will be understood that core 12 may have any plurality of filaments of 140 Denier nylon. Nylon may also give Warp Yarn 10 a softer touch and texture. In other examples, core 12 may be made of 1-ply, 2-ply, 3-ply, or 4-ply nylon.

[0031] In some embodiments, core 12 may be made from nylon filaments that are greater than or, in another example, less than 140 Denier. Core 12 may also comprise more than 72 filaments of the 140 Denier nylon. In some embodiments, core 12 may comprise less than or more than 72 filaments of the 140 Denier nylon. It will be understood that, in modifying the Denier and / or count of the nylon filaments used in core 12, the cut resistant properties of core 12 may be increased (by increasing Denier and / or increasing the count of filaments) or decreased (by decreasing Denier and / or decreasing the count of filaments).

[0032] FIG. 1A illustrates an example partial detail view of an end of a first covering later 14 of the example Warp Yarn illustrated in FIG. 1. Shown in FIG. 1A, first covering layer 14 may comprise UHMWPE, specifically, 400 Denier UHMWPE. First covering 14, made from UHMWPE, serves to provide Warp Yarn 10 with cut-resistant properties.

[0033] As one example, first covering 14 may comprise 200 filament strands of 400 Denier UHMWPE. While the exemplary drawing shown in FIG. 1A may not to scale illustrate exactly 200 such filaments of 400 Denier UHMWPE, it will be understood that first covering 14 may have 200 such filaments or any other plurality of filaments of 400 Denier UHMWPE. This construction may ensure that Warp Yarn 10 maintains stretchability and flexibility while offering cut resistance, which makes it suitable for applications requiring both flexibility and protection to the wearer.

[0034] In some embodiments, first covering 14 may be made from UHMWPE that is greater than or, in another example, less than 400 Denier. In some embodiments, first covering 14 may also comprise more than 200 filaments of 400 Denier UHMWPE, or fewer than 200 filaments of 400 Denier UHMWPE. It will be understood that, in modifying the Denier (i.e., the linear density) and / or count of the UHMWPE filaments used in first covering 14, the cut-resistant properties of first covering 14 may be increased (by increasing Denier or linear density and / or increasing the count of filaments) or decreased (by decreasing Denier or linear density and / or decreasing the count of filaments).

[0035] FIG. 1B illustrates an example partial detail view of an end of a second covering 16 of the example Warp Yarn illustrated in FIG. 1. Shown in FIG. 1B, Warp Yarn 10 may further comprise a second covering 16. Second covering 16 may be wrapped over first covering 14. In some embodiments, second covering 16 may include or be made from 1-ply strand of 72 filament, 140 Denier nylon. While the exemplary drawing shown in FIG. 1B may not to scale illustrate exactly 72 such filaments of 140 Denier nylon, it will be understood that second covering 16 may have 72 such filaments or any other plurality of filaments of 140 Denier nylon.

[0036] In some embodiments, the nylon may be blue nylon. The blue nylon may give the denim its blue appearance. In another example, a nylon with a color other than blue may be used to produce a denim textile with a color other than blue. The blue nylon may give the denim its blue appearance. In some embodiments, a nylon with a color other than blue may be used to produce a denim textile with a color other than blue. Nylon may also give Warp Yarn 10 a softer touch and texture.

[0037] In some embodiments, second covering 16 may be made of 1-, 2-, 3-, or 4-ply nylon, which different ply numbers can impart different effects such as softer handfeel, altered surface texture, or different visual appearance. In some embodiments, second covering 16 may be made from nylon that is greater than or, in another example, less than 140 Denier. Second covering 16 may comprise more than 72 filaments of 140 Denier nylon. In some embodiments, second covering 16 may comprise fewer than 72 filaments of 140 Denier nylon. It will be understood that, in modifying the Denier or linear density and / or the count of the nylon filaments used in second covering 16, the cut resistant properties of second covering 16 may be increased (by increasing Denier or linear density and / or increasing the count of filaments) or decreased (by decreasing Denier or linear density and / or decreasing the count of filaments).Weft Yarn

[0038] FIG. 2 of the drawings discloses a second yarn (“Weft Yarn 20”) to be used in manufacturing a denim textile for use in cut-resistant clothing. In some embodiments, Weft Yarn 20 features a core 22 around which is spun or wrapped a first covering layer 24. A second covering layer 26 is wrapped around first covering layer 24. In some embodiments, core 22 may include or be made from a 21 singles cotton count in a spun blend of cotton, polyester and rayon fibers. In some embodiments, the blend of cotton, polyester and rayon fibers is 60-70% cotton, 15-20% polyester, and 15-20% rayon. For example, the blend of cotton, polyester and rayon fibers may be approximately 68% cotton, approximately 18% polyester, and approximately 14% rayon fibers. In that example, that specific blend ratio of polyester to cotton may give Weft Yarn 20, and the resulting denim textile, a softer touch and feel, and a more authentic denim feel. In another example, the ratio of polyester fibers to cotton fibers may be altered to change the touch and feel of Weft Yarn 20, and thus change the touch and feel of the resulting denim textile.

[0039] It will be understood that, in modifying the ratio and / or cotton count or gauge thickness of the cotton-polyester-rayon fiber blend used in core 22, the cut resistant properties of core 22 may be increased (by increasing gauge thickness and / or cotton count) or decreased (by decreasing gauge thickness and / or cotton count).

[0040] In some embodiments for producing a stretch version of the denim textile, core 22 may further include stretch fibers in addition to the polyester-cotton blend. For example, as shown in FIG. 2C, core 22 may be a bicomponent elastic fiber comprising a stretch polyester fiber (22b) and spandex fiber (22c), which are positioned within or alongside the 21 singles cotton-polyester-rayon spun yarn (22a) that wraps around them. The stretch polyester fiber may have a Denier of approximately 50, though other Deniers may be used. The spandex fiber (e.g., Lycra fiber or elastane) may have a Denier of approximately 40, though other Deniers may be used. The stretch polyester fiber may be elasterell-p, a polyester that has an inherent mechanical stretch property due to its crimped or coiled structure, which allows it to stretch and recover. The spandex fiber provides elasticity and recovery, while the polyester fiber helps the fabric snap back to its original shape after stretching. This combination results in a stretch denim that maintains its shape and fit even after repeated wearing and washing. The 21 singles cotton-polyester-rayon spun yarn may wrap around or otherwise cover the stretch polyester and spandex core fibers.

[0041] It will be understood that, in modifying the ratio and / or cotton count or gauge thickness of the cotton-polyester-rayon fiber blend used in core 22, the cut resistant properties of core 22 may be increased (by increasing gauge thickness and / or cotton count) or decreased (by decreasing gauge thickness and / or cotton count). Similarly, the addition of stretch polyester and spandex fibers to core 22 may slightly increase the weight and thickness of the resulting textile, which may impact cut resistance and other physical properties.

[0042] Weft Yarn 20 may further comprise a first covering 24. First covering layer 24 may surround core 22. FIG. 2A illustrates an example partial detail view of an end of a first covering 24 of the example Weft Yarn 20 illustrated in FIG. 2. Shown in FIG. 2A, in some embodiments, first covering may comprise UHMWPE, specifically, first covering 24 may comprise 400 Denier UHMWPE. First covering 24, made from UHMWPE, may provide Weft Yarn 20 with cut-resistant properties. As one example, first covering 24 may comprise 200 filament strands of 400 Denier UHMWPE. While the exemplary drawing shown in FIG. 2A may not to scale illustrate exactly 200 such filaments of 400 Denier UHMWPE, it will be understood that first covering 24 may have 200 such filaments or any other plurality of filaments of 400 Denier UHMWPE. This construction may ensure that Warp Yarn 20 maintains stretchability and flexibility while offering cut resistance, making it suitable for applications requiring both flexibility and protection to the wearer. In some embodiments, first covering 24 may be made from UHMWPE that is greater than or, in another example, less than 400 Denier. First covering 24 may comprise more than 200 filaments of 400 Denier UHMWPE. In some embodiments, first covering 24 may comprise fewer than 200 filaments of 400 Denier UHMWPE. It will be understood that, in modifying the Denier (i.e., the linear density) and / or count of the UHMWPE filaments used in first covering 24, the cut-resistant of first covering 24 may be increased (by increasing Denier or linear density and / or increasing the count of filaments) or decreased (by decreasing Denier and or linear density and / or decreasing the count of filaments).

[0043] Weft Yarn 20 may further comprise a second covering 26. Second covering 26 may be wrapped over first covering 24. FIG. 2B illustrates an example partial detail view of an end of a second covering 26 of the example Weft Yarn illustrated in FIG. 2. Shown in FIG. 2B, in some embodiments, second covering 26 may include or be made from 1-ply-end of 72 filament, 140 Denier nylon. While the exemplary drawing shown in FIG. 2B may not to scale illustrate exactly 72 such filaments of 140 Denier nylon, it will be understood that second covering 26 may have 72 such filaments or any other plurality of filaments of 140 Denier nylon. In some embodiments, the nylon may be blue nylon. The blue nylon may give the denim its blue appearance. In some embodiments, a nylon with a color other than blue may be used to produce a denim textile with a color other than blue. Nylon may also give Weft Yarn 20 a softer touch and texture.

[0044] In some embodiments, second covering 26 may be made of 1-, 2-, 3, or 4-ply nylon, which different ply numbers can impart different effects such as softer handfeel, altered surface texture, or different visual appearance. In some embodiments, second covering 26 may be made from nylon that is greater than or, in another example, less than 140 Denier. Second covering 26 may comprise more than 72 filaments of the 140 Denier nylon. In some embodiments, second covering 26 may comprise fewer than 72 filaments of the 140 Denier nylon. It will be understood that, in modifying the Denier or linear density and / or count of the nylon filaments used in second covering, the cut resistant properties of second covering 26 may be increased (by increasing Denier or linear density and / or increasing the count of filaments) or decreased (by decreasing Denier or linear density and / or decreasing the count of filaments).

[0045] FIG. 3A illustrates an example method 300A for producing a covered yarn, such as Warp Yarn 10 or Weft Yarn 20 illustrated in FIGS. 1 and 2, respectively. For stretch denim embodiments utilizing Weft Yarn 20 (as in FIG. 2C) with stretch fibers, a ring spinning operation (described below and illustrated in FIG. 3B) may be performed prior to method 300A to create the stretch core yarn. In the example, a first step may include, at block 302, providing a core for the yarn and unspooling the core from a first spool. For example, cores 12, 22 are provided for the core of Warp Yarn 10 and Weft Yarn 20, respectively. In some embodiments, a core yarn may be any suitable yarn to serve as a core, such as the nylon of core 12, the cotton polyester blend of core 22, or another yarn comprising UHMWPE. For stretch denim embodiments, the core provided at block 302 is the stretch core yarn produced by the ring spinning operation described below with regard to FIG. 3B.

[0046] Method 300A may further include, at block 304, unspooling a first covering yarn. For example, a first covering yarn may be first covering yarns 14, 24 of the Warp Yarn 10 and Weft Yarn 20, respectively.

[0047] Method 300A may further include, at block 306, feeding the yarn through a first covering process. In some embodiments, cores 12, 22 may be unspooled from a first spool and fed, through machinery, to a first covering station. At the first covering station, a winding machine may unspool a covering yarn from a separate spool. In some embodiments, first covering yarns 14, 24 may be unspooled from a separate spool, and then first covering yarns 14, 24 may be wound or spun around the cores 12, 22, respectively at approximately 5.1 twists per inch in the “S” direction of twist. In some embodiments, covering yarns may be wound or spun around the core at twists per inch of other than approximately 5.1. In some embodiments, covering yarns may be wound or spun around the core in the “Z” direction of twist instead of or in addition to the “S” direction of twist. The direction of twist may be selected based on manufacturing preferences and desired textile properties. It will be known that varying the twists per inch or the direction of twist may vary the surface covering, and thus other physical properties of the covered yarn, such as thickness, weight, cut resistance, and other properties.

[0048] Method 300A may further include, at block 308, unspooling a second covering yarn. For example, a second covering yarn may be second covering yarns 16, 26 of Warp Yarn 10 and Weft Yarn 20, respectively. In some embodiments, a covering yarn may be any suitable yarn to serve as a covering yarn, such as the nylon of second covering 16 and 26, or a cotton polyester blend. In some embodiments, second covering may be made from blue nylon. The blue nylon may give the denim its blue appearance. In some embodiments, a nylon with a color other than blue may be used to produce a denim textile with a color other than blue.

[0049] Method 300A may further include, at block 310, feeding the covered core through a second covering process. In some embodiments, the core covered with first covering may further be fed from the first covering step at block 306 to a second covering step, block 310. In the example, the additional covering may be twisted or turned at approximately 5.1 twists per inch (or 200 twists per meter) in a “Z” direction of twist. In some embodiments, aramid filament may be wound or spun at twists per inch of other than approximately 5.1. In some embodiments, covering yarns may be wound or spun around the core in the “S” direction of twist instead of or in addition to the “Z” direction of twist. The direction of twist may be selected based on manufacturing preferences and desired textile properties. It will be known that varying the twists per inch or the direction of twist may vary the surface covering, and thus other physical properties of the covered yarn, such as thickness, weight, cut resistance, and other properties.

[0050] FIG. 3B illustrates an example ring spinning method 300B for producing a stretch core yarn for use in the stretch denim embodiment of Weft Yarn 20. The method 300B may be performed prior to method 300A. The resulting stretch core yarn produced by method 300B may then serve as the core yarn (core 22) that is used at block 302 for subsequent covering with UHMWPE and nylon as described above.

[0051] Method 300B may further include, at block 312, unspooling a spandex fiber core. For example, the spandex fiber may be approximately 40 Denier spandex, though other Deniers may be used.

[0052] Method 300B may further include, at block 314, unspooling a stretch polyester fiber core. For example, the stretch polyester fiber may be elasterell-p of approximately 50 Denier, though other Deniers may be used.

[0053] Method 300B may further include, at block 316, ring spinning a covering yarn around the spandex and stretch polyester cores. In this ring spinning process, the spandex and polyester fibers (the stretch fibers) are fed through a ring spinning apparatus. Simultaneously, a roving comprising the 21 singles fiber blend (e.g., cotton, polyester, and / or rayon) is fed through a series of drafting rollers that thin and draw out the fibers. The drafted 21 singles fibers and the stretch fibers pass are then brought together and pass through a thread guide. As the combined yarns descend, they pass through a traveler that runs along a circular spinning ring. Below the ring, a rotating spindle winds the yarn onto a bobbin. The spindle rotates at a first rate while the traveler moves around the ring at a second rate slower than the first rate. This differential rotation inserts twist into the yarn, causing the drafted 21 singles fibers to wrap around the stretch fibers. The twist may be between 10 and 20 twists per inch, e.g., approximately 15.5 twists per inch.

[0054] The ring spinning process creates a textured, fuzzy appearance characteristic of spun yarns while allowing the stretch fibers to remain the functional elastic core. The resulting stretch core yarn produced by method 300B then serves as the core yarn (core 22) that is fed into method 300 at block 302 for subsequent covering with UHMWPE and nylon as described above.

[0055] FIG. 4 of the drawings discloses a partial detail view of Warp Yarn 10, illustrating an example partial construction of Warp Yarn 10. Illustrated in FIG. 4, core 12 of Warp Yarn 10, comprising 140 Denier blue nylon, may include one filament or strand of 140 Denier nylon in one example, and in another example core 12 may include multiple strands of 140 Denier nylon aligned in a substantially parallel or linear orientation. Covering 14 of Warp Yarn 10 may include, for example, one filament or strand of 75 Denier polyester. In another example, covering 14 may include multiple strands or filaments of 75 Denier polyester.

[0056] Illustrated in FIG. 4 and using existing machinery and the process illustrated in FIG. 3A and described above, covering 14, which may comprise 400 Denier UHNWPE, may be spun or wound around core 12 according to a specified twist 18. The twist 18 of covering 14 may be measured in twists-per-inch, or winding angle at which covering 14 turns around core 12 with respect to the longitudinal axis of core 12. In some embodiments, covering 14 may be wound around core 12 at a twist of 5.1 twists per inch. In some embodiments, the twist 18 of covering 14 may be increased or decreased, which may consequently increase or decrease an amount of covering 14 that is applied to core 12.

[0057] It will be known that increasing or decreasing the twist 18 increases or decreases an amount of covering 14 that may be applied to core 12, and consequently may affect the cut resistant properties of Warp Yarn 10. It will also be hereafter known that for coverings for any yarn in this application (including Warp Yarn 10 and Weft Yarn 20), the twists per inch of winding or spinning for any covering of any yarn may be adjusted to increase or decrease an amount of covering applied to a core yarn material, which may, in turn, affect the cut resistance properties of a yarn.Weaving / Loom Process—Warp / Weft Process

[0058] FIG. 5 illustrates an example schematic of a loom weaving assembly 50. In the example, Warp Yarn 10 may be placed on yarn packages or bobbins 502 to be fed into the warp feed or shedding 504 of the loom weaving assembly 50. In some embodiments, multiple yarn packages or bobbins 502 of Warp Yarn 10 of the same composition may be supplied to warp feed or shedding 504. In another example, yarn packages or bobbins 502 feeding into warp feed or shedding 504 may contain yarns of varying compositions, coverings having varied twists per inch, or of different core and covering components as disclosed and described, above. In some embodiments, yarn packages 502 containing Warp Yarn 10 may be unspooled and fed onto a beam 503 in a beaming process. Adding yarn packages 502 to beam 503 may ensure that all individual Warp Yarn 10 ends are fed into shedding 504 at the same or similar rate. In the example illustrated in FIG. 5, Weft Yarn 20 may be placed on a yarn package or bobbin 506 which may feed into a weft feed or nozzle 508. In some embodiments, loom weaving assembly 50 may be an air loom weaving assembly and nozzle 508 may be an air nozzle which feeds Weft Yarn 20 though shedding 504 using pressurized air. In another example, loom weaving assembly 50 may be a standard loom weaving assembly and Weft Yarn 20 may be fed through shedding 504 using a shuttle or projectile. In the example illustrated in FIG. 5, loom weaving assembly 50 is an air loom weaving assembly and Weft Yarn 20 is fed through nozzle 508, such that pressurized air forces Weft Yarn 20 through shedding 504. In the example, a series of profile reeds 510 may arrange shedding 504 such that Weft Yarn 20 passes through a plurality of warp yarn feeds or shedding 504 in a pattern of Weft Yarn 20 crossing over some feeds of Warp Yarn 10 and crossing under other feeds of Warp Yarn 10.

[0059] FIGS. 6A-6B illustrate example patterns of Weft Yarn 20 crossing over and under Warp Yarn 10. In the example loom weaving pattern illustrated in FIGS. 6A-6B, Weft Yarn 20 crosses under Warp Yarn 10 for three consecutive feeds of Warp Yarn 10, and crosses over Warp Yarn 10 on every fourth feed. This is accomplished by adjusting individual profile reeds 510, as illustrated in FIG. 5, to move a feed of Warp Yarn 10 either below or above Weft Yarn 20 for a particular pass of Weft Yarn 20 through shedding 504.

[0060] In the example patterns illustrated in FIGS. 6A-6B, the pattern 60 may be accomplished by moving an individual profile reed 510 and thus Warp Yarn 10 below Weft Yarn 20 for three consecutive passes, and then moving Warp Yarn 10 above Weft Yarn 20 on a fourth consecutive pass. Each profile reed 510 in a series of profile reeds along a direction of travel of Weft Yarn 20 may move Warp Yarn 10 above Weft Yarn 20 in a pass that is immediately prior to or immediately subsequent to the profile reed 510 next to it. This creates a pattern where the passes of Warp Yarn 10 over Weft Yarn 20 appear in a visible diagonal pattern, spaced three stiches apart from the next diagonally visible pattern of Warp Yarn 10. As shown in FIG. 6A, the diagonal pattern forms a right-hand twill, where the diagonal lines run from upper right to lower left. As shown in FIG. 6B, the diagonal pattern forms a left-hand twill, where the diagonal lines run from upper left to lower right.

[0061] It will be apparent that the weave pattern of the denim construction may be altered, changed, or adjusted (for example, changing to a two-by-one right-handed twill, a two-by-two right-handed twill, a four-by-one right-handed twill, using left-handed twill instead of right-handed twill, etc.). Changing the pattern of the twill will change the number or amount of Warp Yarn 10 and Weft Yarn 20 used in the construction of the denim textile, and therefore may change the resulting denim textile's performance in cut resistance or other durability tests. Changing the pattern of the twill may also change the touch or feel, resulting weight or density, shrinkage after wash, and other physical properties of the resulting denim textile.

[0062] In some embodiments, a denim material may be made with Warp Yarn 10 and Weft Yarn 20 as disclosed and described, above. In the example shown in FIG. 6A, the Warp Yarn 10 and Weft Yarn 20 may be woven together in a loom in a three-by-one left-handed twill pattern, using a weaving process as disclosed and described above. In some embodiments, the denim material produced from Warp Yarn 10 and Weft Yarn 20 in the three-by-one left-handed twill pattern according to the materials and methods disclosed may have a before washing weight of about 11.8 ounces per square yard and may have an after washing weight of about 13.3 ounces per square yard.

[0063] In another example using the stretch version of the Weft Yarn 20 including stretch polyester and spandex fibers, the before washing weight may be approximately 12.5 ounces per square yard and the after washing weight may be approximately 14 ounces per square yard. The additional weight may be attributed to the stretch polyester and spandex fibers in the weft yarn core, as well as the increased shrinkage and densification of the fabric structure that results from the stretch fibers collapsing the fabric during the manufacturing pre-wash process.

[0064] The denim produced according to the materials and methods described above may have a shrinkage after washing of about 13 percent in the warp direction and eight percent in the weft direction. The denim produced according to the materials and methods described above may have a cut resistance of at least ANSI Level 6. Very high abrasion resistance can be maintained with this construction. At a minimum the denim material of the construction disclosed can achieve a satisfactory score for abrasion resistance after testing per ASTM D3886. The denim material may achieve a pilling resistance score of 3.5 out of 5.0 score using ASTM method ASTM D4970. The material may also achieve a snagging resistance score of 3.5 minimum out of 5.0 score using ASTM method ASTM D3939. The denim produced from the materials and methods disclosed may achieve very high tensile and tear strength rating as tested against ASTM D5034 for tensile strength and ASTM D1424 for tear strength.

[0065] The foregoing disclosure describes systems and methods for manufacturing a fabric or textile to be used in personal protective equipment. However, as will be appreciated by those skilled in the art, the systems and methods of the present disclosure may be applicable to other textile manufacturing processes (e.g., fabrics or textiles for improved composite qualities). In an example, the yarns disclosed in this application may be utilized for other woven constructions and weights such as khaki and twill textiles used to make top and / or bottom garments (e.g., shirts, shorts, pants, gloves, jackets). The yarns and materials disclosed in this application can also be used to make lighter weight woven garments of all types (e.g., button up work shirts, khaki work pants, etc.) The yarns disclosed in this application may also be utilized in knitting configurations to make knitted garments. Thus, various embodiments as described herein provide a method for creating composite textiles or fabric exhibiting multiple beneficial characteristics.

[0066] Among those benefits and improvements that have been disclosed, other objects and advantages will become apparent from the description taken in conjunction with the accompanying figures. The figures constitute a part of this specification, include illustrative embodiments of the present disclosure, and illustrate various objects and features thereof. Any measurements, specifications and the like disclosed herein are intended to be illustrative, and not restrictive. Thus, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art. While various embodiments of the new technology described herein have been described in detail, modifications and adaptations of the embodiments will occur to those skilled in the art and remain within the spirit and scope of the presently disclosed technology.

[0067] In addition, as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the term “and / or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,”“an,” and “the” include plural references, unless the context clearly dictates otherwise. The meaning of “in” includes “in” and “on,” unless the context clearly dictates otherwise.

Examples

Embodiment Construction

[0022]Reference will now be made in detail to examples of yarns and textiles for cut resistant denim, which are illustrated in the accompanying drawings. While the present disclosure includes descriptions of certain examples, it is understood that they are not intended to limit the coverage of this disclosure. On the contrary, this disclosure is intended to cover alternatives, modifications, and equivalents. Furthermore, in this disclosure, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments. However, it is understood that such embodiments may be practiced without these specific details. In other instances, well known methods, procedures, and components have not been described in detail so as not to unnecessarily obscure aspects of the disclosed embodiments.

[0023]Generally speaking, various embodiments provide for a denim textile for use in clothing and a method to produce denim textiles that are thinner, lighter, and more ...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure claims priority to U.S. Provisional Application 63 / 743,052, filed on Jan. 8, 2025, and entitled “YARNS AND TEXTILES FOR CUT RESISTANT DENIM”, which is incorporated by reference in its entirety.BACKGROUND

[0002] In some work environments, industrial workers require their clothing to be cut resistant. Denim is a preferred clothing material for some industrial workers due to its versatility, durability, comfort, and low maintenance. Denim and twill are textile materials that have been used for decades in workwear bottoms. When it comes to providing cut resistant clothing made from denim material, the market has not provided many solutions that are designed for achieving flexibility of the material, comfort, and high cut resistance. Historically, denim has been produced from the use of spun cotton yarns and twill. Denim textiles woven from cotton and twill are not designed to provide high level of cut resistance. Workers often wear articles of clothing made from denim that are not cut resistant, only to supplement their clothing with an additional layer of PPE that is cut resistant. In other cases, workers may wear denim articles of clothing that are not cut resistant and not supplement with additional PPE. This creates a safety hazard, as statistics historically show that most injuries are caused through careless behavior such as removing PPE during the work process. Considering this issue, the industry is in an endless pursuit to provide the most comfortable, high flexibility cut-resistant denim, while ensuring that clothing made from such denim remains highly protective.BRIEF SUMMARY

[0003] A textile for use in making protective garments comprises a first composite yarn and a second composite yarn. The first composite yarn includes a first core yarn comprising nylon filaments, a first covering yarn comprising ultra-high molecular weight polyethylene (UHMWPE), and a second covering yarn comprising nylon filaments. The second composite yarn includes a second core yarn comprising a blend of cotton, polyester and rayon fibers, a third covering yarn comprising UHMWPE, and a fourth covering yarn comprising nylon filaments.

[0004] In some embodiments, the nylon filaments of the first core yarn comprise one or more ply strands of 72-filament, 140 Denier nylon, wherein the one or more ply strands are selected from 1-ply, 2-ply, 3-ply, or 4-ply. In some embodiments, the first covering yarn comprises 200 filaments of 400 Denier UHMWPE. In some embodiments, the second covering yarn comprises one or more ply strands of 72-filament, 140 Denier nylon, wherein the one or more ply strands are selected from 1-ply, 2-ply, 3-ply, or 4-ply. In some embodiments, the blend of cotton, polyester and rayon fibers of the second core yarn comprises approximately 68% cotton, approximately 18% polyester, and approximately 14% rayon. In some embodiments, the third covering yarn comprises 200 filaments of 400 Denier UHMWPE. In some embodiments, the fourth covering yarn comprises one or more ply strands of 72-filament, 140 Denier nylon, wherein the one or more ply strands are selected from 1-ply, 2-ply, 3-ply, or 4-ply. In some embodiments, the first composite yarn and the second composite yarn are woven in a three-by-one left-hand twill configuration. In some embodiments, the textile is formed as any one or more of a pair of pants, a jacket, a shirt, or a glove. In some embodiments, the UHMWPE does not protrude through a surface of the textile after washing. In some embodiments, the textile achieves a level of cut resistance equivalent to at least ANSI Level A4. In some embodiments, the second core yarn further comprises one or more stretch fibers, wherein the blend of cotton, polyester and rayon fibers wraps around the stretch fibers by a ring spinning process.

[0005] A method for producing a textile comprises manufacturing a first composite yarn including a first core yarn of nylon filaments, a first covering yarn of UHMWPE, and a second covering yarn of nylon filaments; manufacturing a second composite yarn including a second core yarn of cotton, polyester and rayon fibers, a third covering yarn of UHMWPE, and a fourth covering yarn of nylon filaments; and weaving the first and second composite yarns into the textile. In some embodiments, the textile has a three-by-one left-hand twill configuration.

[0006] In some embodiments, the method further comprises forming the textile as any one or more of a pair of pants, a jacket, a shirt, or a glove. In some embodiments, the UHMWPE does not protrude through a surface of the textile after washing. In some embodiments, the textile achieves a level of cut resistance equivalent to at least ANSI Level A4. In some embodiments, the second core yarn further comprises one or more stretch fibers, wherein the blend of cotton, polyester and rayon fibers wraps around the stretch fibers by a ring spinning process.

[0007] A method for producing protective garments comprises providing a textile comprising a first composite yarn and a second composite yarn, wherein the first composite yarn includes a nylon core, UHMWPE covering, and nylon covering, and the second composite yarn includes a polyester-cotton core, UHMWPE covering, and nylon covering; and constructing a garment from the textile.

[0008] In some embodiments, the method further comprises washing the textile to pre-shrink it, wherein the UHMWPE does not protrude through a surface of the textile after pre-shrinking.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is an elevated view of an example first yarn (Warp Yarn) which may be incorporated into a denim textile.

[0010] FIG. 1A is a front perspective and partial detail view of an example first covering yarn of the example first yarn (Warp Yarn) illustrated in FIG. 1.

[0011] FIG. 1B is a front perspective and partial detail view of an example second covering yarn of the example first yarn (Warp Yarn) illustrated in FIG. 1.

[0012] FIG. 2 is an elevated view of an example second yarn (Weft Yarn) which may be incorporated into a denim textile.

[0013] FIG. 2A is a front perspective and partial detail view of an example first covering yarn of the example second yarn (Weft Yarn) illustrated in FIG. 2.

[0014] FIG. 2B is a front perspective and partial detail view of an example second covering yarn of the example second yarn (Weft Yarn) illustrated in FIG. 2.

[0015] FIG. 2C is an elevated view of an example second yarn (Weft Yarn) which may be incorporated into a stretch denim textile.

[0016] FIG. 3A is flow diagram of an example method for preparing a covered yarn.

[0017] FIG. 3B is flow diagram of an example method for preparing a covered yarn for stretch denim.

[0018] FIG. 4 is an elevated partial front detail view of the example first yarn illustrated in FIG. 1, showing a partial construction of the example first yarn.

[0019] FIG. 5 is an illustration of an example loom weaving assembly for manufacturing a denim textile in accordance with one or more embodiments.

[0020] FIG. 6A is a top plan view illustrating an example weaving pattern diagram of the example denim textile in accordance with one or more embodiments.

[0021] FIG. 6B is a top plan view illustrating another example weaving pattern diagram of the example denim textile in accordance with one or more embodiments.DETAILED DESCRIPTION

[0022] Reference will now be made in detail to examples of yarns and textiles for cut resistant denim, which are illustrated in the accompanying drawings. While the present disclosure includes descriptions of certain examples, it is understood that they are not intended to limit the coverage of this disclosure. On the contrary, this disclosure is intended to cover alternatives, modifications, and equivalents. Furthermore, in this disclosure, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments. However, it is understood that such embodiments may be practiced without these specific details. In other instances, well known methods, procedures, and components have not been described in detail so as not to unnecessarily obscure aspects of the disclosed embodiments.

[0023] Generally speaking, various embodiments provide for a denim textile for use in clothing and a method to produce denim textiles that are thinner, lighter, and more comfortable while maintaining high levels of cut resistance, towards increasing worker safety by reducing the likelihood of removal of cut-resistant clothing articles during work. The denim textile may be manufactured with a composite yarn comprising ultra-high molecular weight polyethylene (“UHMWPE”) that is advantageous over products currently in the cut resistant clothing market. Instead of using an older spun yarn technology (which may feel scratchier than heavy cotton), embodiments disclosed herein include cut resistant clothing products produced from UHMWPE via a process called filament spinning to create filament yarns.

[0024] Filament extruding technology has enabled the creation of new products made from extruded filaments. In particular, filament extrusions may be spun to produce yarns for use in the creation of textiles. Textiles made from extruded filaments as disclosed herein may achieve better ratings for cut resistance and durability testing than conventional denim materials. In some embodiments, UHMWPE is an extruded filament which may have a linear density that is higher than conventional yarn materials. The UHMWPE may also have better durability and cut resistance properties. UHMWPE may be used in the fabrication of denim textiles to impart cut resistance properties to a denim textile and overcome limitations of conventional cut resistant materials which traditionally may not be added to denim.

[0025] In conventional cut resistant textiles, metal, fiberglass, basalt, or any other type of cut resistant fiber may be traditionally spun into a yarn, and the resulting yarn used to impart cut resistant properties to a textile. However, when attempting to add metal, fiberglass, basalt, or other conventional cut resistant fibers to denim textiles, the shrinkage of the denim yarn / material during the manufacturing wash process creates an issue with the resulting textile due to the differential shrinkage between the traditional cut resistant fibers and the fibers being blended with the cut resistant fibers (like cotton, polyester, etc.).

[0026] Specifically, denim textiles are traditionally known to shrink by around ten percent after a denim garment washing process. In denim constructions, if metal, glass, or basalt is used as the cut resistant fiber, such a fiber would not shrink at the same shrinkage rate of the surrounding denim textile yarn. As a result, the glass, metal, or basalt fibers would poke through the denim and hit the skin of a wearer of the garment, causing irritation or an uncomfortable wearing experience. Glass, metal, or basalt may continue to irritate the skin and may worsen over subsequent washes, which may further shrink surrounding denim textile yarns.

[0027] In some embodiments, the manufacture of denim garments involves a wash process performed to pre-shrink the garments before selling commercially. In a first operation, the denim garments are constructed in an oversized configuration to account for anticipated shrinkage. The denim garments are then washed to shrink the garments to a proper size. In some embodiments, a stone washing process may produce a stone washed look and may also shrink the garment to an actual wearing size. Without washing a denim garment during the manufacture of the garment, the garment would tend to shrink around ten percent in both the length and width directions after consumer purchase, producing an undesirable fit.

[0028] The materials as described in this specification utilizing UHMWPE yarn may shrink at a same or substantially similar shrinkage rate along with the rest of the materials used in the construction of a denim textile. Because the UHMWPE filaments shrink compatibly with the nylon, rayon, cotton, and polyester fibers in the denim construction, the pre-shrinking wash process can effectively prioritize the occurrence of substantially all shrinkage before the garment reaches the consumer. This is a technical improvement over the conventional cut resistant fibers, such as metal, fiberglass, basalt, and other abrasive cut resistant yarns, that tend to protrude through the textile surface in such a way that they might cause irritation to the person wearing the cut-resistant denim. This protrusion was particularly pronounced after washing the textiles made with the conventional cut resistant fibers, as the conventional cut-resistant fibers typically did not shrink compatibly with the other fibers in the denim construction. Therefore, the materials as described in this specification utilizing UHMWPE yarn may be more comfortable and / or less irritable than conventional cut resistant fibers such as metal, glass, basalt, and other abrasive cut resistant yarns.

[0029] The materials as described in this specification are also able to obtain an ANSI Level 6 cut resistant performance that greatly exceeds conventional denim textiles in the market today. By adjusting the Denier of certain yarns, such as the UHMWPE covering yarns, the construction may achieve even higher levels of cut resistance, including ANSI Level A7, A8, and A9. These yarns, and textiles comprising the yarns, achieve added flexibility and comfort as well as cut resistance, which in turn may decrease the need, want, or desire for workers to remove cut-resistant clothing before work is completed. This may translate into greater worker safety across a workforce which is required to use cut-resistant clothing. The present disclosure creates a denim or twill construction that may elevate the cut level from above A2 and easily achieve A4, A5, A6, and higher. Furthermore, the construction of the denim of the present disclosure can be manipulated, changed, or modified to obtain any different level ANSI cut rewsistance in order to provide a wearer the most comfortable experience with the right level of protection.Warp Yarn

[0030] FIG. 1 of the drawings discloses a first yarn (“Warp Yarn 10”) to be used in manufacturing a denim textile for use in cut-resistant clothing. In some embodiments, Warp Yarn 10 features a core 12 around which is wrapped a first covering layer 14. A second covering layer 16 is wrapped around first covering layer 14. In some embodiments, core 12 may include or be made from 2-ply ends of 72 filament, 140 Denier nylon. Although the exemplary drawing as shown in FIG. 1 may not illustrate 72 such filaments of the 140 Denier nylon, it will be understood that core 12 may have any plurality of filaments of 140 Denier nylon. Nylon may also give Warp Yarn 10 a softer touch and texture. In other examples, core 12 may be made of 1-ply, 2-ply, 3-ply, or 4-ply nylon.

[0031] In some embodiments, core 12 may be made from nylon filaments that are greater than or, in another example, less than 140 Denier. Core 12 may also comprise more than 72 filaments of the 140 Denier nylon. In some embodiments, core 12 may comprise less than or more than 72 filaments of the 140 Denier nylon. It will be understood that, in modifying the Denier and / or count of the nylon filaments used in core 12, the cut resistant properties of core 12 may be increased (by increasing Denier and / or increasing the count of filaments) or decreased (by decreasing Denier and / or decreasing the count of filaments).

[0032] FIG. 1A illustrates an example partial detail view of an end of a first covering later 14 of the example Warp Yarn illustrated in FIG. 1. Shown in FIG. 1A, first covering layer 14 may comprise UHMWPE, specifically, 400 Denier UHMWPE. First covering 14, made from UHMWPE, serves to provide Warp Yarn 10 with cut-resistant properties.

[0033] As one example, first covering 14 may comprise 200 filament strands of 400 Denier UHMWPE. While the exemplary drawing shown in FIG. 1A may not to scale illustrate exactly 200 such filaments of 400 Denier UHMWPE, it will be understood that first covering 14 may have 200 such filaments or any other plurality of filaments of 400 Denier UHMWPE. This construction may ensure that Warp Yarn 10 maintains stretchability and flexibility while offering cut resistance, which makes it suitable for applications requiring both flexibility and protection to the wearer.

[0034] In some embodiments, first covering 14 may be made from UHMWPE that is greater than or, in another example, less than 400 Denier. In some embodiments, first covering 14 may also comprise more than 200 filaments of 400 Denier UHMWPE, or fewer than 200 filaments of 400 Denier UHMWPE. It will be understood that, in modifying the Denier (i.e., the linear density) and / or count of the UHMWPE filaments used in first covering 14, the cut-resistant properties of first covering 14 may be increased (by increasing Denier or linear density and / or increasing the count of filaments) or decreased (by decreasing Denier or linear density and / or decreasing the count of filaments).

[0035] FIG. 1B illustrates an example partial detail view of an end of a second covering 16 of the example Warp Yarn illustrated in FIG. 1. Shown in FIG. 1B, Warp Yarn 10 may further comprise a second covering 16. Second covering 16 may be wrapped over first covering 14. In some embodiments, second covering 16 may include or be made from 1-ply strand of 72 filament, 140 Denier nylon. While the exemplary drawing shown in FIG. 1B may not to scale illustrate exactly 72 such filaments of 140 Denier nylon, it will be understood that second covering 16 may have 72 such filaments or any other plurality of filaments of 140 Denier nylon.

[0036] In some embodiments, the nylon may be blue nylon. The blue nylon may give the denim its blue appearance. In another example, a nylon with a color other than blue may be used to produce a denim textile with a color other than blue. The blue nylon may give the denim its blue appearance. In some embodiments, a nylon with a color other than blue may be used to produce a denim textile with a color other than blue. Nylon may also give Warp Yarn 10 a softer touch and texture.

[0037] In some embodiments, second covering 16 may be made of 1-, 2-, 3-, or 4-ply nylon, which different ply numbers can impart different effects such as softer handfeel, altered surface texture, or different visual appearance. In some embodiments, second covering 16 may be made from nylon that is greater than or, in another example, less than 140 Denier. Second covering 16 may comprise more than 72 filaments of 140 Denier nylon. In some embodiments, second covering 16 may comprise fewer than 72 filaments of 140 Denier nylon. It will be understood that, in modifying the Denier or linear density and / or the count of the nylon filaments used in second covering 16, the cut resistant properties of second covering 16 may be increased (by increasing Denier or linear density and / or increasing the count of filaments) or decreased (by decreasing Denier or linear density and / or decreasing the count of filaments).Weft Yarn

[0038] FIG. 2 of the drawings discloses a second yarn (“Weft Yarn 20”) to be used in manufacturing a denim textile for use in cut-resistant clothing. In some embodiments, Weft Yarn 20 features a core 22 around which is spun or wrapped a first covering layer 24. A second covering layer 26 is wrapped around first covering layer 24. In some embodiments, core 22 may include or be made from a 21 singles cotton count in a spun blend of cotton, polyester and rayon fibers. In some embodiments, the blend of cotton, polyester and rayon fibers is 60-70% cotton, 15-20% polyester, and 15-20% rayon. For example, the blend of cotton, polyester and rayon fibers may be approximately 68% cotton, approximately 18% polyester, and approximately 14% rayon fibers. In that example, that specific blend ratio of polyester to cotton may give Weft Yarn 20, and the resulting denim textile, a softer touch and feel, and a more authentic denim feel. In another example, the ratio of polyester fibers to cotton fibers may be altered to change the touch and feel of Weft Yarn 20, and thus change the touch and feel of the resulting denim textile.

[0039] It will be understood that, in modifying the ratio and / or cotton count or gauge thickness of the cotton-polyester-rayon fiber blend used in core 22, the cut resistant properties of core 22 may be increased (by increasing gauge thickness and / or cotton count) or decreased (by decreasing gauge thickness and / or cotton count).

[0040] In some embodiments for producing a stretch version of the denim textile, core 22 may further include stretch fibers in addition to the polyester-cotton blend. For example, as shown in FIG. 2C, core 22 may be a bicomponent elastic fiber comprising a stretch polyester fiber (22b) and spandex fiber (22c), which are positioned within or alongside the 21 singles cotton-polyester-rayon spun yarn (22a) that wraps around them. The stretch polyester fiber may have a Denier of approximately 50, though other Deniers may be used. The spandex fiber (e.g., Lycra fiber or elastane) may have a Denier of approximately 40, though other Deniers may be used. The stretch polyester fiber may be elasterell-p, a polyester that has an inherent mechanical stretch property due to its crimped or coiled structure, which allows it to stretch and recover. The spandex fiber provides elasticity and recovery, while the polyester fiber helps the fabric snap back to its original shape after stretching. This combination results in a stretch denim that maintains its shape and fit even after repeated wearing and washing. The 21 singles cotton-polyester-rayon spun yarn may wrap around or otherwise cover the stretch polyester and spandex core fibers.

[0041] It will be understood that, in modifying the ratio and / or cotton count or gauge thickness of the cotton-polyester-rayon fiber blend used in core 22, the cut resistant properties of core 22 may be increased (by increasing gauge thickness and / or cotton count) or decreased (by decreasing gauge thickness and / or cotton count). Similarly, the addition of stretch polyester and spandex fibers to core 22 may slightly increase the weight and thickness of the resulting textile, which may impact cut resistance and other physical properties.

[0042] Weft Yarn 20 may further comprise a first covering 24. First covering layer 24 may surround core 22. FIG. 2A illustrates an example partial detail view of an end of a first covering 24 of the example Weft Yarn 20 illustrated in FIG. 2. Shown in FIG. 2A, in some embodiments, first covering may comprise UHMWPE, specifically, first covering 24 may comprise 400 Denier UHMWPE. First covering 24, made from UHMWPE, may provide Weft Yarn 20 with cut-resistant properties. As one example, first covering 24 may comprise 200 filament strands of 400 Denier UHMWPE. While the exemplary drawing shown in FIG. 2A may not to scale illustrate exactly 200 such filaments of 400 Denier UHMWPE, it will be understood that first covering 24 may have 200 such filaments or any other plurality of filaments of 400 Denier UHMWPE. This construction may ensure that Warp Yarn 20 maintains stretchability and flexibility while offering cut resistance, making it suitable for applications requiring both flexibility and protection to the wearer. In some embodiments, first covering 24 may be made from UHMWPE that is greater than or, in another example, less than 400 Denier. First covering 24 may comprise more than 200 filaments of 400 Denier UHMWPE. In some embodiments, first covering 24 may comprise fewer than 200 filaments of 400 Denier UHMWPE. It will be understood that, in modifying the Denier (i.e., the linear density) and / or count of the UHMWPE filaments used in first covering 24, the cut-resistant of first covering 24 may be increased (by increasing Denier or linear density and / or increasing the count of filaments) or decreased (by decreasing Denier and or linear density and / or decreasing the count of filaments).

[0043] Weft Yarn 20 may further comprise a second covering 26. Second covering 26 may be wrapped over first covering 24. FIG. 2B illustrates an example partial detail view of an end of a second covering 26 of the example Weft Yarn illustrated in FIG. 2. Shown in FIG. 2B, in some embodiments, second covering 26 may include or be made from 1-ply-end of 72 filament, 140 Denier nylon. While the exemplary drawing shown in FIG. 2B may not to scale illustrate exactly 72 such filaments of 140 Denier nylon, it will be understood that second covering 26 may have 72 such filaments or any other plurality of filaments of 140 Denier nylon. In some embodiments, the nylon may be blue nylon. The blue nylon may give the denim its blue appearance. In some embodiments, a nylon with a color other than blue may be used to produce a denim textile with a color other than blue. Nylon may also give Weft Yarn 20 a softer touch and texture.

[0044] In some embodiments, second covering 26 may be made of 1-, 2-, 3, or 4-ply nylon, which different ply numbers can impart different effects such as softer handfeel, altered surface texture, or different visual appearance. In some embodiments, second covering 26 may be made from nylon that is greater than or, in another example, less than 140 Denier. Second covering 26 may comprise more than 72 filaments of the 140 Denier nylon. In some embodiments, second covering 26 may comprise fewer than 72 filaments of the 140 Denier nylon. It will be understood that, in modifying the Denier or linear density and / or count of the nylon filaments used in second covering, the cut resistant properties of second covering 26 may be increased (by increasing Denier or linear density and / or increasing the count of filaments) or decreased (by decreasing Denier or linear density and / or decreasing the count of filaments).

[0045] FIG. 3A illustrates an example method 300A for producing a covered yarn, such as Warp Yarn 10 or Weft Yarn 20 illustrated in FIGS. 1 and 2, respectively. For stretch denim embodiments utilizing Weft Yarn 20 (as in FIG. 2C) with stretch fibers, a ring spinning operation (described below and illustrated in FIG. 3B) may be performed prior to method 300A to create the stretch core yarn. In the example, a first step may include, at block 302, providing a core for the yarn and unspooling the core from a first spool. For example, cores 12, 22 are provided for the core of Warp Yarn 10 and Weft Yarn 20, respectively. In some embodiments, a core yarn may be any suitable yarn to serve as a core, such as the nylon of core 12, the cotton polyester blend of core 22, or another yarn comprising UHMWPE. For stretch denim embodiments, the core provided at block 302 is the stretch core yarn produced by the ring spinning operation described below with regard to FIG. 3B.

[0046] Method 300A may further include, at block 304, unspooling a first covering yarn. For example, a first covering yarn may be first covering yarns 14, 24 of the Warp Yarn 10 and Weft Yarn 20, respectively.

[0047] Method 300A may further include, at block 306, feeding the yarn through a first covering process. In some embodiments, cores 12, 22 may be unspooled from a first spool and fed, through machinery, to a first covering station. At the first covering station, a winding machine may unspool a covering yarn from a separate spool. In some embodiments, first covering yarns 14, 24 may be unspooled from a separate spool, and then first covering yarns 14, 24 may be wound or spun around the cores 12, 22, respectively at approximately 5.1 twists per inch in the “S” direction of twist. In some embodiments, covering yarns may be wound or spun around the core at twists per inch of other than approximately 5.1. In some embodiments, covering yarns may be wound or spun around the core in the “Z” direction of twist instead of or in addition to the “S” direction of twist. The direction of twist may be selected based on manufacturing preferences and desired textile properties. It will be known that varying the twists per inch or the direction of twist may vary the surface covering, and thus other physical properties of the covered yarn, such as thickness, weight, cut resistance, and other properties.

[0048] Method 300A may further include, at block 308, unspooling a second covering yarn. For example, a second covering yarn may be second covering yarns 16, 26 of Warp Yarn 10 and Weft Yarn 20, respectively. In some embodiments, a covering yarn may be any suitable yarn to serve as a covering yarn, such as the nylon of second covering 16 and 26, or a cotton polyester blend. In some embodiments, second covering may be made from blue nylon. The blue nylon may give the denim its blue appearance. In some embodiments, a nylon with a color other than blue may be used to produce a denim textile with a color other than blue.

[0049] Method 300A may further include, at block 310, feeding the covered core through a second covering process. In some embodiments, the core covered with first covering may further be fed from the first covering step at block 306 to a second covering step, block 310. In the example, the additional covering may be twisted or turned at approximately 5.1 twists per inch (or 200 twists per meter) in a “Z” direction of twist. In some embodiments, aramid filament may be wound or spun at twists per inch of other than approximately 5.1. In some embodiments, covering yarns may be wound or spun around the core in the “S” direction of twist instead of or in addition to the “Z” direction of twist. The direction of twist may be selected based on manufacturing preferences and desired textile properties. It will be known that varying the twists per inch or the direction of twist may vary the surface covering, and thus other physical properties of the covered yarn, such as thickness, weight, cut resistance, and other properties.

[0050] FIG. 3B illustrates an example ring spinning method 300B for producing a stretch core yarn for use in the stretch denim embodiment of Weft Yarn 20. The method 300B may be performed prior to method 300A. The resulting stretch core yarn produced by method 300B may then serve as the core yarn (core 22) that is used at block 302 for subsequent covering with UHMWPE and nylon as described above.

[0051] Method 300B may further include, at block 312, unspooling a spandex fiber core. For example, the spandex fiber may be approximately 40 Denier spandex, though other Deniers may be used.

[0052] Method 300B may further include, at block 314, unspooling a stretch polyester fiber core. For example, the stretch polyester fiber may be elasterell-p of approximately 50 Denier, though other Deniers may be used.

[0053] Method 300B may further include, at block 316, ring spinning a covering yarn around the spandex and stretch polyester cores. In this ring spinning process, the spandex and polyester fibers (the stretch fibers) are fed through a ring spinning apparatus. Simultaneously, a roving comprising the 21 singles fiber blend (e.g., cotton, polyester, and / or rayon) is fed through a series of drafting rollers that thin and draw out the fibers. The drafted 21 singles fibers and the stretch fibers pass are then brought together and pass through a thread guide. As the combined yarns descend, they pass through a traveler that runs along a circular spinning ring. Below the ring, a rotating spindle winds the yarn onto a bobbin. The spindle rotates at a first rate while the traveler moves around the ring at a second rate slower than the first rate. This differential rotation inserts twist into the yarn, causing the drafted 21 singles fibers to wrap around the stretch fibers. The twist may be between 10 and 20 twists per inch, e.g., approximately 15.5 twists per inch.

[0054] The ring spinning process creates a textured, fuzzy appearance characteristic of spun yarns while allowing the stretch fibers to remain the functional elastic core. The resulting stretch core yarn produced by method 300B then serves as the core yarn (core 22) that is fed into method 300 at block 302 for subsequent covering with UHMWPE and nylon as described above.

[0055] FIG. 4 of the drawings discloses a partial detail view of Warp Yarn 10, illustrating an example partial construction of Warp Yarn 10. Illustrated in FIG. 4, core 12 of Warp Yarn 10, comprising 140 Denier blue nylon, may include one filament or strand of 140 Denier nylon in one example, and in another example core 12 may include multiple strands of 140 Denier nylon aligned in a substantially parallel or linear orientation. Covering 14 of Warp Yarn 10 may include, for example, one filament or strand of 75 Denier polyester. In another example, covering 14 may include multiple strands or filaments of 75 Denier polyester.

[0056] Illustrated in FIG. 4 and using existing machinery and the process illustrated in FIG. 3A and described above, covering 14, which may comprise 400 Denier UHNWPE, may be spun or wound around core 12 according to a specified twist 18. The twist 18 of covering 14 may be measured in twists-per-inch, or winding angle at which covering 14 turns around core 12 with respect to the longitudinal axis of core 12. In some embodiments, covering 14 may be wound around core 12 at a twist of 5.1 twists per inch. In some embodiments, the twist 18 of covering 14 may be increased or decreased, which may consequently increase or decrease an amount of covering 14 that is applied to core 12.

[0057] It will be known that increasing or decreasing the twist 18 increases or decreases an amount of covering 14 that may be applied to core 12, and consequently may affect the cut resistant properties of Warp Yarn 10. It will also be hereafter known that for coverings for any yarn in this application (including Warp Yarn 10 and Weft Yarn 20), the twists per inch of winding or spinning for any covering of any yarn may be adjusted to increase or decrease an amount of covering applied to a core yarn material, which may, in turn, affect the cut resistance properties of a yarn.Weaving / Loom Process—Warp / Weft Process

[0058] FIG. 5 illustrates an example schematic of a loom weaving assembly 50. In the example, Warp Yarn 10 may be placed on yarn packages or bobbins 502 to be fed into the warp feed or shedding 504 of the loom weaving assembly 50. In some embodiments, multiple yarn packages or bobbins 502 of Warp Yarn 10 of the same composition may be supplied to warp feed or shedding 504. In another example, yarn packages or bobbins 502 feeding into warp feed or shedding 504 may contain yarns of varying compositions, coverings having varied twists per inch, or of different core and covering components as disclosed and described, above. In some embodiments, yarn packages 502 containing Warp Yarn 10 may be unspooled and fed onto a beam 503 in a beaming process. Adding yarn packages 502 to beam 503 may ensure that all individual Warp Yarn 10 ends are fed into shedding 504 at the same or similar rate. In the example illustrated in FIG. 5, Weft Yarn 20 may be placed on a yarn package or bobbin 506 which may feed into a weft feed or nozzle 508. In some embodiments, loom weaving assembly 50 may be an air loom weaving assembly and nozzle 508 may be an air nozzle which feeds Weft Yarn 20 though shedding 504 using pressurized air. In another example, loom weaving assembly 50 may be a standard loom weaving assembly and Weft Yarn 20 may be fed through shedding 504 using a shuttle or projectile. In the example illustrated in FIG. 5, loom weaving assembly 50 is an air loom weaving assembly and Weft Yarn 20 is fed through nozzle 508, such that pressurized air forces Weft Yarn 20 through shedding 504. In the example, a series of profile reeds 510 may arrange shedding 504 such that Weft Yarn 20 passes through a plurality of warp yarn feeds or shedding 504 in a pattern of Weft Yarn 20 crossing over some feeds of Warp Yarn 10 and crossing under other feeds of Warp Yarn 10.

[0059] FIGS. 6A-6B illustrate example patterns of Weft Yarn 20 crossing over and under Warp Yarn 10. In the example loom weaving pattern illustrated in FIGS. 6A-6B, Weft Yarn 20 crosses under Warp Yarn 10 for three consecutive feeds of Warp Yarn 10, and crosses over Warp Yarn 10 on every fourth feed. This is accomplished by adjusting individual profile reeds 510, as illustrated in FIG. 5, to move a feed of Warp Yarn 10 either below or above Weft Yarn 20 for a particular pass of Weft Yarn 20 through shedding 504.

[0060] In the example patterns illustrated in FIGS. 6A-6B, the pattern 60 may be accomplished by moving an individual profile reed 510 and thus Warp Yarn 10 below Weft Yarn 20 for three consecutive passes, and then moving Warp Yarn 10 above Weft Yarn 20 on a fourth consecutive pass. Each profile reed 510 in a series of profile reeds along a direction of travel of Weft Yarn 20 may move Warp Yarn 10 above Weft Yarn 20 in a pass that is immediately prior to or immediately subsequent to the profile reed 510 next to it. This creates a pattern where the passes of Warp Yarn 10 over Weft Yarn 20 appear in a visible diagonal pattern, spaced three stiches apart from the next diagonally visible pattern of Warp Yarn 10. As shown in FIG. 6A, the diagonal pattern forms a right-hand twill, where the diagonal lines run from upper right to lower left. As shown in FIG. 6B, the diagonal pattern forms a left-hand twill, where the diagonal lines run from upper left to lower right.

[0061] It will be apparent that the weave pattern of the denim construction may be altered, changed, or adjusted (for example, changing to a two-by-one right-handed twill, a two-by-two right-handed twill, a four-by-one right-handed twill, using left-handed twill instead of right-handed twill, etc.). Changing the pattern of the twill will change the number or amount of Warp Yarn 10 and Weft Yarn 20 used in the construction of the denim textile, and therefore may change the resulting denim textile's performance in cut resistance or other durability tests. Changing the pattern of the twill may also change the touch or feel, resulting weight or density, shrinkage after wash, and other physical properties of the resulting denim textile.

[0062] In some embodiments, a denim material may be made with Warp Yarn 10 and Weft Yarn 20 as disclosed and described, above. In the example shown in FIG. 6A, the Warp Yarn 10 and Weft Yarn 20 may be woven together in a loom in a three-by-one left-handed twill pattern, using a weaving process as disclosed and described above. In some embodiments, the denim material produced from Warp Yarn 10 and Weft Yarn 20 in the three-by-one left-handed twill pattern according to the materials and methods disclosed may have a before washing weight of about 11.8 ounces per square yard and may have an after washing weight of about 13.3 ounces per square yard.

[0063] In another example using the stretch version of the Weft Yarn 20 including stretch polyester and spandex fibers, the before washing weight may be approximately 12.5 ounces per square yard and the after washing weight may be approximately 14 ounces per square yard. The additional weight may be attributed to the stretch polyester and spandex fibers in the weft yarn core, as well as the increased shrinkage and densification of the fabric structure that results from the stretch fibers collapsing the fabric during the manufacturing pre-wash process.

[0064] The denim produced according to the materials and methods described above may have a shrinkage after washing of about 13 percent in the warp direction and eight percent in the weft direction. The denim produced according to the materials and methods described above may have a cut resistance of at least ANSI Level 6. Very high abrasion resistance can be maintained with this construction. At a minimum the denim material of the construction disclosed can achieve a satisfactory score for abrasion resistance after testing per ASTM D3886. The denim material may achieve a pilling resistance score of 3.5 out of 5.0 score using ASTM method ASTM D4970. The material may also achieve a snagging resistance score of 3.5 minimum out of 5.0 score using ASTM method ASTM D3939. The denim produced from the materials and methods disclosed may achieve very high tensile and tear strength rating as tested against ASTM D5034 for tensile strength and ASTM D1424 for tear strength.

[0065] The foregoing disclosure describes systems and methods for manufacturing a fabric or textile to be used in personal protective equipment. However, as will be appreciated by those skilled in the art, the systems and methods of the present disclosure may be applicable to other textile manufacturing processes (e.g., fabrics or textiles for improved composite qualities). In an example, the yarns disclosed in this application may be utilized for other woven constructions and weights such as khaki and twill textiles used to make top and / or bottom garments (e.g., shirts, shorts, pants, gloves, jackets). The yarns and materials disclosed in this application can also be used to make lighter weight woven garments of all types (e.g., button up work shirts, khaki work pants, etc.) The yarns disclosed in this application may also be utilized in knitting configurations to make knitted garments. Thus, various embodiments as described herein provide a method for creating composite textiles or fabric exhibiting multiple beneficial characteristics.

[0066] Among those benefits and improvements that have been disclosed, other objects and advantages will become apparent from the description taken in conjunction with the accompanying figures. The figures constitute a part of this specification, include illustrative embodiments of the present disclosure, and illustrate various objects and features thereof. Any measurements, specifications and the like disclosed herein are intended to be illustrative, and not restrictive. Thus, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art. While various embodiments of the new technology described herein have been described in detail, modifications and adaptations of the embodiments will occur to those skilled in the art and remain within the spirit and scope of the presently disclosed technology.

[0067] In addition, as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the term “and / or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,”“an,” and “the” include plural references, unless the context clearly dictates otherwise. The meaning of “in” includes “in” and “on,” unless the context clearly dictates otherwise.

Examples

Embodiment Construction

[0022]Reference will now be made in detail to examples of yarns and textiles for cut resistant denim, which are illustrated in the accompanying drawings. While the present disclosure includes descriptions of certain examples, it is understood that they are not intended to limit the coverage of this disclosure. On the contrary, this disclosure is intended to cover alternatives, modifications, and equivalents. Furthermore, in this disclosure, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments. However, it is understood that such embodiments may be practiced without these specific details. In other instances, well known methods, procedures, and components have not been described in detail so as not to unnecessarily obscure aspects of the disclosed embodiments.

[0023]Generally speaking, various embodiments provide for a denim textile for use in clothing and a method to produce denim textiles that are thinner, lighter, and more ...

Claims

1. A textile for use in making protective garments comprising:a first composite yarn comprising:a first core yarn comprising nylon filaments;a first covering yarn comprising ultra-high molecular weight polyethylene; anda second covering yarn comprising nylon filaments; anda second composite yarn comprising:a second core yarn comprising a blend of cotton, polyester and rayon fibers;a third covering yarn comprising ultra-high molecular weight polyethylene; anda fourth covering yarn comprising nylon filaments.

2. The textile of claim 1, wherein the nylon filaments of the first core yarn comprise one or more ply strands of 72 filament, 140 Denier nylon, wherein the one or more ply strands are selected from 1-ply, 2-ply, 3-ply, or 4-ply.

3. The textile of claim 1, wherein the ultra-high molecular weight polyethylene of the first covering yarn comprises 200 filaments of 400 Denier ultra-high molecular weight polyethylene.

4. The textile of claim 1, wherein the nylon filaments of the second covering yarn further comprise one or more ply strands of 72 filament, 140 Denier nylon, wherein the one or more ply strands are selected from 1-ply, 2-ply, 3-ply, or 4-ply.

5. The textile of claim 1, wherein the blend of cotton, polyester and rayon fibers of the second core yarn comprises approximately 1-20% rayon, approximately 15-20% polyester, and approximately 60-80% cotton.

6. The textile of claim 1, wherein the ultra-high molecular weight polyethylene of the third covering yarn comprises 200 filaments of 400 Denier ultra-high molecular weight polyethylene.

7. The textile of claim 1, wherein the nylon filaments of the fourth covering yarn further comprise one or more ply strands of 72 filament, 140 Denier nylon, wherein the one or more ply strands are selected from 1-ply, 2-ply, 3-ply, or 4-ply.

8. The textile of claim 1, wherein the first composite yarn and the second composite yarn are woven in a three by one left-hand twill configuration.

9. The textile of claim 1, wherein the textile is formed as any one or more of a pair of pants, a jacket, a shirt, or a glove.

10. The textile of claim 1, wherein the ultra-high molecular weight polyethylene does not protrude through a surface of the textile after washing the textile.

11. The textile of claim 1, wherein the textile achieves a level of cut resistance that is equivalent to at least ANSI Level A4 cut resistance.

12. The textile of claim 1, wherein the second core yarn further comprises one or more stretch fibers, wherein the blend of cotton, polyester and rayon fibers wraps around the stretch fibers by a ring spinning process.

13. A method for producing a textile comprising:manufacturing a first composite yarn comprising:a first core yarn comprising nylon filaments;a first covering yarn comprising ultra-high molecular weight polyethylene; anda second covering yarn comprising nylon filaments;manufacturing a second composite yarn comprising:a second core yarn comprising a blend of cotton, polyester and rayon fibers;a third covering yarn comprising ultra-high molecular weight polyethylene; anda fourth covering yarn comprising nylon filaments; andweaving the first composite yarn and the second composite yarn into the textile.

14. The method of claim 13, wherein the textile has a three by one left-hand twill configuration.

15. The method of claim 13, further comprising forming the textile as any one or more of a pair of pants, a jacket, a shirt, or a glove.

16. The method of claim 13, wherein the ultra-high molecular weight polyethylene does not protrude through a surface of the textile after washing the textile.

17. The method of claim 13, wherein the textile achieves a level of cut resistance that is equivalent to at least ANSI Level A4 cut resistance.

18. The method of claim 13, wherein the second core yarn further comprises one or more stretch fibers, wherein the blend of cotton, polyester and rayon fibers wraps around the stretch fibers by a ring spinning process.

19. A method for producing protective garments comprising:providing a textile comprising a first composite yarn and a second composite yarn, wherein:the first composite yarn includes (1) a first core yarn comprising nylon filaments, (2) a first covering yarn comprising ultra-high molecular weight polyethylene, and (3) a second covering yarn comprising nylon filaments, andthe second composite yarn includes (1) a second core yarn comprising a spun blend of cotton, polyester and rayon fibers, (2) a third covering yarn comprising ultra-high molecular weight polyethylene, and (3) a fourth covering yarn comprising nylon filaments; andconstructing a garment from the textile.

20. The method of claim 19, further comprising washing the textile thereby pre-shrinking the textile, wherein the ultra-high molecular weight polyethylene does not protrude through a surface of the textile after pre-shrinking.

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