Hollow synthetic fiber and materials and articles comprising same

Abstract

Described is a material that includes a plurality of warp yarns and a weft yarn woven through the plurality of warp yarns. The weft yarn includes at least one synthetic fiber having a hollow structure. The hollow structure can have a delta cross-sectional outer profile. The material can be used as a secondary backing for a carpet.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 63 / 486,081, filed Feb. 21, 2023, the entirety of which is hereby incorporated by reference herein.FIELD

[0002] This disclosure is directed to hollow synthetic fibers, products comprising hollow synthetic fibers, and methods for forming hollow synthetic fibers and products comprising hollow synthetic fibers.BACKGROUND

[0003] Conventionally, textiles such as carpet are formed from synthetic fibers having solid (not hollow) fibers. For example, carpet can comprise a primary backing having face fibers tufted therethrough, and a secondary backing can be coupled to the primary backing. The secondary backing of conventional carpet includes only solid synthetic fibers.

[0004] It is desirable to reduce the amount of polymer in carpet in order to reduce manufacturing costs as well as to reduce the carbon footprint of the carpet. Accordingly, there is a need for synthetic fibers and materials made from the synthetic fibers that can be used in carpets that have a reduced amount of material, such as polymer, to reduce cost and resources. Such synthetic fibers, materials, and methods are disclosed herein.SUMMARY

[0005] Disclosed herein, is a material comprising a plurality of warp yarns and a weft yarn woven through the plurality of warp yarns. The weft yarn comprises at least one synthetic fiber having a hollow structure.

[0006] Also disclosed is an article comprises a primary backing defining a first surface and a second surface. A plurality of face fibers are associated with the primary backing and extend from the first surface of the primary backing along a first axis. A secondary backing is coupled to the second surface of the primary backing. The secondary backing comprises a material comprising a plurality of warp yarns and a weft yarn woven through the plurality of warp yarns. The weft yarn comprises at least one synthetic fiber having a hollow structure.

[0007] Also disclosed herein is a method of producing a textured yarn comprising the step of texturizing, with an air texturizer, a core yarn and an effect yarn. The core yarn and the effect yarn each comprise at least one synthetic fiber having a hollow structure.

[0008] Also disclosed herein is a method comprising weaving, through a plurality of warp yarns, a weft yarn comprising at least one synthetic fiber having a hollow structure.

[0009] Additional advantages of the disclosed system and method will be set forth in part in the description which follows, and in part will be understood from the description, or may be learned by practice of the disclosed system and method. The advantages of the disclosed system and method will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a schematic diagram of a woven material as disclosed herein.

[0011] FIG. 2 is an end view of synthetic fibers having hollow structures as disclosed herein, showing cross sectional profiles of the synthetic fibers.

[0012] FIG. 3 is a schematic cross section of a synthetic fiber having a hollow structure as disclosed herein.

[0013] FIG. 4 is a schematic drawing of an exemplary carpet in accordance with embodiments disclosed herein.

[0014] FIG. 5 is an end view of a die for forming synthetic fibers having hollow structures as disclosed herein.

[0015] FIG. 6 is a close-up view of a set of cutouts of the die of FIG. 5 that form a synthetic fiber having a hollow structure as disclosed herein.

[0016] FIG. 7 is a partial end view of a portion of the die of FIG. 5.DETAILED DESCRIPTION

[0017] The disclosed system and method may be understood more readily by reference to the following detailed description of particular embodiments and the examples included therein and to the Figures and their previous and following description.

[0018] It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present disclosure which will be limited only by the appended claims.

[0019] It must be noted that as used herein and in the appended claims, the singular forms “a,”“an,” and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a synthetic fiber” can include one or more of such synthetic fibers, and so forth,

[0020] “Optional” or “optionally” means that the subsequently described event, circumstance, or material may or may not occur or be present, and that the description includes instances where the event, circumstance, or material occurs or is present and instances where it does not occur or is not present.

[0021] Ranges may be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, also specifically contemplated and considered disclosed is the range from the one particular value and / or to the other particular value unless the context specifically indicates otherwise. Similarly, when values are expressed as approximations by use of the antecedent “about,” it will be understood that the particular value forms another, specifically contemplated embodiment that should be considered disclosed unless the context specifically indicates otherwise. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint unless the context specifically indicates otherwise. Finally, it should be understood that all of the individual values and sub-ranges of values contained within an explicitly disclosed range are also specifically contemplated and should be considered disclosed unless the context specifically indicates otherwise. The foregoing applies regardless of whether in particular cases some or all of these embodiments are explicitly disclosed.

[0022] Optionally, in some aspects, when values are approximated by use of the antecedents “about,”“substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.

[0023] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed apparatus, system, and method belong. Although any apparatus, systems, and methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present apparatus, system, and method, the particularly useful methods, devices, systems, and materials are as described.

[0024] Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. In particular, in methods stated as comprising one or more steps or operations it is specifically contemplated that each step comprises what is listed (unless that step includes a limiting term such as “consisting of”), meaning that each step is not intended to exclude, for example, other additives, components, integers or steps that are not listed in the step.

[0025] It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification. Thus, words denoting order, such as “first” or “next,” should be interpreted as optional aspects unless plain meaning or logic dictates otherwise.

[0026] As used herein, the term “denier” refers to the weight in grams of 9,000 meters of yarn. “Denier per filament” refers to the denier (weight in grams of 9,000 meters) of a single filament of a yarn. When the yarn consists of a single end yarn, the “total denier” of the yarn can refer to the combined denier (i.e., the sum of the respective deniers) of all filaments of the single end yarn. When the yarn includes a plurality of yarn ends (a plurality of single end yarns) that are entangled or otherwise commingled with one another such that the yarn ends are no longer individually or independently moveable, then the “total denier” of the yarn can refer to the combined denier (i.e., the sum of the respective deniers) of the plurality of yarn ends (the plurality of single end yarns that define the multiple end yarn).

[0027] As used herein, the term “polymer,” such as used in “polymer flow” or “main polymer supply” or “polymer product,” can comprise any suitable polymer such as, for example, a polyamide, a polyester, polylactic acid, polyurethane, polyvinyl chloride, polyolefin, acrylonitrile butadiene styrene, polystyrene, biopolymers, or a combination thereof. The polymer disclosed herein can be used to make the synthetic fiber disclosed herein.

[0028] The term “polyamide,” as utilized herein, is defined to be any long-chain polymer in which the linking functional groups are amide (—CO—NH—) linkages. The term polyamide is further defined to include copolymers, terpolymers and the like as well as homopolymers and also includes blends of two or more polyamides. In one example, the polyamide can comprise one or more of nylon 6, nylon 66, nylon 10, nylon 612, nylon 12, nylon 11, or any combination thereof. In another example, the polyamide can comprise nylon 6 or nylon 66. In yet another example, the polyamide is nylon 6. In a yet further example, the polyamide is nylon 66.

[0029] As defined herein, the term “polyolefin” refers to any class of polymers produced from a simple olefin (also called an alkene with the general formula CnH2n) as a monomer. The polyolefin can comprise, for example, polyethylene, polypropylene, both homopolymer and / or copolymers, poly(1-butene), poly(3-methyl-1-butene), or poly(4-methyl-1-pentene) and the like, as well as combinations or mixtures of two or more of the foregoing. In one example, the polyolefin can comprise polyethylene or polypropylene. In another example, the polyolefin can comprise polyethylene. In yet another example, the polyolefin can comprise polypropylene.

[0030] As used herein, the term “polyester” refers to a category of polymers that contain the ester functional group in their main chain. Polyesters disclosed herein include naturally occurring chemicals, such as in the cutin of plant cuticles, as well as synthetics produced through step-growth polymerization. An non-limiting example of polyesters includes any long-chain synthetic polymer composed of at least 85% by weight of an ester of a substituted aromatic dicarboxylic acid, including but not restricted to substituted terephthalic units, p(—R—O—C—C6H4—CO—O—)x and parasubstituted hydroxy-benzoate units, p(—R—O—CO—C6H4—O)x. In certain examples, the polyesters comprise polyethylene terephthalate (PET) homopolymer and copolymers, polypropylene terephthalate (PPT) homopolymer and copolymers and polybutylene terephthalate (PBT) homopolymer and copolymers, and the like, including those that contain comonomers such as cyclohexanedimethanol, cyclohexanedicarboxylic acid, isophthalic acid, and the like.

[0031] As defined herein, the term “polyurethane” refers to any class of polymers composed of a chain of organic units joined by carbamate (urethane, R1—O—CO—NR2—R3, wherein R1, R2, and R3 are the same or different) links.

[0032] As defined herein, the term “polystyrene” refers to any class of synthetic polymers produced from a simple styrene as a monomer. It is understood that the term “polystyrene” includes isotactic, atactic, and syndiotactic polystyrenes. In some specific aspects, described are also co-polystyrenes including a high-impact polystyrenes (HIPS), acrylonitrile butadiene styrene (ABS) or copolymer of styrene with acrylonitrile (SAN), or copolymer of styrene with maleic acid (SMA).Material with Weft Yarn Comprising Synthetic Fiber with Hollow Structure

[0033] Referring to FIGS. 1-2, disclosed herein is a material 10 that comprises a plurality of warp yarns 12 and a weft yarn 14 woven through the plurality of warp yarns. The weft yarn 12 comprises at least one synthetic fiber 20 having a hollow structure.

[0034] In some aspects, the weft yarn can comprise a plurality of synthetic fibers 20 having a hollow structure. For example, in some aspects, at least 25% of the fibers of the weft yarn can be synthetic fibers 20 having a hollow structure. In some aspects, at least 50% of the fibers of the weft yarn can be synthetic fibers 20 having a hollow structure. In some aspects, at least 75%, at least 80%, at least 85, or at least 90% of the fibers of the weft yarn can be synthetic fibers 20 having a hollow structure. In some aspects, from about 25% to about 95% of the fibers of the weft yarn can be synthetic fibers 20 having a hollow structure. For example, from about 50% to about 95% of the fibers of the weft yarn can be synthetic fibers 20 having a hollow structure. In another example, from about 25% to about 75% of the fibers of the weft yarn can be synthetic fibers 20 having a hollow structure. In further aspects, substantially all of the fibers of the weft yarn can be synthetic fibers 20 having a hollow structure. In further aspects, all fibers of the plurality of synthetic fibers of the weft yarn 14 can have a hollow structure. In other aspects, only a portion of the plurality of synthetic fibers of the weft yarn 14 have a hollow structure. For example, some fibers of the synthetic plurality of fibers of the weft yarn 14 can have a solid (i.e., non-hollow) structure, and other fibers of the synthetic plurality of fibers can have a hollow structure. For example, from about 25% to about 99% of the fibers of the weft yarn can be synthetic fibers 20 having a hollow structure and from about 75% to about 1% can be solid (non-hollow) fibers.

[0035] In some aspects, the weft yarn 14 can be continuous filament yarn. As used herein, a “continuous filament yarn” can be understood as a yarn comprising at least one continuous filament. In these aspects, the at least one synthetic fiber of the weft yarn is a continuous filament. This can contrast to staple fibers that are spun together, which are conventionally under 10 cm in length (e.g., 3.80 cm-long, 4.80 cm-long, or 5.10-cm-long). The continuous filaments can be textured or crimped. The texturing and crimping can add bulk and can be used to mimic spun staple fibers. In one aspect, the continuous filament yarn can have a length of at least 25 cm, 50 cm, 100 cm, 250 cm, 500 cm, 1,000 cm, 5,000 cm, or 10,000 cm.

[0036] Referring also to FIG. 3, in some aspects, the one or plurality of synthetic fibers 20 having a hollow structure can have a delta cross-sectional outer profile. The delta cross sectional profile can have, in cross section, an outer perimeter, with the outer perimeter having three regions that are spaced from a centroid of the outer perimeter relative to the other regions of the outer perimeter. The three regions can be circumferentially (peripherally) spaced from each other around the outer perimeter. In some aspects, the three regions that are spaced from the centroid of the outer perimeter relative to the other regions of the outer perimeter can be equally circumferentially (peripherally) spaced, or generally equally circumferentially (peripherally) spaced, from each other. In other aspects, the three regions that are spaced from the centroid of the outer perimeter relative to the other regions of the outer perimeter can be unevenly circumferentially (peripherally) spaced from each other.

[0037] It is contemplated that the delta cross-sectional outer profile can provide advantageous bulking effects. For example, the delta cross-sectional outer profile can inhibit nesting of fibers, thereby providing a bulkier yarn.

[0038] In some aspects, the delta cross-sectional outer profile can comprise three generally flat sides 30 and rounded corners 32 coupling (extending between) adjacent sides of the three generally flat sides. In some aspects, the rounded corners 32 can have constant radii. In other aspects, the rounded corners 32 can have variable radii.

[0039] Although embodiments disclosed herein show a delta cross-sectional profile, it is further contemplated that the synthetic fiber having a hollow structure can have other cross sectional profiles, such as, for example, a circular, oval, or other round outer perimeter, a square or rectangular outer perimeters, a pentagonal or hexagonal outer perimeter, a star-shaped outer perimeter, or any suitable outer perimeter.

[0040] In some aspects, the hollow structure can comprise, in cross section, a continuous outer perimeter 34 and a continuous inner perimeter 36 defining a polymer region therebetween 38. The continuous inner perimeter can surround a void space 40. The void space 40 can extend along the length of the synthetic fiber to create the hollow structure. That is, the void space of the cross section, when projected along an axis of elongation of the synthetic fiber, can form a longitudinal interior channel, as further disclosed herein, that extends through at least a part of the length or the entire length of the synthetic fiber. In some aspects, the void space can extend through the synthetic fiber along the entire length of the synthetic fiber. In other aspects, the void space can extend through the synthetic fiber along only a portion of a length of the synthetic fiber. For example, there can be multiple longitudinal interior channels in the synthetic fiber, wherein the longitudinal interior channels are separated by solid material, such as polymer. Such an arrangement can be caused by defects in manufacturing or by intentionally separating longitudinal interior channels. In another example, the longitudinal interior channel can extend through the synthetic fiber along substantially the entire length or the entire length of the synthetic fiber.

[0041] The continuous inner perimeter 36 defines a first area 42, and the continuous outer perimeter 34 defines a second area 44. In some aspects, a ratio of the first area 42 to the second area 44 is at least 0.05. Accordingly, the void fraction of the synthetic fiber 20 can be at least 5%. For example, in some aspects, the ratio of the first area 42 to the second area 44 can be from 0.1 to 0.2. Accordingly, the void fraction of the synthetic fiber 20 can be from about 10% to about 20%. In some aspects, the ratio of the first area 42 to the second area 44 can be from 0.1 to 0.15. Accordingly, the void fraction of the synthetic fiber can be from about 10% to about 25%. In some aspects, the ratio of the first area 42 to the second area 44 can be about 12%. Accordingly, the void fraction of the synthetic fiber 20 can be about 12%.

[0042] In some optional aspects, the continuous inner perimeter 36 has a delta shape. In other aspects, the continuous inner perimeter 36 can be circular or generally circular. In still other aspects, the continuous inner perimeter 36 can have any suitable profile, such as, for example, but not limited to, square or oval or otherwise round.

[0043] It is further contemplated that, in other aspects, the void space 40 can be only partially circumferentially surrounded by the polymer region 38 of the synthetic fiber. For example, in some aspects, the synthetic fiber(s) having the hollow structure can, in cross section, have a C-shaped profile. However, it is contemplated that the void space 40 being entirely circumferentially surrounded by the polymer region 38 can advantageously prevent collapsing of the synthetic fiber.

[0044] In some aspects, the weft yarn 14 can be an air textured weft yarn. For example, the weft yarn can comprise a plurality of core synthetic fibers and a plurality of loop fibers that are air textured together. In some optional aspects, each synthetic fiber of the plurality of core fibers and the plurality of loop synthetic fibers can have a hollow structure. In some aspects, only a portion of the fibers of the core synthetic fibers have a hollow structure. In some aspects, only a portion of the synthetic fibers of the loop synthetic fibers have a hollow structure. In some aspects, some or all of the synthetic fibers of the core fibers have a hollow structure, and none of the loop synthetic fibers have a hollow structure. In some aspects, some or all of the fibers of the loop synthetic fibers have a hollow structure, and none of the core synthetic fibers have a hollow structure. Systems and methods for forming air textured yarns are disclosed in U.S. Pat. No. 4,095,320, granted Jun. 20, 1978, the entirety of which is incorporated by reference herein for its disclosure related to the formation of air textured yarns.

[0045] In some aspects, the weft yarn 14 can have a denier of less than 1000. For example, in some aspects, the weft yarn 14 can have a denier from about 880 to about 960. In other aspects, the weft yarn can have a denier at or below 960. In some aspects, the weft yarn 14 can have a denier from about 800 to about 1000. In some aspects, the weft yarn 14 can have a denier from about 600 to about 1000. In some aspects, the weft yarn 14 can have a denier from about 600 to about 960. In some aspects, the weft yarn 14 can have a denier from about 600 to about 880. In some aspects, the weft yarn 14 can have a denier from about 850 to about 980. It should be understood that, for conventional carpet secondary backing, the weft yarn does not have a denier at or below 1000.

[0046] In some aspects, the material 10 can have a weight of less than 1.5 oz / square yard. In some aspects, the material 10 can have a weight of less than 1.2 oz / square yard. In some aspects, the material 10 can have a weight of from about 1 oz / square yard to about 1.5 oz / square yard. In some aspects, the material 10 can have a weight of from about 1.09 oz / square yard to about 1.19 ounces per square yard. It is contemplated that the material 10 can provide a lower weight than conventional carpet secondary backing.

[0047] In some aspects, the at least one synthetic fiber 20 having a hollow structure can comprise nylon, polyester, polypropylene or polyethylene terephthalate. For example, the at least one synthetic fiber 20 having a hollow structure can comprise nylon. In another example, the at least one synthetic fiber 20 having a hollow structure can comprise polyester. In another example, the at least one synthetic fiber 20 having a hollow structure can comprise polypropylene. In another example, the at least one synthetic fiber 20 having a hollow structure can comprise polyethylene terephthalate.

[0048] In various aspects, the weft yarn 14 can be woven through the plurality of warp 12 yarns in a leno weave. In other aspects, the weft yarn 14 can be woven through the plurality of warp yarns 12 in a plain weave.

[0049] In some optional aspects, the material 10 can comprise a plurality of weft yarns 14. In other aspects, the material 10 can have only a single weft yarn 14.

[0050] In some aspects, the hollow structure can be defined by a polymer shell 50 that surrounds a longitudinal interior channel 52 or a plurality of longitudinally spaced longitudinal interior channels. That is, it is contemplated that the interior channel 52 can extend continuously along an entire length of the synthetic fiber 20. In other aspects, the longitudinal interior channel 52 can extend continuously through substantially an entire length of the hollow structure.

[0051] In other aspects, the hollow structure can be defined by a polymer shell that 50 surrounds a plurality of longitudinally spaced longitudinal interior channels 52. The plurality of longitudinally spaced longitudinal interior channels can cooperatively extend along at least 90% of a length of the hollow structure. In some aspects, the plurality of longitudinally spaced longitudinal interior channels can cooperatively extend along at least 95%, or at least 98%, or at least 99% of a length of the hollow structure. Accordingly, the interior channel need not extend continuously along the entire length of the hollow structure. For example, it is contemplated that the synthetic fiber 20 can comprise portions along its length where the synthetic fiber is not hollow. This can be intentional or due to a manufacturing defect.

[0052] In some aspects, the longitudinal interior channel(s) 52 can be entirely circumferentially surrounded by the polymer shell 50. In other aspects, the longitudinal interior channel(s) 52 can be only partially circumferentially surrounded by the polymer shell. For example, as described herein, in some optional aspects, the hollow structure can have a C-shaped cross section.

[0053] In some aspects, the synthetic fiber(s) 20 can have a denier per filament of about 3.5 to about 20. In further aspects, the synthetic fiber(s) 20 can have a denier per filament of about 3.5 to about 12.

[0054] In some optional aspects, all of the fibers of the warp yarns 12 can be solid (not hollow) fibers.Article Comprising Material with Weft Yarn Comprising Synthetic Fiber with Hollow Structure

[0055] Referring to FIG. 4, an article 100 can comprise a primary backing 104 defining a first surface 120 and an opposed second surface 122. A plurality of face fibers 102 can be associated with the primary backing and can extend from the first surface of the primary backing along a first axis. For example, in some aspects, the plurality of face fibers 102 can be tufted through the primary backing. In other aspects, the face fibers 102 can be knit or woven into the primary backing 103. A secondary backing 112 can be coupled to the second surface of the primary backing. The secondary backing 112 can comprise, or can be, the material 10. Accordingly, the secondary backing 112 can comprise a plurality of warp yarns 12 and a weft yarn 14 woven through the plurality of warp yarns. The weft yarn 12 can comprise at least one synthetic fiber 20 having a hollow structure.

[0056] Optionally, the primary backing 104 can comprise or can be, the material 10 (comprising a plurality of warp yarns 12 and a weft yarn 14 woven through the plurality of warp yarns, the weft yarn 12 comprising at least one synthetic fiber 20 having a hollow structure). In other aspects, the primary backing 104 can be a conventional primary backing material. For example, the primary backing 104 can comprise only solid fibers.

[0057] In some aspects, the article 100 can be carpet, such as a broadloom carpet or carpet tile. In some aspects, the article 100 can be synthetic turf. In some optional aspects, the synthetic turf can comprise single tufts. That is, each tuft can comprise a single yarn. In some aspects, the synthetic turf can comprise double tufts. That is, each yarn can comprise two yarns. In other aspects, the article 100 can serve as ground cover (e.g., for erosion control). In still other aspects, the article 100 can serve as scrim for cementitious board or stucco reinforcement. Optionally, in these aspects, the article 100 can comprise a leno weave.Exemplary Article Structure

[0058] FIG. 4 schematically shows an exemplary aspect of the article 100 disclosed herein. Specifically, FIG. 4 demonstrates an exemplary article carpet tile. A plurality of face fibers 102 are attached to or tufted into a primary backing component 104 and extending from a face surface of the primary backing component. A portion of the plurality of fibers is exposed at a back surface of the primary backing component in the form of back stitches 106. An optional precoat layer 108 is applied to the back surface of the primary backing component and the back stiches. An adhesive composition 110 is further applied to the article. As further disclosed herein, the reinforcement material 111 and the secondary backing 112 are co-laminated to the primary backing component, with a portion of the adhesive composition passing through the reinforcement material 111 to permit contact between the adhesive composition 110 and the secondary backing 112.

[0059] Although one embodiment is shown, it should be understood that embodiments herein can be used with any article comprising face fibers (e.g., various types of carpet, such as carpet having cut face fibers or turf). Still further, it is contemplated that the disclosed material 10 can be used in applications such as water filters (e.g., sediment filtration), upholstery, or mattress ticking (e.g., knitted or woven mattress ticking).Forming the Synthetic Fiber with Hollow Structure

[0060] Referring to FIGS. 5-7, the synthetic fibers 20 can be extruded from a spinneret 200. The spinneret 200 can comprise one or more cutout sets 202 that are configured to form the synthetic fiber 20 having the hollow structure. In some aspects, the cutout sets 202 can comprise a plurality of cutouts 204 that form portions the synthetic fiber 20. For example, each cutout 204 can comprise an opening that forms about one third of the synthetic fiber 20. In some aspects, each opening can comprise a rounded portion 206 and a pair of legs 208 that extend from the rounded portion. The polymer exiting cutouts the spinneret 200 can expand (swell) to contact and bind with polymer exiting other cutouts 204 of the cutout set 202. The rounded portion 206 can generally form the rounded corners 32 of the cross sectional profile, and adjacent legs 208 of two cutouts 204 can cooperate to form the generally flat sides 30 of the cross sectional profile.Forming the Yarn

[0061] Disclosed herein is method of producing a textured yarn comprising texturizing, with an air texturizer, a core yarn and an effect yarn. At least one of the core yarn or the effect yarn comprises at least one synthetic fiber having a hollow structure. Optionally, each of the core yarn and the effect yarn can comprise at least one synthetic fiber having a hollow structure. For example, in some aspects, all of the fibers of the core yarn and the effect yarn can be synthetic fibers having a hollow structure.

[0062] The method can further comprise stretching the yarn after texturing to ensure ideal tension.Forming the Material

[0063] Disclosed herein is a method comprising weaving, through a plurality of warp yarns, a weft yarn comprising at least one synthetic fiber having a hollow structure.Exemplary Aspects

[0064] In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

[0065] Aspect 1: a material comprising:

[0066] a plurality of warp yarns; and

[0067] a weft yarn woven through the plurality of warp yarns, wherein the weft yarn comprises at least one synthetic fiber having a hollow structure.

[0068] Aspect 2: The material of aspect 1, wherein the weft yarn comprises a plurality of synthetic fibers having a hollow structure.

[0069] Aspect 3: The material of aspect 2, wherein all synthetic fibers of the plurality of synthetic fibers of the weft yarn have a hollow structure.

[0070] Aspect 4: The material of any one of the preceding aspects, wherein the weft yarn is continuous filament yarn, wherein the at least one synthetic fiber of the weft yarn is a continuous filament.

[0071] Aspect 5: The material of any one of the preceding aspects, wherein the plurality of synthetic fibers having a hollow structure comprise a delta cross-sectional outer profile.

[0072] Aspect 6: The material of aspect 5, wherein the delta cross-sectional outer profile comprises:

[0073] three generally flat sides; and

[0074] rounded corners extending between adjacent sides of the three generally flat sides.

[0075] Aspect 7: The material of any one of the preceding aspects, wherein the hollow structure comprises, in cross section, a continuous outer perimeter and a continuous inner perimeter defining a polymer region therebetween, wherein the continuous inner perimeter surrounds a void space.

[0076] Aspect 8: The material of aspect 7, wherein the continuous inner perimeter defines a first area, wherein the continuous outer perimeter defines a second area, wherein a ratio of the first area to the second area is at least 0.05.

[0077] Aspect 9: The material of aspect 8, wherein the ratio of the first area to the second area is from 0.1 to 0.15.

[0078] Aspect 10: The material of any one of aspects 6-8, wherein the inner perimeter has a delta shape.

[0079] Aspect 11: The material of any one of the preceding aspects, wherein the weft yarn is an air textured weft yarn.

[0080] Aspect 12: The material of aspect 11, wherein the weft yarn comprises a plurality of core synthetic fibers and a plurality of loop synthetic fibers, wherein each of the plurality of core synthetic fibers and the plurality of loop synthetic fibers have a hollow structure.

[0081] Aspect 13: The material of any one of the preceding aspects, wherein the weft yarn has a denier of less than 1000.

[0082] Aspect 14: The material of aspect 13, wherein the weft yarn has a denier from about 880 to about 960.

[0083] Aspect 15: The material of any one of the preceding aspects, wherein the material has a weight of less than 1.2 oz / square yard.

[0084] Aspect 16: The material of aspect 15, wherein the material has a weight from 1.0 oz / square yard to 1.5 ounces per square yard.

[0085] Aspect 17: The material of any one of the preceding aspects, wherein the at least one synthetic fiber having a hollow structure comprises nylon, polyester, polypropylene or polyethylene terephthalate.

[0086] Aspect 18: The material of any one of the preceding aspects, wherein the weft yarn is woven through the plurality of warp yarns in a leno weave.

[0087] Aspect 19: The material of any one of the preceding aspects, wherein the material comprises a plurality of weft yarns, wherein the plurality of weft yarns comprises the weft yarn.

[0088] Aspect 20: The material of any one of the preceding aspects, wherein the hollow structure is defined by a polymer shell that surrounds a longitudinal interior channel or a plurality of longitudinally spaced longitudinal interior channels.

[0089] Aspect 21: The material of aspect 20, wherein the hollow structure is defined by a polymer shell that surrounds a longitudinal interior channel, wherein the longitudinal interior channel extends continuously through substantially an entire length of the hollow structure.

[0090] Aspect 22: The material of aspect 20, wherein the hollow structure is defined by a polymer shell that surrounds a plurality of longitudinally spaced longitudinal interior channels, wherein the plurality of longitudinally spaced longitudinal interior channels cooperatively extend along at least 90% of a length of the hollow structure.

[0091] Aspect 23: The material of any one of the preceding aspects, wherein the at least one synthetic fiber has a denier per filament of about 3.5 to about 12.

[0092] Aspect 24: an article comprising:

[0093] a primary backing defining a first surface and a second surface;

[0094] a plurality of face fibers associated with the primary backing and extending from the first surface of the primary backing along a first axis; and

[0095] a secondary backing coupled to the second surface of the primary backing, wherein the secondary backing comprises the material as in any one of aspects 1-23.

[0096] Aspect 25: The article of aspect 24, wherein the plurality of face fibers are tufted through the primary backing.

[0097] Aspect 26: The article of aspect 24 or aspect 25, wherein the primary backing comprises the material as in any one of aspects 1-23.

[0098] Aspect 27: A method of producing a textured yarn comprising:

[0099] texturizing, with an air texturizer, a core yarn and an effect yarn, wherein the core yarn and the effect yarn each comprise at least one synthetic fiber having a hollow structure.

[0100] Aspect 28: The method of aspect 27, further comprising stretching the yarn.

[0101] Aspect 29: A method comprising:

[0102] weaving, through a plurality of warp yarns, a weft yarn comprising at least one synthetic fiber having a hollow structure.

[0103] Although several embodiments of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed herein, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.

Claims

1. A material comprising:a plurality of warp yarns; anda weft yarn woven through the plurality of warp yarns, wherein the weft yarn comprises at least one synthetic fiber having a hollow structure.

2. The material of claim 1, wherein the weft yarn comprises a plurality of synthetic fibers having a hollow structure.

3. (canceled)4. The material of claim 1, wherein the weft yarn is continuous filament yarn, wherein the at least one synthetic fiber of the weft yarn is a continuous filament.

5. The material of claim 1, wherein the plurality of synthetic fibers having a hollow structure comprise a delta cross-sectional outer profile.

6. The material of claim 5, wherein the delta cross-sectional outer profile comprises:three generally flat sides; androunded corners extending between adjacent sides of the three generally flat sides.

7. The material of claim 1, wherein the hollow structure comprises, in cross section, a continuous outer perimeter and a continuous inner perimeter defining a polymer region therebetween, wherein the continuous inner perimeter surrounds a void space.

8. The material of claim 7, wherein the continuous inner perimeter defines a first area, wherein the continuous outer perimeter defines a second area, wherein a ratio of the first area to the second area is at least 0.05.

9. The material of claim 8, wherein the ratio of the first area to the second area is from 0.1 to 0.15.

10. The material of claim 6, wherein the continuous inner perimeter has a delta shape.

11. The material of claim 1, wherein the weft yarn is an air textured weft yarn.

12. The material of claim 11, wherein the weft yarn comprises a plurality of core synthetic fibers and a plurality of loop synthetic fibers, wherein each of the plurality of core synthetic fibers and the plurality of loop synthetic fibers have a hollow structure.

13. The material of claim 1, wherein the weft yarn has a denier of less than 1000.

14. (canceled)15. The material of claim 1, wherein the material has a weight of less than 1.2 oz / square yard.

16. (canceled)17. The material of claim 1, wherein the at least one synthetic fiber having a hollow structure comprises nylon, polyester, polypropylene or polyethylene terephthalate.

18. (canceled)19. (canceled)20. The material of claim 1, wherein the hollow structure is defined by a polymer shell that surrounds a longitudinal interior channel or a plurality of longitudinally spaced longitudinal interior channels.

21. The material of claim 20, wherein the hollow structure is defined by a polymer shell that surrounds a longitudinal interior channel, wherein the longitudinal interior channel extends continuously through substantially an entire length of the hollow structure.

22. The material of claim 20, wherein the hollow structure is defined by a polymer shell that surrounds a plurality of longitudinally spaced longitudinal interior channels, wherein the plurality of longitudinally spaced longitudinal interior channels cooperatively extend along at least 90% of a length of the hollow structure.

23. The material of claim 1, wherein the at least one synthetic fiber has a denier per filament of about 3.5 to about 12.

24. An article comprising:a primary backing defining a first surface and a second surface;a plurality of face fibers associated with the primary backing and extending from the first surface of the primary backing along a first axis; anda secondary backing coupled to the second surface of the primary backing, wherein the secondary backing comprises the material as in claim 1.25.-27. (canceled)26. The article of claim 24, wherein the primary backing comprises a material comprising: a plurality of warp yarns; and a weft yarn woven through the plurality of warp yarns, wherein the weft yarn comprises at least one synthetic fiber having a hollow structure.27.-29. (canceled)

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