Combination yarns and fabrics including combination yarns

Abstract

A combination yarn having the ability to provide protection from ultraviolet light while also having good hand feel, colorfastness, moisture management properties, along with sufficiently high tenacity and sufficiently low stretch for use in commercial knitting machines is disclosed, along with fabrics including the combination yarn and methods of making the yarn and fabrics. The combination yarn includes a first yarn and a second yarn. Both the first yarn and the second yarn include fine denier fibers or filaments, such as fibers or filaments having an average liner mass density per fiber or filament of 1 denier per fiber or filament or less. A ratio of the total average denier per filament of the combination yarn divided by the total average weight percent of titanium dioxide in the combination yarn is 0.4 or less.

Description

COMBINATION YARNS AND FABRICS INCLUDING COMBINATION YARNS FIELD

[0001] The present disclosure is directed to yarns, fabrics made using the yarns, and articles incorporating the fabrics, as well as methods of making the yarns, fabrics and articles. BACKGROUND

[0002] The materials used to make the fibers and filaments in yarns typically incorporate additives to introduce properties and characteristics that enhance the value and uses of the yarn. Such additives include compositions that introduce color, such as pigments and dyes, and other properties, including additives to absorb, reflect or scatter ultraviolet (UV) light. With the increased awareness of the importance of providing protection against sun damage and the desire to avoid the use of sunscreens containing potentially toxic chemicals, there is an increased demand for fabrics and articles capable of providing high levels of protection from ultraviolet light, particularly fabrics for articles of apparel. SUMMARY

[0003] There exists a need in the art for yarns, fabrics made from the yarns, and articles such as apparel made from the fabrics that provide high levels of protection from UV light. One approach for increasing the level of UV light protection provided by man-made fibers and filaments is to incorporate UV protective additives when spinning the fibers or filaments. One such additive is titanium dioxide (TiO2). TiO2 is a mineral often added to polymeric compositions from which synthetic polymer fibers and filaments are spun. TiO2 can be added to fibers and filaments for a variety of purposes, including as a white pigment and to dull the luster of polymers, in addition to using it to impart ultraviolet protection factor (UPF) properties.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0004] For a number of reasons, it can be difficult to use high concentrations of TiO2when spinning fibers and filaments under commercial conditions, particularly when spinning fine fibers and filaments (such as fibers or filaments having a linear mass density per filament of about 1 denier per fiber or filament (dpf) or less, including a dpf of 0.6 or less) from a molten polymeric composition. Adding a high concentration of TiO2 to a polymeric composition will significantly increase the viscosity of the polymeric composition, as TiO2 remains solid in the polymeric composition. When manufacturing fibers or filaments by extruding a polymeric composition through spinnerets, the increased viscosity of the polymeric composition increases the pressure required to pass the polymeric composition through the spinnerets. Also, TiO2particles can agglomerate and clog filters and spinnerets, further increasing the pressure needed. In fibers or filaments spun from compositions including TiO2, hard, solid TiO2 particles are suspended in the polymeric composition once it solidifies, and form part of the outer surface of the extruded fiber or filament. Using higher concentrations of TiO2 in the composition results in a lower concentration of polymer being present to hold together the TiO2 particles. Also, the higher the concentration of TiO2in the composition, the greater the density of TiO2particles there will be on the surface of the resulting fiber or filament. The presence of high concentrations of TiO2in yarns, including high densities of TiO2particles on the outer surface, weakens the fibers and filaments and can also abrade the surfaces of the spinning equipment. The use of high concentrations of TiO2 particles in polymeric compositions and the increased density of TiO2 particles on their outer surfaces weaken the fibers and filaments, resulting in the fibers and filaments breaking under lower forces than when lower concentrations of TiO2 are used, making it difficult to spin the fibers, filaments, and yarns at commercially viable speeds and to obtain commercially viable yields. These issues become more pronounced when making and using fine fibers and filaments containing high concentrations of TiO2. As a result, the commercially available yarns with man-made fibers or filaments having high enough concentrations of TiO2to provide high levels of UV protection also have higher than desired deniers per fiber filament. However, these thicker man-made fibers and filaments cannot provide the samePLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 levels of hand feel, drape, and moisture management provided by conventional yarns with lower levels of UV light protection.

[0005] Combination yarns which include a first yarn and a second yarn can provide a good balance of properties as different materials can be used in the first yarn than in the second yarn in order to meet competing requirements. For example, fibers or filaments of a harder, stronger polymeric material may be used in the first yarn to provide good tenacity while fine fibers or yarns of a weaker, softer polymeric material may be used in the second yarn to provide good hand feel. A more hydrophobic polymeric material may be used in the fibers or filaments of the first yarn, and a more hydrophilic polymeric material may be used in the fibers or filaments of the second yarn to make the combination yarn have good moisture management properties and be quick drying. The second yarn may at least partially surround the first yarn, or the first yarn may at least partially surround the second yarn. Additionally or alternatively, fibers or filaments of the first yarn and of the second yarn may be entangled with each other. However, in order to obtain a high level of protection from UV light, it is necessary to use high levels of TiO2 in both the first yarn and in the second yarn. Using thicker fibers or filaments in one of the first yarn and the second yarn with finer filaments in the other yarn may not provide the desired hand feel and drape required for uses such as in apparel. Using fine fibers and filaments containing high concentrations of TiO2present additional problems as due to the fineness of the fibers and filaments, the TiO2 particles occupy sufficiently high percentages of the total surface area and of the total volume of individual fibers or filaments to significantly weaken the fibers or filaments.

[0006] It has been found that, for fine fibers and filaments, by using a ratio of denier per fiber or filament divided by a weight percent of TiO2in the polymeric composition of the fine fibers or filaments in a particular range, it is possible to spin fine fibers and filaments having sufficient tenacity to allow them to be spun into combination yarns under commercially viable conditions. These combination yarns, including combination yarns comprising a multifilament first yarn and a multifilament second yarn using major proportions of fine filaments having this ratio, have sufficiently high tenacitiesPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 making the fibers or filaments and yarns comprising the fibers or filaments suitable for use in commercial yarn spinning and texturizing processes, the yarns have suitably high tenacities making them suitable for use in commercial knitting and weaving processes, and the fabrics knitted or woven from these combination yarns provide high levels of UV light protection while also providing the high levels of hand feel, drape, moisture management, and colorfastness necessary for the fabrics to be suitable for use in a variety of commercial products including in apparel.

[0007] In one aspect, the present disclosure provides a combination yarn comprising a) a first yarn comprising or consisting of first staple fibers or first filaments, the first staple fibers or first filaments having an average linear mass density per fiber or filament of about 1 denier per fiber or filament (dpf) or less, the first fibers or filaments comprising or consisting of a first composition comprising a first thermoplastic polymer and titanium dioxide (TiO2); and b) a second yarn, the second yarn comprising or consisting of a multifilament yarn, the multifilament yarn comprising or consisting of second filaments having an average linear mass density per filament of about 1 dpf or less, the second filaments of the second yarn comprising or consisting of a second composition comprising a second thermoplastic polymer and TiO2; wherein a ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2in the combination yarn is 0.4 or less. In one aspect, the ratio ranges from about 0.25 to about 0.4. In another aspect, the ratio can be 0.33 or less. In another aspect, the ratio ranges from about 0.25 to about 0.33. In another aspect, the ratio is 0.3 or less. In yet another aspect, the ratio ranges from about 0.25 to about 0.3. In one aspect, the second yarn at least partially surrounds the first yarn. In another aspect, the first yarn at least partially surrounds the second yarn. In another aspect, the first yarn and the second yarn have been spun or texturized together into the combination yarn. In yet another aspect, in the combination yarn, fibers or filaments of the first yarn are entangled with filaments of the second yarn. In another aspect, the present disclosure provides a fabric comprising: a knitted or woven fabric including a combination yarn comprising a first yarn and a second yarn; wherein the first yarn comprises or consists of first staple fibers or firstPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 filaments, the first staple fibers or first filaments have an average linear mass density per fiber or filament of about 1 denier per fiber or filament (dpf) or less, and the first fibers or filaments comprise or consist of a first composition comprising a first thermoplastic polymer and TiO2; the second yarn comprises or consists of a second multifilament yarn, the second multifilament yarn comprises or consists of second filaments having an average linear mass density per filament of about 1 dpf or less, and the second filaments of the second yarn comprise or consist of a second composition comprising a second thermoplastic polymer and TiO2; wherein a ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2in the combination yarn is 0.4 or less; and the fabric has an ultraviolet protection factor (UPF) of at least 45 under dry conditions. In one aspect, the second yarn at least partially surrounds the first yarn. In another aspect, the first yarn at least partially surrounds. In another aspect, the first yarn and the second yarn have been spun or texturized together into the combination yarn. In yet another aspect, in the combination yarn, fibers or filaments of the first yarn are entangled with filaments of the second yarn.

[0008] In another aspect, the present disclosure provides a method of manufacturing a combination yarn, the method comprising: a) forming a first yarn by forming a first composition comprising a molten thermoplastic polyester and TiO2; spinning the molten first thermoplastic composition into first filaments having a liner mass density per filament of about 1 dpf or less, wherein the spinning includes extruding the molten first composition through a plurality of spinnerets at a first temperature and winding the extruded first filaments at a first winding speed; and combining the extruded first filaments to form the first yarn; b) forming a second yarn by forming a second composition comprising a molten thermoplastic polyamide and TiO2; spinning the molten second thermoplastic composition into second filaments having a liner mass density per filament of about 1 dpf or less, wherein the spinning includes extruding the molten second composition through a plurality of spinnerets at a second temperature, and winding the extruded second filaments at a second winding speed ranging; and combining the extruded second filaments to form the second yarn; and c) forming the combination yarnPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 by combining the first yarn and the second yarn into the combination yarn; wherein the combination yarn has a ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2in the combination yarn is 0.4 or less. In one aspect, the second yarn at least partially surrounds the first yarn. In another aspect, the first yarn at least partially surrounds. In another aspect, the first yarn and the second yarn have been spun or texturized together into the combination yarn. In yet another aspect, in the combination yarn, fibers or filaments of the first yarn are entangled with filaments of the second yarn. In another aspect, the present disclosure provides a fabric comprising: a knitted or woven construction including a combination yarn, wherein the combination yarn comprises a first yarn and a second; the first yarn is a first spun staple fiber yarn or is a first multifilament yarn, and the first yarn comprises first fibers or first filaments having an average linear mass density per fiber or filament of about 0.6 denier per fiber or filament (dpf) or less, the second yarn is a second multifilament yarn and comprises second filaments having an average linear mass density per filament of about 0.6 dpf or less, the combination yarn has an average ratio of total dpf divided by total weight percent of TiO2 of 0.3 or less; and wherein the fabric has an average ultraviolet protection factor (UPF) of at least 50 under dry conditions and wet conditions. In one aspect, the second yarn at least partially surrounds the first yarn. In another aspect, the first yarn at least partially surrounds the second yarn. In another aspect, the first yarn and the second yarn have been spun or texturized together into the combination yarn. In yet another aspect, in the combination yarn, fibers or filaments of the first yarn are entangled with filaments of the second yarn.

[0009] In another aspect, the present disclosure provides a knitted fabric comprising: a jersey or pique knit construction including a combination yarn and an elasticated yarn, wherein the combination yarn comprises a first yarn and a second yarn; the first yarn is a first multifilament yarn and consists of first filaments having an average linear mass density per filament of about 0.6 denier per fiber or filament (dpf) or less, the first filaments comprising a first composition including polyethylene terephthalate (PET) and TiO2, the second yarn is a second multifilament yarn and consists of second filamentsPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 having an average linear mass density per filament of about 0.6 dpf or less, the second filaments comprising a second composition including nylon 6 and TiO2, the combination yarn is a dyed and reduction cleared yarn having an average ratio of total dpf divided by total weight percent of TiO2 of 0.3 or less; and wherein the fabric has an average ultraviolet protection factor (UPF) of at least 50 under dry conditions and wet conditions. In one aspect, the second yarn at least partially surrounds the first yarn. In another aspect, the first yarn at least partially surrounds the second yarn. In another aspect, the first yarn and the second yarn have been spun or texturized together into the combination yarn. In yet another aspect, in the combination yarn, fibers or filaments of the first yarn are entangled with filaments of the second yarn.

[0010] In another aspect, the disclosure provides a combination yarn having a staple fiber first yarn (i.e., a core yarn) and a second filament yarn in an outer sheath surrounding the staple fiber first yarn. The second filament yarn and the staple fiber first yarn may be dyed. At least one of the first yarn and the second filament yarn contains an ultraviolet (UV) light protection additive. The staple fiber first yarn and the second filament yarn are texturized to improve hand and the level of ultraviolet protection provided by the combination yarn. Also, including UV light protection additives in a yarn may improve the yarn’s resistance to fading and deterioration by UV radiation.

[0011] In another aspect, the disclosure provides a combination yarn having a staple fiber first yarn, with a second filament yarn and an additional filament yarn in an outer sheath surrounding the staple fiber first yarn. At least one of the second filament yarn, the additional filament yarn, and the first staple fiber yarn contains a UV protection additive and may be dyed. In the combination yarn, the second and additional filament yarns and the staple fiber first yarn are texturized to further enhance the level of UV protection provided by the combination yarn.

[0012] In another aspect, the disclosure provides a method of manufacturing the combination yarn. The method includes separately manufacturing a first yarn and at least a second yarn. The first and second yarns may be texturized during formation of the combination yarn, typically by air-jet texturization.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0013] In another aspect, the combination yarn as disclosed herein can be used to manufacture a fabric that has an ultraviolet protection factor (UPF) of at least about 50. The combination yarn exhibits good retention of properties and characteristics including colorfastness while also having the necessary properties for use in commercial knitting and weaving machines.

[0014] Other systems, methods, features and advantages of the disclosure will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the disclosure, and be protected by the following claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The disclosure can be better understood with reference to the following drawings and description. Throughout the drawings, reference numbers may be re-used to indicate correspondence between referenced elements. The drawings are provided to illustrate example aspects described herein and are not intended to limit the scope of the disclosure. Sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes and sizes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility.

[0016] FIG.1 is a representative view of an example aspect of a combination yarn including one yarn surrounded by another yarn;

[0017] FIG.2A is a representative view of an example aspect of manufacturing a combination yarn with one yarn surrounding another yarn;

[0018] FIG.2B is a representative view of an example aspect of manufacturing a combination yarn with two yarns surrounding another yarn;

[0019] FIG.3 is a flowchart of an example aspect of a method for manufacturing a first yarn, a second yarn, and a combination yarn from the first yarn and the second yarn;PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0020] FIG.4 is a schematic view of an example aspect of a yarn manufacturing machine for manufacturing a combination yarn disclosed herein;

[0021] FIG.5 is a flowchart of an example aspect of a method for manufacturing an article using a fabric knit or woven with the combination yarn disclosed herein;

[0022] FIG.6 is a representative view of an example aspect of a woven fabric incorporating at least one combination yarn disclosed herein; and

[0023] FIG. 7 is a representative view of an example aspect of a knit fabric incorporating at least one combination yarn disclosed herein. DETAILED DESCRIPTION

[0024] Yarns are complex materials often used to make fabrics included in many articles. A desirable property of such yarns, fabrics made with the yarns, and articles made with the yarns is to offer protection from ultraviolet (UV) radiation (i.e., UV light), in order to protect articles covered by the fabrics (such as a wearer) as well as the yarns and fabrics themselves from UV light. For example, UV radiation may adversely affect properties and characteristics of yarns in the fabrics and articles. The innate ultraviolet protection factor (UPF) in yarns may be insufficient to resist such changes; it is common to include additives such as titanium dioxide (TiO2) in order to increase their UPF. However, the addition of TiO2 to fibers and filaments of yarns, affects the performance and behavior of fabrics incorporating those yarns and affects their use in various applications, including in apparel and other fabric products.

[0025] Ultraviolet protection factor (UPF) of a fabric is the reciprocal of the percentage of UV radiation that passes through the fabric. Thus, a UPF of 50 means that 1 / 50, or 2 percent, of the UV radiation, passes through a fabric. Similarly, an ultraviolet protection factor of 30 means that approximately 3.3 percent of the UV radiation passes through the fabric.

[0026] Damage or degradation of properties and characteristics of yarns in fabrics and articles reduces the performance of the yarn and the materials and articles made with the yarn. The level of protection from UV light provided by a yarn may bePLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 decreased by chemicals added to the yarn. Reduction of UV protection by additives may reduce the life of the yarn and of textiles and articles made with the yarn. Similarly, there are limits to the concentrations of additives can be added to the fibers and filaments in a yarn. Such limits may be established by adverse effects of the additive or a limit on the ability to incorporate the additive.

[0027] The level of protection of UV light provided by a yarn can be increased by addition of selected compositions to the yarn. These compositions may be incorporated into the yarn during formation of the yarn or may be coated thereon after the yarn is formed.

[0028] It has been found that, for yarns comprising fibers or filaments or both fibers and filaments having an average linear mass density per filament of about 1 denier per fiber or filament (dpf) or less, choosing a concentration of TiO2 to use in the polymeric composition used to extrude the fibers or filaments such that a ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2 in the combination yarn is 0.4 or less results in fibers and filaments which both provide a high level of protection against UV light while also being commercially manufacturable and providing good hand feel and drape in commercially knitted or woven fabrics. In one aspect, the ratio ranges from about 0.25 to about 0.4. In another aspect, the ratio can be 0.33 or less. In another aspect, the ratio ranges from about 0.25 to about 0.33. In another aspect, the ratio is 0.3 or less. In yet another aspect, the ratio ranges from about 0.25 to about 0.3.

[0029] In aspects of the present disclosure, fibers or filaments or both fibers and filaments of the first yarn and of the second yarn have a ratio of total average dpf of the fiber, filament, or yarn divided by total average weight percent of TiO2 in the fiber, filament or combination yarn of 0.4 or less. In one aspect, the ratio of average dpf of the first fibers or filaments divided by total average weight percent of TiO2in the first fibers or filaments is 0.4 or less. In another aspect, the ratio of average dpf of the first yarn divided by average weight percent of TiO2in the first yarn is 0.4 or less. In another aspect, the ratio of average dpf of the second filaments divided by average weight percent of TiO2 in the second filaments is 0.4 or less. In another aspect, the ratio of average dpf of thePLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 second divided by average weight percent of TiO2in the second yarn is 0.4 or less. In another aspect, the ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2in the combination yarn is 0.4 or less. The ratio can range from about 0.25 to about 0.4. The ratio can be 0.33 or less. The ratio can range from about 0.25 to about 0.33. The ratio can be 0.3 or less. The ratio can range from about 0.25 to about 0.3.

[0030] In aspects of the disclosure, the average concentration of titanium dioxide in the combination yarn is greater than about 1.8 weight percent (wt%), or is about 2 wt% or greater. In aspects of the disclosure, increasing the concentration of titanium dioxide in the combination yarn to at least about 1.8 wt%, or to at least 2 wt%, or to from about 1.8 wt% to about 2.3 wt%, can be achieved by adjusting the spinning conditions used to make the fibers and filaments of the first yarn and the second yarn and to make the combination yarn, including speeds and overspeeds used to combine and texturize the combination yarn. Products of the disclosure include fabrics that have high ultraviolet protection factors (UPF), typically a UPF greater than about 45.

[0031] In aspects of the disclosure, the high titanium dioxide concentration also dulls the luster of the yarn. Fibers and filaments of synthetic polymers typically are bright or shiny. However, inclusion of titanium dioxide in accordance with the disclosure dulls the yarn and makes it look more like cotton and has a hand feel like cotton.

[0032] Combination yarns for incorporation into a fabric are described herein. The combination yarns described herein include concentrations of TiO2 effective to provide high UPFs when the combination yarns are used in fabrics while also providing other desirable fabric properties including good hand feel and drape, moisture management, and colorfastness. Fabrics including the combination yarns and articles incorporating the fabrics, including sportswear and other garments, and other articles made using the combination yarns are also described herein. The disclosure also provides methods of manufacturing the combination yarns and methods of manufacturing fabrics which incorporate the combination yarns.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0033] In one aspect, the combination yarn is a wrapped yarn with the second yarn wrapped around the first yarn. In another aspect, the combination yarn is a twisted yarn with the first yarn twisted with the second yarn. In another aspect, the combination yarn is a wrapped yarn with the first yarn wrapped around the second yarn. In another aspect, the combination yarn is a twisted yarn with the second yarn twisted with the first yarn. In another aspect, the combination yarn is an entangled yarn with the first yarn entangled with the second yarn. In another aspect, the combination yarn is an entangled yarn with fibers or filaments of the first yarn entangled with filaments of the second yarn. In yet another aspect, the combination yarn is a single-spun yarn, or is a double-spun yarn, or is a vortex-spun yarn.

[0034] When the first yarn includes staple fibers, using a high concentration of first staple fibers in the first yarn increases the level of UV protection offered by the combination yarn. In one aspect, the first yarn of the combination yarn is a spun staple fiber yarn consisting of a plurality of staple fibers including first staple fibers comprising the first composition. In another aspect, the plurality of staple fibers the first spun staple fiber yarn comprises at least 50 wt% of the first staple fibers. In another aspect, the plurality of staple fibers includes at least 75 wt% of the first staple fibers. In another aspect, the plurality of staple fibers includes at least 90 wt% of the first staple fibers. In another aspect, the plurality of staple fibers includes at least 95 wt% of the first staple fibers. In yet another aspect, the plurality of staple fibers includes consists of the first staple fibers.

[0035] When the first yarn includes filament fibers, using a high concentration of first filaments in the first yarn increases the level of UV protection offered by the first yarn. In one aspect, the first yarn of the combination yarn is a multifilament yarn comprising or consisting of the first filaments. In another aspect, the multifilament yarn comprises at least 50 wt% of the first filaments. In another aspect, the multifilament yarn comprises at least 75 wt% of the first filaments. In another aspect, the multifilament yarn comprises at least 90 wt% of the first filaments. In another aspect, the multifilament yarn comprises at least 95 wt% of the first filaments. In yet another aspect, the multifilament yarn comprises consists of the first filaments.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0036] Using a high concentration of second filaments in the second yarn increases the level of UV protection offered by the second yarn. In one aspect, the second yarn of the combination yarn is a second multifilament yarn comprising or consisting of the second filaments. In another aspect, the second multifilament yarn comprises at least 50 wt% of the second filaments. In another aspect, the second multifilament yarn comprises at least 75 wt% of the second filaments. In another aspect, the second multifilament yarn comprises at least 90 wt% of the second filaments. In another aspect, the second multifilament yarn comprises at least 95 wt% of the second filaments. In yet another aspect, the second multifilament yarn consists of the second filaments.

[0037] In one aspect, the combination yarn includes a first yarn which is a spun staple fiber yarn consisting of a plurality of staple fibers including first staple fibers comprising the first composition. Optionally the plurality of staple fibers the first spun staple fiber yarn consists of the first staple fibers. In another aspect, the combination yarn includes a first yarn which is a multifilament yarn comprising or consisting of the first filaments. Optionally the first yarn is a multifilament yarn consisting of the first filaments. In yet another aspect, the second yarn of the combination yarn is a second multifilament yarn. The second multifilament yarn may consist of the second filaments.

[0038] The first fibers or filaments of the first yarn are fine fibers or filaments having an average linear mass density of about 1 denier per fiber or filament (dpf) or less. In one aspect, an average linear mass density per filament of the first filaments ranges from about 1 dpf to about 0.45 dpf. In another aspect, an average linear mass density per filament of the first filaments is less than 0.75 dpf. In another aspect, an average linear mass density per filament of the first filaments ranges from about 0.75 to about 0.45 dpf. In another aspect, an average linear mass density per filament of the first filaments is less than 0.6 dpf. In another aspect, an average linear mass density per filament of the first filaments ranges from about 0.6 dpf to about 0.45 dpf. In another aspect, an average linear mass density per filament of the first filaments is less than 0.5 dpf. In yet another aspect, an average linear mass density per filament of the first filaments ranges from about 0.5 dpf to about 0.45 dpf.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0039] The second filaments of the second yarn are also fine filaments having an average linear mass density of about 1 denier per fiber or filament (dpf) or less. In one aspect, the average linear mass density per filament of the second filaments ranges from about 1 dpf to about 0.45 dpf. In another aspect, an average linear mass density per filament of the second filaments is less than 0.75 dpf. In another aspect, an average linear mass density per filament of the second filaments ranges from about 0.75 to about 0.45 dpf. In another aspect, an average linear mass density per filament of the second filaments is less than 0.6 dpf. In another aspect, an average linear mass density per filament of the second filaments ranges from about 0.6 dpf to about 0.45 dpf. In another aspect, an average linear mass density per filament of the second filaments is less than 0.5 dpf. In yet another aspect, an average linear mass density per filament of the second filaments ranges from about 0.5 dpf to about 0.45 dpf.

[0040] When the first yarn is a multifilament yarn, using a large number of fine filaments improves the hand feel and drape of the yarn while also providing good UV protection. In the combination yarn disclosed herein, an average number of first filaments in the first yarn can range from about 50 to about 235. In another aspect, the average number of filaments ranges from about 100 to about 200. In another aspect, the average number of filaments ranges from about 125 to about 175. In another aspect, the average number of filaments ranges from about 50 to about 150. In yet another aspect, the average number of filaments ranges from about 75 to about 125.

[0041] In the second yarn which is a multifilament yarn, using a large number of fine filaments improves the hand feel and drape of the yarn while also providing good UV protection. In one aspect, an average number of second filaments in the second yarn ranges from about 50 to about 235. In another aspect, an average number of second filaments in the second yarn ranges from about 100 to about 200. In another aspect, an average number of second filaments in the second yarn ranges from about 125 to about 175. In another aspect, an average number of second filaments in the second yarn ranges from about 50 to about 150. In yet another aspect, an average number of second filaments in the second yarn ranges from about 75 to about 125.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0042] The size of the first yarn also impacts the level of UV protection of the yarn and the hand feel and drape of the yarn. In one aspect, an average linear mass density of the first yarn ranges from about 30 denier (D) to about 200 D. In another aspect, an average linear mass density of the first yarn ranges from about 30 D to about 150 D. In another aspect, an average linear mass density of the first yarn ranges from about 30 D to about 100 D. In yet another aspect, an average linear mass density of the first yarn ranges from about 40 D to about 60 D.

[0043] The size of the second yarn also impacts the level of UV protection of the yarn and the hand feel and drape of the yarn. In one aspect, an average linear mass density of the second yarn ranges from about 30 denier (D) to about 200 D. In another aspect, an average linear mass density of the second yarn ranges from about 30 D to about 150 D. In another aspect, an average linear mass density of the second yarn ranges from about 30 D to about 100 D. In yet another aspect, an average linear mass density of the second yarn ranges from about 40 D to about 60 D.

[0044] The polymers used to make the fibers and filaments can impact the moisture management properties of the combination yarn. Use of more hydrophobic polymers in the first yarn can make the first yarn have a lower moisture regain, resulting in the combination yarn taking up a lower amount of moisture. In one aspect, the first thermoplastic polymer of the first composition comprises or consists of a polyester. In another aspect, when the first thermoplastic composition comprises or consists of a polyester, the polyester comprises or consists of polyethylene terephthalate (PET) or polytrimethylene terephthalate (PTT) or a combination of PET and PTT. In another aspect, when the first thermoplastic polymer comprises or consists of a polyester, the polyester comprises or consists of PET. In yet another aspect, when the first thermoplastic composition comprises or consists of a polyester, the polyester consists of PET.

[0045] Use of more hydrophilic polymers in the second yarn can make the second yarn take up moisture and move it away from the skin of the wearer to evaporate. In one aspect, the second thermoplastic polymer of the second composition comprises or consists of a polyamide. In another aspect, when the second thermoplastic polymerPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 comprises or consists of a polyamide, the polyamide comprises or consists of nylon 6. In yet another aspect, when the second thermoplastic polymer comprises or consists of a polyamide, the polyamide consists of nylon 6.

[0046] A particularly beneficial pair of synthetic polymers to use in the combination yarn are polyesters and polyamides. Using a polyester in the first yarn results in the first yarn having a relatively low moisture regain, while using a polyamide in the second yarn at least partially surrounding the first yarn results in the second yarn taking up moisture from the skin of a wearer and moving it away from the skin of the wearer to evaporate. In one aspect, the first thermoplastic polymer of the first composition comprises or consists of a polyester and the second thermoplastic polymer of the second composition comprises or consists of a polyamide. In another aspect, the first thermoplastic polymer of the first composition comprises or consists of PET and the second thermoplastic polymer of the second composition comprises or consists of nylon 6. In yet another aspect, the first thermoplastic polymer of the first composition consists of PET and the second thermoplastic polymer of the second composition consists of nylon 6.

[0047] Providing relatively high concentrations of TiO2in all the man-made fibers or filaments of the combination yarn increases the level of UV protection provided by the yarn. In one aspect, an average concentration of TiO2in all man-made fibers and filaments of the combination yarn ranges from about 1.8 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2 in all man-made fibers and filaments of the combination yarn ranges from about 1.9 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2 in all man-made fibers and filaments of the combination yarn ranges from about 2.0 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2in all man-made fibers and filaments of the combination yarn ranges from about 2.1 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2in all man-made fibers and filaments of the combination yarn ranges from about 2.1 wt% to about 2.3 wt%.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0048] In one aspect, an average concentration of TiO2in all man-made filaments of the combination yarn ranges from about 1.8 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2in all man-made filaments of the combination yarn ranges from about 1.9 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2 in all man-made filaments of the combination yarn ranges from about 2.0 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2 in all man-made filaments of the combination yarn ranges from about 2.1 wt% to about 2.3 wt%. In yet another aspect, an average concentration of TiO2in all man-made filaments of the combination yarn ranges from about 2.1 wt% to about 2.3 wt%.

[0049] In one aspect, an average concentration of TiO2in the first yarn is at least 1.6 wt%. In another aspect, an average concentration of TiO2in the first yarn is at least 1.8 wt%. In another aspect, an average concentration of TiO2 in the first yarn ranges from about 1.8 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2 in the first yarn is at least 2.0 wt%. In another aspect, an average concentration of TiO2 in the first yarn ranges from about 2.0 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2in the first yarn is at least 2.1 wt%. In one aspect, an average concentration of TiO2in the first yarn ranges from about 2.1 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2in the first yarn is at least 2.3 wt%. A particle size of the TiO2in the first composition can range from about 300 nanometers (nm) to about 500 nm. The TiO2 in the first composition may be anatase TiO2 or rutile TiO2. The TiO2 in the first composition may be rutile TiO2. The first composition may further comprise a dispersing agent to reduce or eliminate agglomeration of TiO2 particles during the spinning of the first yarn. The dispersing agent may be a fatty wax and may have a concentration of less than 0.1 wt% in the first composition.

[0050] As previously discussed, the ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2in the combination yarn has been found to impact the level of protection against UV light along with manufacturability of the yarns and fabrics and the hand feel and drape of the yarns and commercially knitted or woven fabrics. In one aspect, the first yarn has an average ratio of total dpf divided byPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 total weight percent of TiO2of 0.4 or less. In another aspect, the ratio ranges from about 0.4 to about 0.25. In another aspect, the ratio is 0.33 or less. In another aspect, the ratio ranges from about 0.25 to about 0.33. In another aspect, the ratio is 0.3 or less. In another aspect, the ratio ranges from about 0.25 to about 0.3.

[0051] In one aspect, an average concentration of TiO2 in the second yarn is at least 1.6 wt%. In another aspect, an average concentration of TiO2 in the second yarn is at least 1.7 wt%. In another aspect, an average concentration of TiO2 in the second yarn is at least 1.8 wt%. In another aspect, an average concentration of TiO2in the second yarn ranges from about 1.8 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2in the second yarn is at least 2.0 wt%. In another aspect, an average concentration of TiO2in the second yarn ranges from about 2.0 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2 in the second yarn is at least 2.1 wt%. In another aspect, an average concentration of TiO2 in the second yarn ranges from about 2.1 wt% to about 2.3 wt%. In another aspect, an average concentration of TiO2 in the second yarn is at least 2.3 wt%. The particle size of the TiO2 in the second composition can ranges from about 300 nm to about 500 nm. The form of TiO2in the second composition can be anatase TiO2or rutile TiO2. The form of TiO2 in the second composition can be rutile TiO2. The second composition may further comprise a dispersing agent to reduce or eliminate agglomeration of TiO2particles during the spinning of the second yarn. The dispersing agent may be a fatty wax and may have a concentration of less than 0.1 wt% in the second composition.

[0052] In one aspect, the second yarn has an average ratio of total dpf divided by total weight percent of TiO2 of 0.4 or less. In another aspect, the ratio ranges from about 0.4 to about 0.25. In another aspect, the ratio is 0.33 or less. In another aspect, the ratio ranges from about 0.25 to about 0.33. In another aspect, the ratio is 0.3 or less. In yet another aspect, the ratio ranges from about 0.25 to about 0.3.

[0053] The configuration of the combination yarn also impacts the level of UV protection provided along with the hand feel, drape, and also impacts the visual appearance of the combination yarn and of fabrics made from the combination yarn. InPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 one aspect, the combination yarn has an external surface including first regions defined by the first staple fibers or first filaments and second regions defined by the second staple fibers or second filaments. In another aspect, the combination yarn is a texturized multifilament combination yarn. In another aspect, the texturized combination yarn is an air texturized combination yarn. The air texturized combination yarn can have an external surface including first regions defined by air texturized first filaments, second regions defined by air texturized second filaments, and third regions defined by the air texturized first filaments intermingled with the air texturized second filaments. In yet another aspect, the combination yarn is a full dull (FD) yarn or is a fully drawn yarn (FDY) or is a full dull fully drawn yarn (FD FDY).

[0054] By controlling the average ratio of total dpf divided by total weight percent of TiO2 for the fine first fibers and filaments, or the first yarn, or the fine second filaments, or the second yarn, or the combination yarn, or any combination thereof, their tenacities are sufficiently high to use commercial fiber and filament and yarn spinning processes to be used to make the first yarn, the second yarn, and the combination yarn. In yarns, tenacity is a measure of a yarn’s strength relative to its linear density. Additionally, the resulting combination yarn has a sufficiently high tenacity to allow it to be knitted on commercial knitting machines or woven on commercial weaving machines to make the disclosed fabrics. A commonly used standard text method for measuring tenacity is ASTM D2256. In one aspect, the combination yarn has a tenacity ranging from about 15 to about 25 grams force per denier. In another aspect, the combination yarn has a tenacity ranging from about 18 to about 22 grams force per denier. Additionally, in many aspects, the shrinkage of the combination yarn sufficiently low to allow it to be knit or woven on commercial equipment. In one aspect, the combination yarn has a shrinkage ranging from about 4 percent to about 6 percent.

[0055] The first fibers or filaments along with the second filaments of the present disclosure can be dyed in order to impart coloration to the yarns and fabrics. In one aspect the combination yarn is a dyed yarn. A variety of different types of dyes are known in the art. One type of dye which is commonly used to dye polyester and nylonPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 fibers and filaments is disperse dyes. In one aspect, the dyed yarn comprises first fibers or filaments or second filaments or both first fibers or filaments and second filaments dyed with a disperse dye. One issue that can arise when dyeing a large number of fine fibers or filaments is that, due to the large surface created by the large number of fine fibers or filaments, more dye is required as compared to when dyeing thicker fibers or filaments. When dyeing different types of polymers in a single yarn, such as the combination of polyester and polyamides, the different types of polymers may have different affinities for different types of dyes. For example, polyamides have greater affinity for disperse dyes than polyamides; when disperse dyes are used to dye yarns containing both polyamides and polyesters, the disperse dyes may heavily stain the polyamide fibers, which can impact colorfastness of the yarns and fabrics made from the yarns. A variety of processes of clearing dye stains from fibers and filaments are known in the art, including standard alkaline reduction clearing processes. In one aspect, the yarn is a dyed and reduction cleared yarn. One example of a reduction clearing process found to work well for the combination yarns disclosed herein includes applying a composition comprising sodium sulfoxylate formaldehyde and acetic acid to the dyed combination yarn. In another aspect, the combination yarn is a colorfast dyed and reduction cleared yarn. In yet another aspect, the combination yarn maintains colorfastness to water after being laundered 40 times and exposed to 200 AATCC Fading Units of simulated sunlight.

[0056] For some uses, it is desirable to use fibers or filaments having different affinities for dyes, as the difference in the levels of uptake of a dye by the first fibers or filaments as compared to the second filaments can impart a heathered appearance to the combination yarn, and heathered combination yarns can impart a heathered appearance to a fabric made using the heathered combination yarn. In one aspect, the first filaments or staple fibers have a first level of dye uptake, the second filaments have a second level of dye uptake, and a difference between the first level of dye uptake and the second level of dye uptake is effective to impart a heathered appearance to the combination yarn. In another aspect, the combination yarn is dyed yarn with a heathered appearance.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0057] The present disclosure is also directed to fabrics comprising the combination yarns disclosed herein. The use of the combination yarns disclosed herein impart a high ultraviolet light protection factor (UPF) to the fabric along with good hand feel and drape, and moisture management. In one aspect, the fabric is a knitted or woven fabric including a combination yarn comprising a first yarn and a second yarn at least partially surrounding or spun with the first yarn; wherein the first yarn first yarn comprises or consists of first staple fibers or first filaments, the first staple fibers or first filaments have an average linear mass density per fiber or filament of about 1 denier per fiber or filament (dpf) or less, and the first fibers or filaments comprise or consist of a first composition comprising a first thermoplastic polymer and titanium dioxide (TiO2); the second yarn comprises or consists of a second multifilament yarn, the second multifilament yarn comprises or consists of second filaments having an average linear mass density per filament of about 1 dpf or less, and the second filaments of the second yarn comprise or consist of a second composition comprising a second thermoplastic polymer and TiO2; wherein a ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2in the combination yarn is 0.4 or less; and the fabric has an ultraviolet protection factor (UPF) of at least 45 under dry conditions. In one aspect, the fabric has an average UPF of at least 50 under dry conditions. In another aspect, the fabric has an average UPF of greater than 50 under dry conditions. In another aspect, the fabric has an average UPF of at least 55 under dry conditions. In another aspect, the fabric has an average UPF of greater than 55 under dry conditions. In another aspect, the fabric has an average UPF of at least 60 under dry conditions. In another aspect, the fabric has an average UPF of greater than 60 under dry conditions. In another aspect, the fabric has an average UPF of greater than 45 under wet conditions, or of at least 50 under wet conditions, or of greater than 50 under wet conditions, or of at least 55 under wet conditions, or of greater than 55 under wet conditions, or of at least 60 under wet conditions, or of greater than 60 under wet conditions.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0058] In another aspect, the fabric has an average UPF of greater than 45, or of at least 50, or of greater than 50, or of at least 55, or of greater than 55, or of at least 60, or of greater than 60 under dry conditions and under wet conditions.

[0059] In yet another aspect, the combination yarn of the fabric is a combination yarn according to any of the aspects described herein.

[0060] In one aspect, the fabric is a knitted fabric or is a woven fabric. In another aspect, the fabric is a warp knitted fabric or is a weft knitted fabric. In another aspect, the fabric is a knitted fabric and has a jersey knit construction, a pique knit construction, or a rib knit construction. In yet another aspect, the fabric is a knitted fabric and has a jersey knit construction or a pique knit construction.

[0061] In one aspect, the fabric is a woven fabric and the warp yarns or the weft yarns or both the warp yarns and the weft yarns include the combination yarn. In one aspect, the weft yarns include the combination yarn. In another aspect, the combination yarn defines a portion of a face side of the woven fabric or defines a portion of a back side of the woven fabric or defines a portion of the face side of the woven fabric and a portion of the back side of the woven fabric.

[0062] Brushing or sanding one or both sides of the fabric can increase the softness of the fabric while improving dye uptake by the fabric. In one aspect, a face side of the fabric is brushed, or a back side of the fabric is brushed, or both the face side of the fabric and the back side of the fabric are brushed.

[0063] The fabric can further comprise a third yarn. In one aspect, the third yarn is the same as the first yarn of the combination yarn. In another aspect, the third yarn is the same as the second yarn of the combination yarn. In another aspect, the third yarn is an elasticated yarn. The fabric can further comprise one or more elasticated yarns in order to provide stretch to the fabric. In another aspect, the elasticated third yarn comprises or consists of one or more elastane filament. In yet another aspect, the elasticated third yarn consists of a single elastane filament.

[0064] The fabric can comprise a first fabric layer and a second fabric layer, at least one of which comprises a combination yarn as disclosed herein. In one aspect, thePLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 fabric is a two-layer fabric and comprises a connecting yarn connecting a first fabric layer to a second fabric layer. The connecting yarn can have a zig-zag structure connecting the first fabric layer to the second fabric layer. In another aspect, the two-layer fabric comprises a first knitted layer and a second knitted layer connected by the connecting yarn. The connecting yarn can be an elasticated yarn. The elasticated connecting can be a single filament elastane yarn.

[0065] When the fabric is a knit fabric and comprises the third yarn, the third yarn can be plated with the combination yarn in a plated knit construction such that the combination yarn predominates on a face side of the knit fabric or on a back side of the knit fabric or on both the face and back sides of the knit fabric. In one aspect, the plated knit construction is a single jersey plated construction or is a double jersey plated construction or is a tricot warp knit plated construction.

[0066] In one aspect, the fabric is a dyed fabric. In another aspect, the dyed fabric includes a plurality of first fibers or filaments and second filaments dyed with a disperse dye. In another aspect, the dyed fabric includes a plurality of first fibers or filaments and second filaments dyed with a disperse dye and cleared in a reduction clearing process. In another aspect, the dyed fabric has a heathered appearance. In yet another aspect, the fabric maintains colorfastness to water after being laundered 40 times and exposed to 200 AATCC Fading Units of simulated sunlight.

[0067] The present disclosure is also directed to an article comprising the fabric according to any of the aspects described herein. In one aspect, the article is an article of apparel.

[0068] The present disclosure is also directed to methods of manufacturing combination yarns according to any of the aspects disclosed herein. In one aspect, the method is a method comprising: a) forming a first yarn by forming a first composition comprising a molten thermoplastic polyester and TiO2; spinning the molten first thermoplastic composition into first filaments having a liner mass density per filament of about 1 dpf or less, wherein the spinning includes extruding the molten first composition through a plurality of spinnerets at a first temperature and winding the extruded firstPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 filaments at a first winding speed; and combining the extruded first filaments to form the first yarn; b) forming a second yarn by forming a second composition comprising a molten thermoplastic polyamide and TiO2; spinning the molten second thermoplastic composition into second filaments having a liner mass density per filament of about 1 dpf or less, wherein the spinning includes extruding the molten second composition through a plurality of spinnerets at a second temperature, and winding the extruded second filaments at a second winding speed ranging; and combining the extruded second filaments to form the second yarn; and c) forming the combination yarn by surrounding, wrapping, twisting or spinning the first yarn with the second yarn; wherein the combination yarn has a ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2in the combination yarn is 0.4 or less. In one aspect, during the forming the first filaments, the spinning the first filaments comprises spinning the first filaments to have an average linear mass density per filament ranging from about 1 dpf to about 0.45 dpf, or of less than 0.75 dpf, or ranging from about 0.75 to about 0.45 dpf, or of less than 0.6 dpf, or ranging from about 0.6 dpf to about 0.45 dpf, or of less than 0.5 dpf, or ranging from about 0.5 dpf to about 0.45 dpf. In another aspect, combining the first filaments comprises combining an average number of first filaments ranging from about 50 to about 235, or ranging from about 100 to about 200, or ranging from about 125 to about 175, or ranging from about 50 to about 150, or ranging from about 75 to about 150, or ranging from about 75 to about 125, to form the first yarn. In another aspect, the spinning the second filaments comprises spinning the second filaments to have an average linear mass density per filament ranging from about 1 dpf to about 0.45 dpf, or of less than 0.75 dpf, or ranging from about 0.75 to about 0.45 dpf, or of less than 0.6 dpf, or ranging from about 0.6 dpf to about 0.45 dpf, or of less than 0.5 dpf, or ranging from about 0.5 dpf to about 0.45 dpf. In another aspect, combining the second filaments comprises combining an average number of second filaments ranging from about 50 to about 235, or ranging from about 100 to about 200, or ranging from about 125 to about 175, or ranging from about 50 to about 150, or ranging from about 75 to about 150, or ranging from about 75 to about 125, to form the second yarn.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0069] In one aspect, a first thermoplastic polymer of the molten first thermoplastic composition comprises or consists of a polyester. In another aspect, the polyester comprises or consists of PET. In another aspect, the first temperature ranges from about 270 degrees Celsius to about 320 degrees Celsius. In another aspect, the second thermoplastic polymer of the molten second thermoplastic composition comprises or consists of a polyamide. In another aspect, the polyamide comprises or consists of nylon 6 (n6). In another aspect, the second temperature ranges from about 250 degrees Celsius to about 265 degrees Celsius, or from about 255 degrees Celsius to about 260 degrees Celsius.

[0070] In one aspect, during the forming of the first fibers or filaments, the first winding speed ranges from about 4000 meters per minute (m / min) to about 5000 m / min, or from about 4200 m / min to about 4800 m / min, or from about 4400 m / min to about 4600 m / min. In another aspect, during the forming the second filaments, the second winding speed ranges from about 4000 m / min to about 5000 m / min or ranges from about 4200 m / min to about 4800 m / min or ranges from about 4400 m / min to about 4600 m / min.

[0071] In one aspect, the combining the first yarn and the second yarn comprises wrapping the second yarn around the first yarn, or wherein the combining comprises twisting the first yarn with the second yarn. In another aspect, combining the first yarn and the second yarn comprises combining the first staple fibers or filaments and the second filaments in single-spinning process, or comprises combining the first staple fibers or filaments and the second filaments in a double-spinning process, or comprises combining the first staple fibers or filaments and the second filaments in a vortex-spinning process. In another aspect, the method further comprises texturizing the combination yarn. In another aspect, the combining comprises combining the first yarn and the second yarn and texturizing the combined first yarn and second yarn. In another aspect, the step of combining the first yarn with the second yarn comprises air texturizing the first yarn with the second yarn; optionally wherein the combining comprises combining the first yarn at a first overspeed with the second yarn at a second overspeed; optionally wherein the first overspeed ranges from about 5% to about 50% and the second overspeed ranges fromPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 about 5% to about 50%; optionally wherein the first overspeed is less than the second overspeed. In another aspect, texturizing the combination yarn comprises air texturizing the combination yarn; optionally wherein the air texturizing comprises using an air jet texturizer; optionally wherein the air texturizing comprises using a speed ranging from about 300 meters per second (m / sec) to about 550 m / sec or ranging from about 350 m / sec to about 500 m / sec, or ranging from about 400 m / sec to about 450 m / sec for the combination yarn. In yet another aspect, the method comprises air texturizing the combination yarn in an air-jet texturizer; optionally wherein the texturizing is effective to expose regions of the first staple fibers or filaments of the first yarn on an outer surface of the combination yarn, or is effective to intermingle a portion of the first staple fibers or filaments with a portion of the second filaments.

[0072] In one aspect, the method further comprises dyeing the combination yarn. In another aspect, dyeing the combination yarn comprises dyeing the combination yarn with a dye composition comprising or consisting of a disperse dye. In another aspect, the dyeing the combination yarn comprises dyeing the combination yarn after texturizing the combination yarn. In another aspect, the method further comprises applying a reduction clearing process to the dyed combination yarn. In another aspect, the reduction clearing process comprises applying a dye reducing composition to the dyed combination yarn. In another aspect, the dye reducing composition comprises sodium sulfoxylate formaldehyde and acetic acid. In yet another aspect, the reduction clearing process increases colorfastness of the dyed yarn.

[0073] In one aspect, the method of manufacturing the combination yarn comprises manufacturing a combination yarn according to any aspect disclosed herein. In another aspect, the combination yarn is a combination yarn manufactured according any of the methods disclosed herein. In yet another aspect, the fabric is a fabric comprising a combination yarn manufactured according to any of the methods disclosed herein.

[0074] The present disclosure is also directed to methods of manufacturing fabrics. In one aspect, the method of manufacturing a fabric comprises knitting or weavingPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 a combination yarn according to any aspect disclosed herein for form the fabric. The present disclosure is also directed to articles comprising the fabrics disclosed herein. In one aspect, the fabric is a fabric made according to any of the methods disclosed herein. In another aspect, the article is an article of apparel. In another aspect, the article of apparel is configured an upper body of a wearer, or a lower body of a wearer, or both an upper body and a lower body of a wearer. In another aspect, the article of apparel is a shirt, an article of headwear, a coat, a jacket, a pant, underwear, a glove, or a sock. In another aspect, the article is an article of footwear. In yet another aspect, the article is an article of sporting equipment.

[0075] In the above and following description, details are set forth to provide an understanding of the application. In some instances, certain structures, techniques, and methods have not been described or shown in detail in order not to obscure the application. In the context of the present disclosure, various terms are used in accordance with what is understood to be the ordinary meaning of those terms. For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated aspects. It will be understood that each of these directional adjectives may be applied to garments or articles of clothing, as well as individual components of the article of clothing or garment. Directional terms such as “top”, “bottom”, “front”, “back”, “upper”, “lower”, “outer” and “inner” are used in the following description for the purpose of providing relative reference only, and are not intended to suggest any limitations on how any article or garment is to be positioned during use, or to be mounted in an assembly or relative to an environment. The use of the word “a” or “an” when used herein in conjunction with the term “comprising” may mean “one”, but it is also consistent with the meaning of “one or more”, “at least one” and “one or more than one”. Any element expressed in the singular form also encompasses its plural form. Any element expressed in the plural form also encompasses its singular form. The term “plurality” as used herein means more than one, for example, two or more, three or more, four or more, and the like.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0076] While various aspects of the disclosure have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more aspects and implementations are possible that are within the scope of the disclosure. Accordingly, the disclosure is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes can be made within the scope of the attached claims. SELECTED ASPECTS AND CLAIM CONCEPTS

[0077] 1. A combination yarn comprising: a first yarn comprising or consisting of first staple fibers or first filaments, the first staple fibers or first filaments having an average linear mass density per fiber or filament of about 1 denier per fiber or filament (dpf) or less, the first fibers or filaments comprising or consisting of a first composition comprising a first thermoplastic polymer and titanium dioxide (TiO2); and a second yarn combined with the first yarn, the second yarn comprising or consisting of a multifilament yarn, the multifilament yarn comprising or consisting of second filaments having an average linear mass density per filament of about 1 dpf or less, the second filaments of the second yarn comprising or consisting of a second composition comprising a second thermoplastic polymer and TiO2; wherein a ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2 in the combination yarn is 0.4 or less.

[0078] 2. The combination yarn of aspect 1, wherein the ratio ranges from about 0.25 to about 0.4; optionally wherein the ratio is 0.33 or less; optionally wherein the ratio ranges from about 0.25 to about 0.33; optionally wherein the ratio is 0.3 or less; optionally wherein the ratio ranges from about 0.25 to about 0.3.

[0079] 3. The combination yarn of aspect 1 or 2, wherein the combination yarn is a wrapped or twisted yarn with the second yarn at least partially wrapped or twistedPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 around the first yarn, or wherein the combination yarn is a wrapped or twisted yarn with the second yarn at least partially wrapped or twisted around the first yarn.

[0080] 4. The combination yarn of any one of aspects 1 to 3, wherein the combination yarn is a spun yarn including fibers or filaments of the first yarn entangled with filaments of the second yarn; optionally wherein the combination yarn is a single- spun yarn, is a double-spun yarn, or is a vortex-spun yarn.

[0081] 5. The combination yarn of any one of aspects 1 to 4, wherein the first yarn is a spun staple fiber yarn consisting of a plurality of staple fibers including first staple fibers comprising the first composition; optionally wherein the plurality of staple fibers the first spun staple fiber yarn comprises at least 50 wt% of the first staple fibers, or includes at least 75 wt% of the first staple fibers, or includes at least 90 wt% of the first staple fibers, or includes at least 95 wt% of the first staple fibers, or consists of the first staple fibers.

[0082] 6. The combination yarn of any one of aspects 1 to 5, wherein the first yarn is a multifilament yarn comprising or consisting of the first filaments; optionally wherein the multifilament yarn comprises at least 50 wt% of the first filaments, or comprises at least 75 wt% of the first filaments, or comprises at least 90 wt% of the first filaments, or comprises at least 95 wt% of the first filaments, or consists of the first filaments.

[0083] 7. The combination yarn of any one of aspects 1 to 6, wherein the second yarn is a second multifilament yarn comprising or consisting of the second filaments; optionally wherein the second multifilament yarn comprises at least 50 wt% of the second filaments, or comprises at least 75 wt% of the second filaments, or comprises at least 90 wt% of the second filaments, or comprises at least 95 wt% of the second filaments, or consists of the second filaments.

[0084] 8. The combination yarn of any one of aspects 6 or 7, wherein the average linear mass density per filament of the first filaments ranges from about 1 dpf to about 0.45 dpf, or is less than 0.75 dpf, or ranges from about 0.75 to about 0.45 dpf, or isPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 less than 0.6 dpf, or ranges from about 0.6 dpf to about 0.45 dpf, or is less than 0.5 dpf, or ranges from about 0.5 dpf to about 0.45 dpf.

[0085] 9. The combination yarn of any one of aspects 1 to 8, wherein the average linear mass density per filament of the second filaments ranges from about 1 dpf to about 0.45 dpf, or is less than 0.75 dpf, or ranges from about 0.75 to about 0.45 dpf, or is less than 0.6 dpf, or ranges from about 0.6 dpf to about 0.45 dpf, or is less than 0.5 dpf, or ranges from about 0.5 dpf to about 0.45 dpf.

[0086] 10. The combination yarn of any one of aspects 6 to 9, wherein an average number of first filaments in the first yarn ranges from about 50 to about 235, or ranges from about 100 to about 200, or ranges from about 125 to about 175, or ranges from about 50 to about 150, or ranges from about 75 to about 150, or ranges from about 75 to about 125.

[0087] 11. The combination yarn of any one of aspects 1 to 10, wherein an average number of second filaments in the second yarn ranges from about 50 to about 235, or ranges from about 100 to about 200, or ranges from about 125 to about 175, or ranges from about 50 to about 150, or ranges from about 75 to about 150, or ranges from about 75 to about 125.

[0088] 12. The combination yarn of any one of aspects 1 to 11, wherein an average linear mass density of the first yarn ranges from about 30 denier (D) to about 200 D, or ranges from about 30 D to about 150 D, or ranges from about 30 D to about 100 D, or ranges from about 40 D to about 60 D.

[0089] 13. The combination yarn of any one of aspects 1 to 12, wherein an average linear mass density of the second yarn ranges from about 30 denier (D) to about 200 D, or ranges from about 30 D to about 150 D, or ranges from about 30 D to about 100 D, or ranges from about 40 D to about 60 D.

[0090] 14. The combination yarn of any one of aspects 1 to 13, wherein the first thermoplastic polymer comprises or consists of a polyester; optionally wherein the polyester comprises or consists of polyethylene terephthalate (PET) or polytrimethylenePLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 terephthalate (PTT) or a combination of PET and PTT; optionally wherein the polyester comprises or consists of PET.

[0091] 15. The combination yarn of any one of aspects 1 to 14, wherein the second thermoplastic polymer comprises or consists of a polyamide; optionally wherein the polyamide comprises or consists of nylon 6.

[0092] 16. The combination yarn of any one of aspects 1 to 15, wherein the first thermoplastic polymer comprises or consists of a polyester and the second thermoplastic polymer comprises or consists of a polyamide; optionally wherein the first thermoplastic polymer comprises or consists of PET and the second thermoplastic polymer comprises or consists of nylon 6.

[0093] 17. The combination yarn of any one of aspects 1 to 16, wherein an average concentration of TiO2 in all man-made fibers and filaments of the combination yarn ranges from about 1.8 wt% to about 2.3 wt%, or ranges from about 2.0 wt% to about 2.3 wt%, or ranges from about 2.1 wt% to about 2.3 wt%, or is at least 2.3 wt%; optionally wherein an average concentration of the TiO2 in all man-made filaments of the combination yarn ranges from about 1.8 wt% to about 2.3 wt%, or ranges from about 2.0 wt% to about 2.3 wt%, or ranges from about 2.1 wt% to about 2.3 wt%.

[0094] 18. The combination yarn of any one of aspects 1 to 17, wherein an average concentration of TiO2in the first yarn is at least 1.6 wt%, or is at least 1.8 wt%, or ranges from about 1.8 wt% to about 2.3 wt%, or or is at least 2.0 wt%, or ranges from about 2.0 wt% to about 2.3 wt%, or is at least 2.1 wt%, or ranges from about 2.1 wt% to about 2.3 wt%, or is at least 2.3 wt%; optionally wherein a particle size of the TiO2 in the first composition ranges from about 300 nm to about 500 nm; optionally wherein the TiO2 in the first composition is rutile TiO2; optionally wherein the first composition further comprises a dispersing agent; optionally wherein the dispersing agent is a fatty wax and has a concentration of less than 0.1 wt% in the first composition.

[0095] 19. The combination yarn of any one of aspects 1 to 18, wherein the first yarn has an average ratio of total dpf divided by total weight percent of TiO2 of 0.4 or less; optionally wherein the ratio ranges from about 0.4 to about 0.25, or the ratio is 0.33 orPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 less, or the ratio ranges from about 0.25 to about 0.33, or the ratio is 0.3 or less, or ratio ranges from about 0.25 to about 0.3.

[0096] 20. The combination yarn of any one of aspects 1 to 19, wherein an average concentration of TiO2 in the second yarn is at least 1.6 wt%, or is at least 1.7 wt%, or is at least 1.8 wt%, or ranges from about 1.8 wt% to about 2.3 wt%, or or is at least 2.0 wt%, or ranges from about 2.0 wt% to about 2.3 wt%, or is at least 2.1 wt%, or ranges from about 2.1 wt% to about 2.3 wt%, or is at least 2.3 wt%; optionally wherein a particle size of the TiO2in the second composition ranges from about 300 nm to about 500 nm; optionally wherein the TiO2in the second composition is rutile TiO2; optionally wherein the second composition further comprises a dispersing agent; optionally wherein the dispersing agent is a fatty wax and has a concentration of less than 0.1 wt% in the second composition.

[0097] 21. The combination yarn of any one of aspects 1 to 20, wherein the second yarn has an average ratio of total dpf divided by total weight percent of TiO2 of 0.4 or less; optionally wherein the ratio ranges from about 0.4 to about 0.25, or the ratio is 0.33 or less, or the ratio ranges from about 0.25 to about 0.33, or the ratio is 0.3 or less, or ratio ranges from about 0.25 to about 0.3.

[0098] 22. The combination yarn of any one of aspects 1 to 21, wherein the combination yarn has an external surface including first regions defined by the first staple fibers or first filaments and second regions defined by the second staple fibers or second filaments.

[0099] 23. The combination yarn of any one of aspects 1 to 22, wherein the combination yarn is a texturized multifilament combination yarn.

[0100] 24. The combination yarn of aspect 23, wherein the texturized combination yarn is an air texturized combination yarn; optionally wherein the air texturized combination yarn has an external surface including first regions defined by air texturized first filaments, second regions defined by air texturized second filaments, and third regions defined by the air texturized first filaments intermingled with the air texturized second filaments.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0101] 25. The combination yarn of any one of aspects 1 to 24, wherein the combination yarn is a full dull (FD) yarn or is a fully drawn yarn (FDY) or is a full dull fully drawn yarn (FD FDY).

[0102] 26. The combination yarn of any one of aspects 1 to 25, wherein the combination yarn has a tenacity ranging from about 15 to about 25 grams force per denier, or ranging from about 18 to about 22 grams force per denier.

[0103] 27. The combination yarn of any one of aspects 1 to 26, wherein the combination yarn has a shrinkage ranging from about 4 percent to about 6 percent.

[0104] 28. The combination yarn of any one of aspects 1 to 27, wherein the combination yarn is a dyed yarn; optionally wherein the dyed yarn comprises a disperse dye; optionally wherein the dyed yarn is a dyed and reduction cleared yarn.

[0105] 29. The combination yarn of any one of aspects 1 to 28, wherein the first filaments or staple fibers have a first level of dye uptake, the second filaments have a second level of dye uptake, and a difference between the first level of dye uptake and the second level of dye uptake is effective to impart a heathered appearance to the combination yarn; optionally wherein the combination yarn is dyed yarn with a heathered appearance.

[0106] 30. A fabric comprising: a knitted or woven fabric including a combination yarn, the combination yarn comprising a first yarn and a second yarn; wherein the first yarn comprises or consists of first staple fibers or first filaments, the first staple fibers or first filaments have an average linear mass density per fiber or filament of about 1 denier per fiber or filament (dpf) or less, and the first fibers or filaments comprise or consist of a first composition comprising a first thermoplastic polymer and titanium dioxide (TiO2); the second yarn comprises or consists of a second multifilament yarn, the second multifilament yarn comprises or consists of second filaments having an average linear mass density per filament of about 1 dpf or less, and the secondPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 filaments of the second yarn comprise or consist of a second composition comprising a second thermoplastic polymer and TiO2; wherein a ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2 in the combination yarn is 0.4 or less; and the fabric has an ultraviolet protection factor (UPF) of at least 45 under dry conditions.

[0107] 31. The fabric of aspect 30, wherein the combination yarn is the combination yarn according to any one of aspects 1 to 29.

[0108] 32. The fabric of aspect 30 or 31, wherein the fabric has an average UPF of at least 50, or of greater than 50, or of at least 55, or of greater than 55, or of at least 60, or of greater than 60 under dry conditions, or has an average UPF of greater than 50, or of at least 55, or of greater than 55, or of at least 60, or of greater than 60 under wet conditions; or has an average UPF of greater than 50, or of at least 55, or of greater than 55, or of at least 60, or of greater than 60 under dry conditions and under wet conditions.

[0109] 33. The fabric of any one of aspects 30 to 32, wherein the fabric is a knitted fabric or is a woven fabric; optionally wherein the fabric is a warp knitted fabric or a weft knitted fabric; optionally wherein the fabric is a knitted fabric and has a jersey knit construction, a pique knit construction, or a rib knit construction; optionally wherein the fabric is a knitted fabric and has a jersey knit construction or a pique knit construction.

[0110] 34. The fabric of any one of aspects 30 to 33, wherein the fabric is a woven fabric and the warp yarns or the weft yarns or both the warp yarns and the weft yarns include the combination yarn; optionally wherein the weft yarns include the combination yarn; optionally wherein the combination yarn defines a portion of a face side of the woven fabric or defines a portion of a back side of the woven fabric or defines a portion of the face side of the woven fabric and a portion of the back side of the woven fabric; optionally wherein the combination yarn is a dyed combination yarn.

[0111] 35. The fabric of any one of aspects 30 to 34, wherein a face side of the fabric is brushed, or wherein a back side of the fabric is brushed, or wherein both the face side of the fabric and the back side of the fabric are brushed.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0112] 36. The fabric of any one of aspects 30 to 35, wherein the fabric comprises at least 50 wt% of the combination yarn; optionally wherein the fabric comprises at least 76 wt% of the combination yarn, or comprises at least 70 wt% of the combination yarn, or comprises at least 80 wt% of the combination yarn.

[0113] 37. The fabric of any one of aspects 30 to 36, wherein the fabric further comprises a third yarn; optionally wherein the third yarn is an elasticated yarn; optionally wherein the elasticated third yarn comprises or consists of one or more elastane filament.

[0114] 38. The fabric of aspect 37, wherein the third yarn is a connecting yarn connecting a first fabric layer to a second fabric layer in the fabric, and the first fabric layer or the second fabric layer or both the first fabric layer and the second fabric layer comprise the combination yarn; optionally wherein the first fabric layer is a first knit fabric layer and the second fabric layer is a second knit fabric layer.

[0115] 39. The fabric of aspect 37 or 38, wherein the fabric is a knit fabric, and the knit fabric comprises the third yarn plated with the combination yarn in a plated knit construction; optionally wherein the plated knit construction includes the combination yarn predominating on a face side of the fabric or predominating on a back side of the fabric or predominating on both the face side and the back side of the fabric; optionally wherein the plated knit construction is a single jersey plated construction or is a double jersey plated construction, or is a tricot warp knit plated construction.

[0116] 40. The fabric of any one of aspects 30 to 39, wherein the fabric is a dyed fabric; optionally wherein the dyed fabric includes a plurality of first and second filaments dyed with a disperse dye.

[0117] 41. The fabric of aspect 40, wherein the dyed fabric is a dyed fabric having a heathered appearance.

[0118] 42. The fabric of aspect 40 or 41, wherein the fabric maintains colorfastness to water after being laundered 40 times and exposed to 200 AATCC Fading Units of simulated sunlight.

[0119] 43. An article comprising the fabric of any one of aspects 30 to 42; optionally wherein the article is an article of apparel.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0120] 44. A method of manufacturing a combination yarn, the method comprising: forming a first yarn by forming a first composition comprising a molten thermoplastic polyester and TiO2; spinning the molten first thermoplastic composition into first filaments having a liner mass density per filament of about 1 dpf or less, wherein the spinning includes extruding the molten first composition through a plurality of spinnerets at a first temperature and winding the extruded first filaments at a first winding speed; and combining the extruded first filaments to form the first yarn; forming a second yarn by forming a second composition comprising a molten thermoplastic polyamide and TiO2; spinning the molten second thermoplastic composition into second filaments having a liner mass density per filament of about 1 dpf or less, wherein the spinning includes extruding the molten second composition through a plurality of spinnerets at a second temperature, and winding the extruded second filaments at a second winding speed ranging; and combining the extruded second filaments to form the second yarn; and forming the combination yarn by combining the first yarn and the second yarn; wherein the combination yarn has a ratio of total average dpf of the combination yarn divided by total average weight percent of TiO2in the combination yarn is 0.4 or less.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0121] 45. The method of aspect 44, wherein a first thermoplastic polymer of the molten first thermoplastic composition comprises or consists of a polyester; optionally wherein the polyester comprises or consists of PET; optionally wherein the first temperature ranges from about 270 degrees Celsius to about 320 degrees Celsius.

[0122] 46. The method of aspect 44 or 45, wherein a second thermoplastic polymer of the molten second thermoplastic composition comprises or consists of a polyamide; optionally wherein the polyamide comprises or consists of nylon 6; optionally wherein the second temperature ranges from about 250 degrees Celsius to about 265 degrees Celsius, or from about 255 degrees Celsius to about 260 degrees Celsius.

[0123] 47. The method of any one of aspects 44 to 46, wherein the first winding speed ranges from about 4000 meters per minute (m / min) to about 5000 m / min, or from about 4200 m / min to about 4800 m / min, or from about 4400 m / min to about 4600 m / min.

[0124] 48. The method of any one of aspects 44 to 47, wherein, during the forming the first filaments, the spinning the first filaments comprises spinning the first filaments to have an average linear mass density per filament ranging from about 1 dpf to about 0.45 dpf, or of less than 0.75 dpf, or ranging from about 0.75 to about 0.45 dpf, or of less than 0.6 dpf, or ranging from about 0.6 dpf to about 0.45 dpf, or of less than 0.5 dpf, or ranging from about 0.5 dpf to about 0.45 dpf.

[0125] 49. The method of any one of aspects 44 to 48, wherein combining the first filaments comprises combining an average number of first filaments ranging from about 50 to about 235, or ranging from about 100 to about 200, or ranging from about 125 to about 175, or ranging from about 50 to about 150, or ranging from about 75 to about 150, or ranging from about 75 to about 125, to form the first yarn.

[0126] 50. The method of any one of aspects 44 to 49, wherein, during the forming the second filaments, the second winding speed ranges from about 4000 m / min to about 5000 m / min or ranges from about 4200 m / min to about 4800 m / min or ranges from about 4400 m / min to about 4600 m / min.

[0127] 51. The method of any one of aspects 44 to 50, wherein the spinning the second filaments comprises spinning the second filaments to have an average linearPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 mass density per filament ranging from about 1 dpf to about 0.45 dpf, or of less than 0.75 dpf, or ranging from about 0.75 to about 0.45 dpf, or of less than 0.6 dpf, or ranging from about 0.6 dpf to about 0.45 dpf, or of less than 0.5 dpf, or ranging from about 0.5 dpf to about 0.45 dpf.

[0128] 52. The method of any one of aspects 44 to 51, wherein combining the second filaments comprises combining an average number of second filaments ranging from about 50 to about 235, or ranging from about 100 to about 200, or ranging from about 125 to about 175, or ranging from about 50 to about 150, or ranging from about 75 to about 150, or ranging from about 75 to about 125, to form the second yarn.

[0129] 53. The method of any one of aspects 44 to 52, wherein the combining the first yarn and the second yarn comprises wrapping or twisting the second yarn at least partially around the first yarn, or wherein the combining comprises wrapping or twisting the first yarn at least partially around the second yarn.

[0130] 54. The method of any one of aspects 44 to 53, wherein the combining the first yarn and the second yarn comprises combining the first staple fibers or filaments and the second filaments in single-spinning process, or comprises combining the first staple fibers or filaments and the second filaments in a double-spinning process, or comprises combining the first staple fibers or filaments and the second filaments in a vortex-spinning process.

[0131] 55. The method of any one of aspects 44 to 54, further comprising texturizing the combination yarn.

[0132] 56. The method of any one of aspects 44 to 54, wherein the combining comprises combining the first yarn and the second yarn into the combination yarn and texturizing the combination yarn.

[0133] 57. The method of aspect 56, wherein the step of combining the first yarn and the second yarn comprises air texturizing the first yarn together with the second yarn; optionally wherein the combining comprises combining the first yarn at a first overspeed with the second yarn at a second overspeed; optionally wherein the first overspeed ranges from about 5% to about 50% and the second overspeed ranges fromPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 about 5% to about 50%; optionally wherein the first overspeed is less than the second overspeed.

[0134] 58. The method of any one of aspects 55 to 57, wherein texturizing the combination yarn comprises air texturizing the combination yarn; optionally wherein the air texturizing comprises using an air jet texturizer; optionally wherein the air texturizing comprises using a speed ranging from about 300 meters per second (m / sec) to about 550 m / sec or ranging from about 350 m / sec to about 500 m / sec, or ranging from about 400 m / sec to about 450 m / sec for the combination yarn.

[0135] 59. The method of any one of aspects 55 to 58 , wherein the method comprises air texturizing the combination yarn in an air-jet texturizer; optionally wherein the texturizing is effective to expose regions of the first staple fibers or filaments of the first yarn on an outer surface of the combination yarn, or is effective to expose regions of the second filaments of the second yarn on an outer surface of the combination yarn, or is effective to intermingle a portion of the first staple fibers or filaments with a portion of the second filaments.

[0136] 60. The method of any one of aspects 44 to 59, further comprising dyeing the combination yarn; optionally wherein dyeing the combination yarn comprises dyeing the combination yarn with a dye composition comprising or consisting of a disperse dye; optionally wherein the dyeing the combination yarn comprises dyeing the combination yarn after texturizing the combination yarn.

[0137] 61. The method of aspect 60, further comprising applying a reduction clearing process to the dyed combination yarn; optionally wherein the reduction clearing process comprises applying a dye reducing composition to the dyed combination yarn; optionally wherein the dye reducing composition comprises sodium sulfoxylate formaldehyde and acetic acid; optionally wherein the reduction clearing process increases colorfastness of the dyed yarn.

[0138] 62. The method of any one of aspects 44 to 61, wherein the combination yarn is the combination yarn of any one of aspects 1 to 29.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0139] 63. A combination yarn made by the method of any one of aspects 44 to 62.

[0140] 64. A fabric comprising a combination yarn manufactured according to any one of methods 44 to 62.

[0141] 65. A method of manufacturing a fabric, the method comprising: knitting or weaving the combination yarn of any one of aspects 1 to 29 for form the fabric.

[0142] 66. An article comprising a fabric manufactured according to method 65; optionally wherein the article is an article of apparel.

[0143] The drawings will now be described. Throughout the drawings, reference numbers may be re-used to indicate correspondence between referenced elements. The drawings are provided to illustrate example aspects described herein and are not intended to limit the scope of the disclosure. Sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes and sizes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility.

[0144] Referring now to FIG.1, an example aspect of a combination yarn 100 is shown. In this aspect, combination yarn 100 includes a first yarn 102 that is at least partially surrounded by a second yarn 104. The surrounding second yarn may serve as an outer sheath 106 that extends along a length of first yarn 102. Second yarn 104 may be spun, wrapped, twisted or otherwise disposed around first yarn 102 along a length of first yarn 102, to form combination yarn 100. In some aspects, the first yarn comprises or consists of a spun staple fiber yarn. In other aspects, the first yarn comprises or consists of a multifilament yarn. The second yarn comprises or consists of a multifilament yarn.

[0145] Referring now to FIG.2A, an example aspect of combination yarn 100 including first yarn 102 and second yarn 104 surrounding first yarn 102 to form outer sheath 106 extending along the length of combination yarn 100 is shown. In one aspect, the second yarn 104 is a multifilament yarn and may be spun, wrapped, or twisted orPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 otherwise disposed at least partially around first yarn 102, for example, using any one of a wrapping and air texturizing process, a single or double spinning process, or a vortex spinning process, to produce combination yarn 100.

[0146] In another aspect, combination yarn 100 may include first yarn 102 that has two mulitfilament yarns (the second yarn 104 and an additional yarn) surrounding first yarn 102 to form outer sheath 106 extending along the length of first yarn 102 to form combination yarn 100. Referring now to FIG. 2B, in this aspect, combination yarn 100 has a second multifilament yarn (e.g., second yarn 104) that is spun, wrapped, twisted or otherwise disposed at least partially around or along a length of first yarn 102 and also an additional multifilament yarn 200 that is spun, wrapped, twisted or otherwise disposed to at least partially surround first yarn 102 along a length of the first yarn 102 to form combination yarn 100. In some cases, second yarn 104 and additional filament yarn 200 may comprise or consist of filaments comprising or consisting of the same polymer(s), such as a polyester (e.g., PET) or a polyamide (e.g., nylon 6), having different properties or characteristics. In other cases, second multifilament yarn 104 and additional filament yarn 200 may be made from different polymeric materials, including different blends or combinations of similar polymeric materials, such as blends or combinations with different ratios of the same polymeric materials or polymeric materials having different properties or characteristics.

[0147] Yarns may be characterized by the average linear mass density of the fibers or filaments present in the yarn, as well as by the average linear mass density of the yarn itself. Denier (D, grams per 9000 meters) is one measure of the linear mass density; tex (tex, grams per 1000 meters) and decitex (dtex, grams per 10,000 meters) are other measures of the linear mass density of fibers, filaments and yarns. Multifilament yarns may be characterized by the number of filaments (F) in the yarn. Thus, a yarn characterized as “80D / 140F” or “80 / 140” is a yarn that contains an average of 140 individual filaments and the combination of the 140 individual filaments have an overall average linear mass density of 80 denier. For fibers and filaments, the average linear mass density per fiber or filament can be measured in units of denier per fiber or denierPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 per filament (dpf). The dpf of filaments in a multifilament yarn is determined by dividing the overall denier of the yarn by the number of filaments in the yarn. Thus, a 80D / 140F yarn has an average dpf of 0.57, and a 110D / 192F yarn also has an average dpf of 0.57. Fibers or filaments having a dpf, less than about 1 are considered to be microfibers. In some aspects, the average denier per filament (dpf) of the fibers or filaments in the yarns disclosed herein ranges from about 1 to about 0.45, or is less than 0.75, or ranges from about 0.75 to about 0.45, or is less than 0.6, or ranges from about 0.6 to about 0.45, or is less than 0.5, or ranges from about 0.5 to about 0.45. In other aspects, the average denier per filament of the fibers or filaments in the yarns is at least about 0.45, typically at least about 0.50, and more typically between about 0.50 and about 1.0, and more typically between about 0.50 and 0.75. Using yarns containing fine denier fibers or filaments to knit or weave fabrics results in fabrics having desirable hand feel and drape. Fabrics having good hand feel and drape can be used in a variety of different consumer products, particularly including apparel.

[0148] In order to provide a high level of protection from ultraviolet light, high levels of titanium dioxide (TiO2) are included in the molten polymeric composition from which fibers or filaments are spun. TiO2is commercially available for use in polymeric compositions in two polymorphs: the anatase form and the rutile form, typically in particle sizes ranging from about 300 nanometers (nm) to about 500 nm. Master batch pellets are available in a variety of base polymers including polyesters and polyamides in concentrations including 30 weight percent (wt%) and 50 wt% TiO2.

[0149] In accordance with the present disclosure, the combination yarn comprises or consists of man-made fibers or filaments having a dpf of about 1 or less (i.e., fine filaments) and the combination yarn as a whole has a ratio of total average dpf divided by total average weight percent of TiO2of 0.4 or less, such as a ratio ranging from about 0.25 to about 0.4, or of 0.33 or less; or ranging from about 0.25 to about 0.33, or of 0.3 or less, or ranging from about 0.25 to about 0.3. It has been found that using the disclosed ratio of dpf to wt% TiO2 results in fibers and filaments that provide good levels of UV light protection while having sufficient tenacity to be commercially manufactured. Fibers andPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 filaments having the disclosed ratio of dpf to wt% TiO2also can be used in combination yarns that have sufficient tenacity to be commercially knitted or woven and produce fabrics having high UPF along with other desirable properties such as good hand feel, drape, moisture management, and colorfastness.

[0150] In some aspects, the number of filaments in the combination yarn is between about 50 and about 235, typically between about 100 and about 200, and more typically between about 125 and about 175. In some aspects, the denier of the first yarn is between about 30 and about 200 and typically is between about 50 and about 100. aspect

[0151] In some aspects, first yarn 102 may comprise or consist of a staple fiber yarn. Staple fibers are non-continuous fibers of relatively short length. In one aspect, the staple fibers of the spun staple fiber yarn may comprise or consist of natural staple fibers or regenerated cellulosic staple fibers or synthetic polymer staple fibers, or any blend or combination thereof. The natural fibers may include cotton, wool, hemp, flax, silk and the like, including any blend or combination thereof. The regenerated cellulosic fibers may include modal, lyocell, and the like, including any blend or combination thereof. The synthetic polymer staple fibers may include but are not limited to synthetic polymers including polyacrylic, polyester, polyamide, polyolefin, polyether, and polyurea, including any blend or combination thereof. Examples of commonly used polymers include polyethylene terephthalate (PET), nylon 6, polypropylene, elastane, thermoplastic polyether ester elastomer (TPEE), and thermoplastic polyurethane (TPU), including any blend or combination thereof. The selection of a material for the first yarn may be a matter of cost and availability. In some aspects of the disclosure, the first typically is any of the polyesters, and typically is PET.

[0152] In other aspects, first yarn 102 comprises or consists of a multifilament yarn. In one aspect, the first yarn 102 consists of a multifilament yarn, such as a multifilament polyester yarn. Filaments are fine, near-continuous fibers of indefinite length, and are typically made using processes such as extrusion. In one aspect, the filaments may comprise or consist of regenerated cellulosic materials or synthetic polymerPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 materials, or any blend or combination thereof. The regenerated cellulosic filaments may include modal, lyocell, and the like, including any blend or combination thereof. The synthetic polymer filaments may include but are not limited to synthetic polymers including polyacrylic, polyester, polyamide, polyolefin, polyether, and polyurea, including any blend or combination thereof. Examples of commonly used polyesters include polyethylene terephthalate (PET) and polytrimethylene terephthalate (PTT). Commonly used polyamides include nylon 6, nylon 6,6, nylon 6,10, nylon 11, and nylon 12. Commonly used polyolefins include polypropylene and polyethylene. Other commonly used synthetic polymers include thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and elastane.

[0153] In some aspects, the polymeric component of the first 102 yarn or the second yarn 104 or both the first yarn 102 and the second yarn 104 may comprise or consist of virgin polyester or recycled polyester. Recycled polyethylene terephthalate (PET) is particularly suitable in some aspects. Recycled polyester may provide properties and characteristics equivalent to virgin PET. Recycled polyester may be obtained at favorable cost. The polymeric component of the first yarn 102 may comprise or consist of recycled PET.

[0154] Filament yarns may be selected from regenerated cellulosic filaments and synthetic polymer filaments, including any blend or combination thereof. In some aspects, the second yarn 104 is a multifilament yarn including filaments that comprise or consist of a synthetic polymeric composition that includes acrylic, nylon, polyester, polypropylene, elastane, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), polyethylene, and / or any blend combination thereof. In some aspects of the disclosure, nylon, typically nylon 6, forms a majority of filaments of the second yarn 104. Nylon 6 also is known as n6 and PA6.

[0155] In other aspects, second yarn 104 comprises or consists of a multifilament yarn. In one aspect, the second yarn 104 consists of a multifilament yarn, such as a multifilament nylon yarn. In one aspect, the filaments may comprise or consistPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 of regenerated cellulosic materials or synthetic polymer materials, or any blend or combination thereof. The regenerated cellulosic filaments may include modal, lyocell, and the like, including any blend or combination thereof. The synthetic polymer filaments may include but are not limited to synthetic polymers including polyacrylic, polyester, polyamide, polyolefin, polyether, and polyurea, including any blend or combination thereof. Examples of commonly used polyesters include polyethylene terephthalate (PET) and polytrimethylene terephthalate (PTT). Commonly used polyamides include nylon 6, nylon 6,6, nylon 6,10, nylon 11, and nylon 12. Commonly used polyolefins include polypropylene and polyethylene. Other commonly used synthetic polymers include thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), and elastane.

[0156] In aspects of the disclosure, second filament yarn 104 and additional filament yarn 200 may both comprise filaments made from a polymeric composition that includes a synthetic polymer such as acrylic, nylon, polyester, elastane, polypropylene, thermoplastic polyether ester elastomer (TPEE), thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), polyethylene, and / or any blend combination thereof. Natural fibers, which provide some UV resistance, also may be used. In some aspects, the filaments of the second yarn comprise or consist of nylon filaments, typically nylon 6 filaments. In accordance with the disclosure, a TiO2is added to the composition used to form the regenerated cellulosic or synthetic polymer filaments in order to increase the ultraviolet protection factor of the second yarn or of the first yarn or of the combination yarn. TiO2 is added to at least one of the first yarn (e.g., first yarn 102) and one or more filament yarns (e.g., second filament yarn 104 and / or additional filament yarn 200). More typically, TiO2is added to the compositions used to form the fibers or filaments of both the first yarn 102 and the second yarn 104. Titanium dioxide is a white, water insoluble pigment used in manufacturing yarns. Titanium dioxide can reflect, scatter, or absorb ultraviolet radiation.

[0157] In accordance with the present disclosure, the combination yarn 100 comprises or consists a first yarn 102 and a second yarn 104, and the first yarn 102 andPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 the second yarn 104 or both comprise or consist of man-made fibers or filaments having a dpf of about 1 or less.

[0158] In one aspect, the combination yarn 100 as a whole has a ratio of total average dpf divided by total average weight percent of TiO2 of 0.4 or less, such as a ratio ranging from about 0.25 to about 0.4, or of 0.33 or less; or ranging from about 0.25 to about 0.33, or of 0.3 or less, or ranging from about 0.25 to about 0.3.

[0159] In one aspect, the first yarn 102 comprises or consists of man-made fibers or filaments having a dpf of about 1 or less and the first yarn 102 as a whole has a ratio of total average dpf divided by total average weight percent of TiO2 of 0.4 or less, such as a ratio ranging from about 0.25 to about 0.4, or of 0.33 or less; or ranging from about 0.25 to about 0.33, or of 0.3 or less, or ranging from about 0.25 to about 0.3. The man-made fibers or filaments of the first yarn 102 may comprise or consist of regenerated cellulosic fibers. The man-made fibers or filaments of the first yarn 102 may comprise or consist of synthetic polymer fibers or filaments. The man-made fibers or filaments of the first yarn 102 may consist of filaments. The man-made fibers or filaments of the first yarn 102 may consist of synthetic polymer filaments. The man-made fibers or filaments of the first 102 yarn may consist of polyester filaments, such as PET filaments.

[0160] In another aspect, the second yarn 104 comprises or consists of man- made fibers or filaments having a dpf of about 1 or less and the second yarn 104 as a whole has a ratio of total average dpf divided by total average weight percent of TiO2 of 0.4 or less, such as a ratio ranging from about 0.25 to about 0.4, or of 0.33 or less; or ranging from about 0.25 to about 0.33, or of 0.3 or less, or ranging from about 0.25 to about 0.3. In one aspect, the second yarn 104 comprises or consists of man-made fibers or filaments having a dpf of about 1 or less and the second yarn 104 as a whole has a ratio of total average dpf divided by total average weight percent of TiO2of 0.4 or less, such as a ratio ranging from about 0.25 to about 0.4, or of 0.33 or less; or ranging from about 0.25 to about 0.33, or of 0.3 or less, or ranging from about 0.25 to about 0.3. The man-made fibers or filaments of the second yarn 104 may comprise or consist of regenerated cellulosic fibers. The man-made fibers or filaments of the second yarn 104PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 may comprise or consist of synthetic polymer fibers or filaments. The man-made fibers or filaments of the second yarn 104 may consist of filaments. The man-made fibers or filaments of the second yarn 104 may consist of synthetic polymer filaments. The man- made fibers or filaments of the second yarn 104 may consist of polyamide filaments, such as nylon 6 filaments.

[0161] In aspects of the disclosure, the total average titanium dioxide concentration of the combination yarn 100 is about 1.8 weight percent (wt%) or greater, or is about 1.9 wt% or greater, or is about 2.0 wt% or greater, or is about 2.1 wt% or greater, or is about 2.2 wt% or greater, or is about 2.3 wt% or greater. In some aspects, the total average concentration of titanium dioxide in the combination yarn 100 ranges from about 1.8 weight percent to about 2.3 weight percent, or ranges from about 2.0 weight percent to about 2.3 weight percent, or ranges from about 2.1 weight percent to about 2.3 weight percent. In one aspect, the total average titanium dioxide concentration of the first yarn 102 is about 1.6 weight percent (wt%) or greater, or is about 1.7 wt% or greater, or is about 1.8 wt% or greater, or is about 1.9 wt% or greater, or is about 2.0 wt% or greater, or is about 2.1 wt% or greater, or is about 2.2 wt% or greater, or is about 2.3 wt% or greater. In some aspects, the total average concentration of titanium dioxide in the first yarn 102 ranges from about 1.8 wt% to about 2.3 wt%, or ranges from about 2.0 wt% to about 2.3 wt%, or ranges from about 2.1 wt% to about 2.3 wt%. In one aspect, the total average titanium dioxide concentration of the second yarn 104 is about 1.6 wt% or greater, or is about 1.7 wt% or greater, or is about 1.8 wt% or greater, or is about 1.9 wt% or greater, or is about 2.0 wt% or greater, or is about 2.1 wt% or greater, or is about 2.2 wt% or greater, or is about 2.3 wt% or greater. In some aspects, the total average concentration of titanium dioxide in the second yarn 104 ranges from about 1.6 wt% to about 2.3 wt%, or ranges from about 1.5 wt% to about 2.3 wt%, or ranges from about 2.0 wt% to about 2.3 wt%, or ranges from about 2.1 wt% to about 2.3 wt%. In an example aspect, the TiO2is incorporated into the fibers or filaments in accordance with known methods, such as masterbatching.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0162] Further, in some aspects, the yarns disclosed herein have good colorfastness. For example, exemplary aspects of the disclosure typically provide excellent colorfastness. Aspects of the disclosure typically provide excellent colorfastness under washing conditions, under crocking (rubbing) conditions, under light exposure conditions, under perspiration conditions, or any combination thereof. A number of international test standards exist for testing colorfastness, such as American Association of Textile Chemists and Colorists (AATCC) tests and International Organization for Standardization (ISO) tests. AATCC 16 Options 1 and 3 are common tests for colorfastness to light, including AATCC TM16.3-2020. ISO 105 E04 and AATCC 15, including AATC TM15-2021e, test colorfastness to perspiration. AATCC TM61- 2013e2(2020) is a common test for colorfastness to washing. AATCC TM8-2016e(2022)e is a common test for colorfastness to crocking. AATCC TM107-2022 is a common test for colorfastness to water.

[0163] Nylon 6 typically have a melting point below that of polyesters and of other nylons, such as nylon 6,6. Nylon 6 is infused with dye (i.e., dyed) at temperatures between about 100 C and about 110 C. Dye starts to come out of the nylon at temperatures between about 130 C and about 140 C. Polyester is infused with color at temperatures between about 120 C and about 130 C. The relationships among these temperatures illustrate why nylon 6 and polyesters are suitable raw materials for use in the combination yarns disclosed herein.

[0164] Polymers including nylon 6 when used in fibers or filaments may provide a finish sheen considered to be a lustrous finish and other advantageous properties and characteristics. Nylon6 fibers and filaments used in aspects of the disclosure typically have a dull finish due to the presence of high levels of TiO2. Aspects of the disclosure may incorporate fibers or filaments having other sheens such as semi-dull, for example. In aspects of the disclosure, the combination yarn may include fibers or filaments having any type of sheen, such as full dull, semi-dull, and dull, or such as bright or semi-bright. Increasing titanium dioxide concentration reduces luster from bright through semi-dull to full dull. Full dull finish resembles cotton.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0165] In aspects, the first yarn 102, the second yarn 104, the optional additional yarn 200, and the combination yarn 100 may be a fully drawn yarn (FDY), an air textured yarn (ATY), an interlock twist yarn (ITY), or a drawn textured yarn (DTY).

[0166] FIG. 3 illustrates a manufacturing process 300 for producing combination yarn 100. The manufacturing process 300 includes manufacturing first yarn 102 in process 310 and manufacturing second yarn 104 in process 340. Processes 310 and 340 may be conducted simultaneously or consecutively. Process 310 includes a step 310A of extruding a first polymeric composition to form first fibers or filaments, and a step 310B of combining the first fibers or filaments, thereby making the first yarn 102. Process 340 includes a step 340A of extruding a second polymeric composition to form second filaments, and a step 340B of combining the second filaments, thereby making the second yarn 104. Process 370 includes combining the first yarn 102 from process 310 with the second yarn 104 from process 340. The combining of process 370 comprises disposing the second yarn 104 at least partially around the first yarn 102 to make the combination yarn 100. In some aspects, disposing the second yarn 104 at least partially around the first yarn 102 comprises twisting or wrapping the second yarn 104 around the first yarn 102. Optionally, the process 370 of combining the first yarn 102 and the second yarn 104 to make the combination yarn 100 may comprise a process of texturizing the combination yarn 100. In some aspects, a texturization process 372 may occur simultaneously with the combining process 370, or, in other aspects, a texturization process 374 of combination yarn 100 may occur following the combining process 370. Optionally, manufacturing process 300 may comprise dyeing combination yarn 100. For example, a dyeing process 395 may include applying a dye solution to the combination yarn 100. In some aspects, the dyeing process 395 may further comprise a reduction clearing process 396 in which a reduction clearing composition is applied to the dyed combination yarn 100 to improve colorfastness of the dyed combination yarn 100.

[0167] Processes 310 or 340 or both 310 and 340 may comprise feeding solidpolymer along with additives such as TiO2 and optionally a dispersion agent into apolymer feed hopper of a screw extruder to form a molten polymeric composition. ThePLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 additives may be added in the form of masterbatched pellets. Molten polymeric composition can then be fed into a metering pump to control flow of the molten polymeric into a spinneret in order to control consistency of filament formation. The spinneret includes multiple small holes through which the molten polymeric composition is fed, with each spinneret forming a single filament. After exiting the spinneret, the extruded filaments go through a cooling or quenching phase and may be drawn before being taken up on a take up spool. Optionally, a spin finish may be applied to the outer surfaces of the filaments.

[0168] FIG.4 illustrates a subset of processes of yarn manufacturing process 300 for producing a combination yarn 100 as described herein. The process illustrated in FIG.4 includes simultaneously combining and air jet texturizing the first yarn and the second yarn. Conventional treatment steps, such as water spraying or drying, are not illustrated in FIG.3 or FIG.4, but may be included as part of manufacturing process 300 as would be known to a skilled artisan. In some aspects, a first fiber or filament yarn 102 from first fiber source 311 is passed through a first speed controller 320 and then introduced as speed controlled first fiber or filament yarn 330 at a controlled first speed to texturizing head 371.

[0169] During the manufacturing process 300 illustrated in FIG. 4, a second filament yarn 104 from second filament yarn source 341 is passed through a second speed controller 350 and then introduced as speed controlled second filament yarn 360 at a controlled second filament yarn speed to texturizing head 371. Speed controlled first fiber or filament yarn 330 and speed controlled second filament yarn 360 are passed through texturizing head 371 together with air from an air jet 375 to form a texturized yarn 380 (combination yarn 100). Texturized yarn 380 (combination yarn 100) is withdrawn at a controlled withdrawal rate by texturized yarn controller 390. Optionally, texturized yarn 380 (combination yarn 100) may proceed to a dyeing process before proceeding to step 390. Texturized yarn 380 (combination yarn 100) then is removed from texturized yarn controller 390 at an operation 399 to optional post-processing, such as drying, winding, manufacture of fabric, and other typical steps described below. In some aspects of thePLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 disclosure, yarn composition and the tenacity, elongation, denier, and denier per filament of the yarns affect the properties and characteristics of the resultant product.

[0170] As described above, texturizing the combination yarn 100 improves the hand feel of the combination yarn 100, and of products manufactured with the combination yarn 100. In some aspects of the disclosure, the desired properties and characteristics may be achieved by operating first yarn speed controller 320 and second filament yarn speed controller 350 at a speed greater than a speed of texturized yarn controller 390. The speed at which texturized yarn controller 390 operates is related to the properties and characteristics of the fibers or filaments of the first yarn 102 and of the second yarn 104, as described with regard to tenacity, denier, and denier per filament.

[0171] The speeds at which first yarn speed controller 320 and second filament yarn speed controller 350 operate may be the same or different and may be greater than the speed of texturized yarn controller 390. In some aspects of the disclosure, the overspeed percentage, also known as the overfeed percentage, i.e., the ratio of the speed of first yarn speed controller 320 or of second filament yarn speed controller 350 to the speed of texturized yarn controller 390, ranges from about 0% to about 50%, typically from about 5% to about 40%, and more typically from about 10% to about 25%. In some aspects of the disclosure, the speed of texturized yarn controller 390 ranges from about 250 meters per minute (m / m) to 450 m / m, typically from about 325 m / m to about 400 m / m, depending on the properties and characteristics of the texturized yarn.

[0172] Referring now to FIG.5, a flowchart of the process of an example aspect of a method 400 of manufacturing an article using a fabric knit or woven with the combination yarn 100 disclosed herein is shown.

[0173] Yarn manufacturing step 300 of FIG. 5 may comprise yarn manufacturing process 300 as described above and illustrated in FIG.3. Optionally, yarn manufacturing process 300 may include the subprocess described above and illustrated in FIG.4. Combination yarn 430 (combination yarn 100) is delivered to an operation of fabric formation 440. In various aspects, operation of fabric formation 440 may include knitting, weaving, or other methods of manufacturing fabric 450 using combination yarnPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 430,100. Continuing with method 400 shown in FIG.5, fabric 450 including combination yarn 430,100 may then be provided or fed to an optional fabric post-processing treatment or finishing operation 460. At optional fabric post-processing treatment or finishing operation 460, one or more finishes or treatments may be applied to the fabric, including various washes, brushing, or other treatments to yield a post-processed fabric 470. Optionally, the post-processing treatment or finishing operation can include dyeing the fabric, or can include dyeing the fabric and applying a reduction clearing composition to the dyed fabric in order to improve colorfastness of the dyed fabric. The resulting post- processed fabric 470, or fabric 450 in the event no post-processing treatment or finish is applied, may then be used to manufacture an article 480. For example, article 480 may incorporate all or a portion of fabric 450 and / or post-processed fabric 470 to form various types and forms of articles, including articles of apparel.

[0174] Additionally, in some aspects of fabric formation process 440, various other yarns may be combined with the combination yarn to provide a particular feature. For example, an elastane yarn may be added to provide stretch in the fabric or an article made therefrom. Example 1

[0175] Second filaments were extruded from a second polymeric composition including virgin nylon6 and a range of about 1.8 weight percent to about 2.3 weight percent titanium dioxide. Following extrusion and drawing, the second filaments were combined into a second filament yarn and were supplied at a speed of 429 m / m (filament speed controller 350) to form a sheath of the second filament yarn around a first filament yarn extruded from a first polymeric composition including recycled PET and about 2.3 weight percent titanium dioxide. Following extrusion and drawing, the first filaments were combined into a first filament yarn and the first yarn was introduced at a rate of 418 m / m from first speed controller 320. The first yarn and the second yarn were combined and texturized in the texturizing head 371 of an air-jet texturizer. Thus-texturized combination yarn 380 was withdrawn from texturizing head 371 at a speed of 380 m / m and recovered for further processing.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 Examples 2, 3, 4 and 5

[0176] Examples 2, 3, 4 and 5 were made in accordance with the method of Example 1. The following yarns were made and texturized and technical data obtained. The combination yarns of Examples 2 and 3 contained 2.3 weight percent titanium dioxide, while the combination yarns of Examples 4 and 5 contained 2.0 weight percent titanium dioxide. All examples were full dull (FD) yarns. CY indicates first yarn, 2Y indicates second yarn, PET indicates polyethylene terephthalate (the polymeric component of the first composition), N6 indicates nylon 6 (the polymeric component of the second composition), RE indicates recycled content, FDY indicates fully drawn yarn, ATY indicates air textured yarn, and N / D indicates not determined.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0177] Table 1PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 Examples 6-10

[0178] In Examples 6-9, the yarn of Example 3 was used to manufacture 4 different knit types of white fabric. In Example 10, the yarn of Example 2 was dyed black and used to manufacture a knit fabric using a 1x1 rib stitch. The composition of all fabrics for examples 6-10 of the disclosure was 48% Nylon 6, 44% Recycled PET, and 8% elastane.

[0179] Two tests were performed on Example 10. Both were carried out in accordance with test AATCC TM183-2020e for determining Transmittance or Blocking of Erythemally Weighted Ultraviolet Radiation through Fabrics. Test A was carried out on fabric as manufactured. Test B was carried out in accordance with modified ASTM D6544-12, a practice for preparation of textiles prior to UV transmission testing. The test specimen was laundered 40 times, then exposed to 200 AATCC Fading Units of simulated sunlight. Although Examples 7A and 7B yielded satisfactorily high UPF values, the fabric did not maintain colorfastness to water when tested according to AATCC TM107-2022. GSM indicates fabric weight in grams per square meter; UVA indicates ultraviolet light of spectrum A; UVB indicates ultraviolet light of spectrum B; UPF indicates ultraviolet light protection factor; N / D indicates not determined.

[0180] Table 2PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1Comparative Examples 1 and 2

[0181] Each of Comparative Examples 1 and 2 comprised a machine knitted fabric comprising a combination yarn including a recycled PET first yarn and a second nylon 6 filament yarn. Both combination yarns were undyed (white). The combination yarns were knit using a single jersey stitch into single-layer white socks on a commercial circular knitting machine using 280 needles. PET indicates polyethylene terephthalate, N6 indicates nylon 6, FDY indicates fully drawn yarn, ATY indicates air-textured yarn.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0182] Table 3

[0183] In some aspects, combination yarn 100 including first yarn 102 and second yarn 104 optionally with additional yarn 200 may be incorporated into a fabric. For example, FIG.6 and FIG.7 illustrate example aspects of different types of fabrics that may be made using a combination yarn 100 as described herein. Referring first to FIG. 6, a representative view of an example aspect of a woven fabric 1000 incorporating at least one combination yarn is shown.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0184] In this aspect, woven fabric 1000 includes a plurality of yarns, including warp yarns 1002 and weft yarns 1004. In one aspect, at least one weft yarn 1004 of woven fabric 1000 includes a weft dyed combination yarn 100 having a first yarn 102 and a second yarn 104 in an outer sheath surrounding the first yarn 102. In some aspects, at least one warp yarn 1002 of woven fabric 1000 includes a dyed combination yarn 100 having a first yarn 102 and a second yarn 104 in an outer sheath surrounding the first yarn 102. In some cases, the dyed combination yarn 100 may form a portion of a face side of woven fabric 1000 and / or a portion of a back side of woven fabric 1000. In some aspects, the at least one weft yarn may further be or include an elastane yarn and the at least one warp yarn may further be or include an elastane yarn. The warp or the weft or both the warp and the weft may comprise a combination yarn 100 plaited with an elastane yarn.

[0185] Additionally, in some aspects, one or more treatments may be applied to the fabric including the combination yarn 100. For example, in one aspect, at least one of the face side and the back side of woven fabric 1000 may be brushed or sanded to increase the softness of the at least one side. In addition to increasing the softness, brushing or sanding the fabric can increase the surface area of the exposed fibers or filaments on the at least one side or roughen the surfaces of the exposed fibers of filaments or both roughening the surface and increasing the surface area. In some aspects, roughening and / or increasing the surface area provides a better or larger area for dyeing, and can increase the colorfastness of the fabric.

[0186] FIG.7 is a representative view of an example aspect of a structure of a knit fabric 1100 incorporating at least one combination yarn 100 in accordance with the present disclosure. As shown in FIG.7, knit fabric 1100 includes a first layer 1102 which is configured to be the layer next to the skin A (inner or back layer) of the wearer and a second layer 1104 which is configured to be the layer of knit fabric 1100 facing the exterior B (outer or face layer) and away from the skin A of the wearer. As illustrated in FIG.7, in one aspect, a connecting yarn 1106 may bind together first fabric layer 1102 and second fabric layer 1104 to tighten knit fabric 1100 together.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1

[0187] In an example aspect, first fabric layer 1102 may include a first yarn 1108 and second fabric layer 1104 may include a second yarn 1110. In other aspects, first fabric layer 1102 may further include a third yarn plated and knitted together with first yarn 1108 to form the next to skin A (inner or back layer) first fabric layer 1102. In one aspect, first yarn 1108 and / or the third yarn may include a combination yarn (e.g., combination yarn 100) as described herein. In some cases, the third yarn may be or include an elastane yarn. The knit structure of the first layer may include the first yarn predominating on its face side or back side or on both its first side and back side.

[0188] In an example aspect, second fabric layer 1104 may further include a fourth yarn plated and knitted together with second yarn 1110 to form (outer or face layer) second fabric layer 1104 facing towards outside B. In one aspect, second yarn 1110 and / or the fourth yarn may include a combination yarn (e.g., combination yarn 100) as described herein. In some cases, the fourth yarn may be or include an elastane yarn. The knit structure of the second layer may include the second yarn predominating on its face side or back side or on both its first side and back side.

[0189] In some aspects, connecting yarn 1106 binding together first fabric layer 1102 and second fabric layer 1104 may be a single strand or multiple strands. In one aspect, connecting yarn 1106 is an elasticated yarn such as an elastane yarn. In other aspects, connecting yarn 1106 may be a yarn comprising a synthetic polymer such as for example a nylon, a polyester, a polypropylene, an acrylic, a polyacrylic or a combination thereof. Alternatively, connecting yarn 1106 as described herein may include a natural fiber or filament or a regenerated cellulosic fiber or filament such as for example a cotton, silk, wool, modal, micro-modal, rayon, lyocell, viscose or a combination thereof. In some aspects, connecting yarn 1106 may also include a combination yarn (e.g., combination yarn 100) as described herein.

[0190] In some cases, connecting yarn 1106 may have a zig-zag structure (an overlap) between first fabric layer 1102 and second fabric layer 1104. The zig-zag structure may include a lapping back and forth between first fabric layer 1102 andPLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 second fabric layer 1104 in order to connect them together as shown in FIG. 7. As described herein, in some aspects, knit fabric 1100 is made with a knitting construction that includes a weft knitted or a warp knitted structure. For example, knit fabric 1100 may be a single jersey plated construction, a double jersey plated construction, for example, or Tricot warp knit plated structure. Other knit structures include seamless, rib, jersey, and pique.

[0191] It should be understood that the fabrics described herein incorporating a combination yarn 100 as disclosed herein, including but not limited to combination yarns manufactured as described herein, including using the method of manufacture with varying tension described herein. The fabrics described herein may be used for any type of articles of apparel including shirts, headwear, coats, jackets, pants, underwear, gloves, socks, and footwear.

[0192] While various aspects of the disclosure have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more aspects and implementations are possible that are within the scope of the disclosure. Accordingly, the disclosure is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Claims

PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 CLAIMS 1. A fabric comprising: a knitted or woven construction including a combination yarn, wherein the combination yarn comprises a first yarn and a second yarn at least partially surrounding or entangled with the first yarn; the first yarn is a first spun staple fiber yarn or is a first multifilament yarn, and the first yarn comprises first fibers or first filaments having an average linear mass density per fiber or filament of about 0.6 denier per fiber or filament (dpf) or less, the second yarn is a second multifilament yarn and comprises second filaments having an average linear mass density per filament of about 0.6 dpf or less, the combination yarn has an average ratio of total dpf divided by total weight percent of TiO2 of 0.3 or less; and wherein the fabric has an average ultraviolet protection factor (UPF) of at least 50 under dry conditions and wet conditions.

2. The fabric of claim 1, wherein an average concentration of TiO2in all man-made fibers and filaments of the combination yarn is at least 2.0 wt%.

3. The fabric of claim 1 or 2, wherein the first fibers or first filaments of the first yarn comprise a first composition comprising a first thermoplastic polymer and about 1.6 wt% to about 2.3 wt% of TiO2.

4. The fabric of any one of claims 1 to 3, wherein the first yarn consists of the first multifilament yarn, the first multifilament yarn consists of the first filaments, and the first filaments consist of the first composition.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 5. The fabric of any one of claims 1 to 4, wherein the second filaments of the second yarn include a second composition comprising a second thermoplastic polymer and at least 1.6 wt% TiO2.

6. The fabric of any one of claims 1 to 5, wherein the second yarn consists of the second filaments, and the second filaments consist of the second composition.

7. The fabric of any one of claims 1 to 6, wherein the combination yarn is a wrapped yarn with the second yarn wrapped around and air texturized with the first yarn, the first yarn is a full dull fully drawn yarn, the second yarn is a full dull fully drawn yarn, and the combination yarn is a full dull air texturized yarn.

8. The fabric of any one of claims 1 to 7, wherein the first yarn is a multifilament yarn, an average number of first filaments in the first yarn ranges from about 75 to about 125, and an average linear mass density of the first yarn ranges from about 40 denier (D) to about 60 D.

9. The fabric of any one of claims 1 to 8, wherein an average number of second filaments in the second yarn ranges from about 75 to about 125, and an average linear mass density of the second yarn ranges from about 40 D to about 60 D.

10. The fabric of any one of claims 1 to 9, wherein the first thermoplastic polymer comprises a polyester, and the second thermoplastic polymer comprises a polyamide.

11. The fabric of any one of claims 1 to 10, wherein the fabric is a knitted fabric or is a woven fabric.PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 12. The fabric of any one of claims 1 to 11, wherein the fabric further comprises a third yarn and the third yarn is an elasticated yarn.

13. The fabric of claim 12, wherein the fabric is a knit fabric and comprises the third yarn plated with the combination yarn in a plated knit construction with the combination yarn predominating at least on a face side of the fabric.

14. The fabric of any one of claims 1 to 13, wherein the combination yarn is a dyed and reduction cleared yarn.

15. The fabric of any one of claims 1 to 14, wherein the fabric maintains colorfastness to water after being laundered 40 times and exposed to 200 AATCC Fading Units of simulated sunlight.

16. An article of apparel comprising the fabric of any one of claims 1 to 15.

17. A knitted fabric comprising: a jersey or pique knit construction including a combination yarn and an elasticated yarn, wherein the combination yarn comprises a first yarn and a second yarn at least partially surrounding and air texturized with the first yarn; the first yarn is a first multifilament yarn and consists of first filaments having an average linear mass density per filament of about 0.6 denier per fiber or filament (dpf) or less, and the first filaments comprise a first composition including polyethylene terephthalate (PET) and TiO2, the second yarn is a second multifilament yarn and consists of second filaments having an average linear mass density per filament of about 0.6 dpf or less, and the second filaments comprise a second composition including nylon 6 and TiO2,PLUMSEA DOCKET NO.140-1072 LULU / P / 301840 / WO / SEC / 1 the combination yarn is a dyed and reduction cleared yarn and has an average ratio of total dpf divided by total weight percent of TiO2of 0.3 or less; and wherein the fabric has an average ultraviolet protection factor (UPF) of at least 50 under dry conditions and wet conditions.

18. The knitted fabric of claim 17, wherein an average number of first filaments in the first yarn ranges from about 75 to about 125, an average linear mass density of the first yarn ranges from about 40 denier (D) to about 60 D, an average number of second filaments in the second yarn ranges from about 75 to about 125, and an average linear mass density of the first yarn ranges from about 40 D to about 60 D.

19. The knitted fabric of claim 17 or 18, wherein the fabric maintains colorfastness to water after being laundered 40 times and exposed to 200 AATCC Fading Units of simulated sunlight.

20. An article of apparel comprising the fabric of any one of claims 17 to 19.

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