Textile product for curtaining applications

Abstract

The present invention relates to a composite yarn (10) that does not contain polyvinyl chloride (PVC) and is specifically designed for shading applications, allowing sunlight to pass through while blocking solar heat, a fabric (20) obtained from this yarn (10), and methods for producing them.

Description

[0001] TEXTILE PRODUCT FOR CURTAINING APPLICATIONS

[0002] Technical Area

[0003] The present invention relates to a composite yarn that does not contain polyvinyl chloride (PVC) for curtaining (screening) applications, a fabric made from this yarn and production methods of this yarn and fabric.

[0004] The invention specifically discloses a composite yarn, a fabric obtained from this yarn, and their production method, wherein the composite yarn is free of polyvinyl chloride (PVC) for curtaining applications that allow solar light to pass through while blocking solar heat.

[0005] State of the Art

[0006] Nowadays, regulating heat and light transmission is important in products used in shading applications. Fabrics for this use are generally produced from yarns blended with fiberglass and PVC. In the current technique, the yarns used in these product groups manufactured to date are coated with PVC material, which is known to be harmful to human health. In addition to the possibility of PVC material flaking off over time, the fact that the product is not suitable for recycling also creates disadvantages. Furthermore, the dust generated when cutting the fabric made from fiberglass yarn during curtain production poses a health risk and creates operational challenges. In the PVC-coated yarn production method, a core yarn is passed through a melt to coat the yarn. While other synthetic yarns such as glass fiber (GF), polyester, nylon, and all kinds of natural, synthetic fibers or mixtures are used in the inner yarn, the outer coating melt is polyvinyl chloride (PVC). In this yarn production method, special machines suitable for the system are required to weave PVC-coated yarns and turn them into finished products. Since the final coating process of the yarn is a chemical process, chemical waste is generated. In this case, the integration of the facility in yarn production is also of particular importance.

[0007] Recently, the sustainability and ecological approach to yarn and fabric used in the textile industry has become increasingly prominent. Consequently, demand for recycled and environmentally friendly products is rapidly increasing. Therefore, alternative solutions to PVC in curtains are being sought.

[0008] The types of yarn and fabrics mentioned above are used in curtain systems, particularly in outdoor spaces. Zip curtains are an example of these outdoor curtain systems. These curtains are very easy to use, have a robust structure, and are resistant to all environmental conditions. Zip curtains offer protection, shading, and are an improved alternative to previously used products in outdoor spaces. The fabric used for this product must be special and resistant to heat and UV rays.

[0009] Fabrics used in this technique, which allow sunlight to pass through while blocking solar heat, are made from a blend of fiberglass and PVC. PVC-coated yarn and the fabric formed from this yarn have an artificial appearance. Furthermore, PVC-coated fabric can change shape and size over time. Fabrics used in conventional curtains are particularly problematic due to their weight, cost, and appearance. The fabric's touching (texture) is primarily made of PVC, which gives it an artificial appearance. Moreover, the PVC's ability to develop unpleasant odors over time when exposed to environmental conditions creates problems for the fabric.

[0010] The invention subject to the application encompasses textiles, yarns, yarn technology, woven fabrics, and weaving technologies. The invention relates to textile products and their production used in indoor and outdoor curtain systems. Our invention discloses a polyvinyl chloride (PVC)- free yarn, a fabric woven from this yarn, and a production method for curtain applications designed to block solar heat while transmitting solar light. This allows yarn having more environmentally friendly properties that do not endanger human health, and fabric made from this yarn, which is manufactured as an improved product for protection and shading in indoor and outdoor spaces, serving as an alternative to previously used products.

[0011] As a result of this situation, some of the techniques developed are given below.

[0012] Patent document No. TR 2015 / 07441 is the applicant's previously registered patent. This invention relates to a yarn consisting of at least one outer polyester yarn wrapped around a polyester inner yarn, rather than using PVC as in the known art, and to the production method of this yarn using a special technique. The composite yarn created with this patent consists of a textured PET yarn with a textured inner yarn and a bicomponent PET melt-blown yarn as the outer yarn. The textured yarns used in the fabric created with the yarn provided by the invention create a grainy appearance in the final curtain fabric. This limits the fabric's aesthetic use. Our invention utilizes acrylic fibers instead of this textured PET inner yarn. In our invention, by using acrylic fiber as the inner yarn, a more natural fiber-like appearance and touching can be achieved, rather than the grainy appearance of the previously created yarn and the fabric produced from this yarn. Furthermore, textured PET yarns have lower UV resistance compared to acrylic fibers. This shows that the durability of the yarn and fabric created in our invention for indoor and outdoor curtains is better than this invention and this feature has been improved. Patent document No. W02007011961A2 relates to a continuous monofilament polymeric yarn consisting of a multifilament core and a coating containing a thermoplastic olefin. It discloses extruding a high-strength core yarn of polypropylene, polyethylene, propylene-based copolymer, ethylene-based copolymer, olefin, or fiberglass, and a coating consisting of a blend of polypropylene and ethylene octane copolymer to form a monofilament yarn. The coating may also include a flame retardant, an ultraviolet inhibitor, or a lubricant. This yarn is inherently recyclable and could address the ecological and health concerns associated with commonly used polyvinyl chloride (PVC)-coated yarns. In our invention, the acrylic used as the inner yarn provides better UV resistance than in the present invention. This also allows for comfortable and long-term use of the yarn in our invention and the fabric created with this yarn, both indoors and outdoors. Additionally, the fabric produced has a more natural and diamante appearance than in the present invention. Also, our invention does not use coatings, which ensures that the features it imparts are more permanent and long-lasting.

[0013] In summary, yarns used in current technology are typically PVC-coated to meet expected specifications. This results in the use of substances that are harmful to human health and the creation of non-recyclable products. Furthermore, the artificial appearance of the PVC used, the deformation and dimensional changes over time, and the unpleasant odor are known technical problems.

[0014] As a result, there is a need to produce environmentally friendly yarns and fabrics made from these yarns, which do not contain PVC in the current technique, can be used in indoor and outdoor curtain systems, and can transmit light at a level that provides ambient illumination while blocking solar heat.

[0015] Objectives and Brief Description of the Invention

[0016] The main purpose of the present invention is to obtain a PVC-free, long-lasting, environmentally friendly and recyclable product.

[0017] Another purpose of the invention is to provide composite yarn and fabric obtained from this yarn, which has high performance and desired UV resistance for indoor and outdoor textiles that can adapt to harsh weather conditions.

[0018] Another purpose of the invention is to obtain a composite yarn with a natural appearance and a fabric obtained from this yarn, that is, a product that does not change shape and size over time, does not create a bad odor and does not have a grainy appearance. To achieve the above-mentioned objectives, the invention is a composite yarn for curtaining applications comprising an inner yarn and an outer yarn wrapped around this inner yarn. The inner yarn in this composite yarn comprises acrylic and / or staple fiber and / or filament. When acrylic is selected, this inner yarn preferably comprises a polymer made of acrylonitrile and a comonomer. The outer yarn in the composite yarn of the invention is a melting bicomponent fiber and has at least two or more polymer components such as PTT, PET, PP, PA, or PE. The melting bicomponent fiber of the outer yarn is conventional PET in the center and co-PET with a low melting point on the outer surface. The melting bicomponent fiber of the outer yarn is 50- 300 denier and 24-144 filaments.

[0019] The production of a composite yarn for curtaining applications comprises the following steps; the inner yarn is twisted 100-500 turns in the S or Z direction to increase the strength of the inner yarn; it is fixed at 60-120°C and 35-120 minutes to fix the twist of the inner yarn; after the fixation process of the inner yarn is completed, it is pulled from the creel with a tension apparatus between 5-25 cN; the outer yarn is passed through the spindle and wound onto the inner yarn in the S or Z direction with a number of turns; the resulting composite yarn is pulled with a tension of 5-25 g and wrapped onto the bobbin; it is taken to the fixation machine and fixed at 60-120°C and 30-120 minutes.

[0020] A curtain fabric is produced by weaving the afore-mentioned composite yarn. Fabric production is achieved by weaving steps in a weaving machine using the produced composite yarn, including warping warp yarns using a yarn, drawing-in the warp and weaving by inserting the weft using the yarn, to weave fabrics in different constructions (plain weave, panama, etc.). The woven fabric undergoes a thermal textile finishing process on stender at 110-190°C, with a speed of 5-35 m / min. The melting yarn within the composite yarn structure of the curtain fabric is melted by the heat applied during this heat treatment, stiffening and stabilizing the curtain fabric. This gives the fabric its shape. The warp and weft yarn density in the resulting fabric is 10-50 yarns per centimeter.

[0021] Brief Description of Figures

[0022] Figure 1 shows the inner and outer yarn appearance details of the yarn subject of the invention.

[0023] Figure 2.1 shows the plain weave fabric structure of the fabric subject of the invention.

[0024] Figure 2.2 shows the panama fabric structure of the fabric subject of the invention. Reference Numbers

[0025] 10. Composite Yarn

[0026] 11. Inner yarn

[0027] 12. Outer yarn

[0028] 20. Fabric

[0029] 21. Weft yarn

[0030] 22. Warp yarn

[0031] Detailed Description of the Invention

[0032] As sustainability and ecological approaches have come to the forefront in the textile industry, demand for recycled and eco-friendly products has rapidly increased. Curtains, especially those used outdoors, are widely used and demand a robust structure, meaning they can withstand all environmental conditions. In outdoor spaces, curtains are required to provide protection and shade while also providing illumination.

[0033] Current technology uses yarns used in indoor and outdoor curtains coated with PVC, a material that is hazardous to human health and cannot be recycled. Furthermore, the use of fiberglass as a core yarn is also common in current technology. Dust generated from the fiberglass fabric produced from this inner yarn during the cutting process of the curtain also poses a health risk. Consequently, due to the drawbacks described above and the inadequacy of existing solutions, further technical development is necessary.

[0034] The invention relates to textile surfaces used in indoor and outdoor curtain systems. This invention relates to a composite yarn (10) that does not contain polyvinyl chloride (PVC) for screening applications, particularly for blocking solar heat while transmitting solar light, a fabric (20) woven from this composite yarn (10), and their production methods.

[0035] The fabric (20) in our invention, unlike curtain fabrics made with fiberglass and PVC yarn used in the art, does not contain PVC. This allows the fabric (20) to achieve a natural appearance, far from a synthetic appearance. The use of acrylic as the inner yarn (11) in our invention ensures that the fabric (20) woven with the composite yarn (10) has a look and feeling closer to natural fibers and improves the touching. PVC comprising fabrics tend to deform in shape and size over time. This problem is eliminated with the acrylic composition used in our invention. In this technique, a grainy appearance forms on the surface of curtain fabrics woven using textured yarn. Our invention eliminates this appearance by using acrylic, resulting in a clean and clear appearance. Acrylic fiber is one of the yarns with the best UV resistance known. Therefore, the developed screen fabric (20) and the curtains made from this fabric (20) can be used for high-performance indoor and outdoor textile products that can withstand harsh weather conditions.

[0036] Curtain fabrics can be divided into various groups, such as curtains, tulle, and mechanical products as roller-screens, depending on their intended use. The fabric (20) in question belongs to the screen fabric category. The invention produces a PVC-free, UV-resistant curtain fabric (20) for indoor and outdoor curtain systems. Thanks to the developed composite yarn (10) structure, the curtain fabric (20) is odorless, user-friendly, and environmentally friendly because it does not contain harmful chemicals such as PVC, formaldehyde, or halogen.

[0037] Thanks to their special fabric structure, screen curtains are highly effective at controlling sunlight in both indoor and outdoor spaces. Direct sunlight can quickly fade home textiles, overheat electronics, warp flooring and furniture, and, most importantly, cause discomfort. Screen curtains block direct sunlight in the environments where they are used thanks to their features. They provide a bright environment while also eliminating UV damage to textiles, electronics, and people. In addition to these features, screen curtains also offer the added advantage of an aesthetically pleasing appearance by allowing for diverse patterns.

[0038] The curtain fabric (20) produced within the scope of the invention not only provides a modern and aesthetic appearance but also provides users with micro-ventilation. The special texture of the fabric (20) provides various advantages such as air circulation, light control, and heat insulation; protection against UV, UVA, and UVB rays; and protection from the burning effects of the sun during sudden weather changes.

[0039] As can be seen in Figure 1 , a composite yarn (10) is formed by twisting an acrylic inner yarn (11) and wrapping it with at least one polyester outer yarn (12). To produce this composite yarn (10), a production method is being developed that allows the inner yarn (11) and outer yarn (12) to be held at certain temperatures for certain periods of time after being wrapped (twisted).

[0040] The inner yarns (11) used in the invention to form the composite yarn (10) comprises one or a mixture of acrylic, staple fiber, or filaments. In the preferred embodiment, if the inner yarn (11) of the invention is acrylic, the acrylic is obtained from a polymer comprises acrylonitrile and a comonomer. This acrylic (11) is the most similar to wool among artificial fibers. This ensures a clean appearance and touching in the final product (20). In our invention, a bicomponent fiber is wound onto the inner yarn (11) as an outer yarn (12). This bicomponent fiber is produced using polymers with at least two or more polymer components. Synthetic fibers are produced by extruding the same or different polymers (PTT, PET, PP, PA, PE, etc.) in each component. This method allows the fibers to be given many different properties. In a preferred embodiment, the bicomponent melting outer yarn (12) has conventional PET at the core of the fiber and co-PET, which has a low melting point, on the outer surface. These yarns are available in 50-300 denier, 24-144 filaments, and in bright, semimatte, full-matte, FDY, POY, FR (flame-retardant), and UV (ultraviolet) versions.

[0041] The production method of composite yarn (10) subject of the invention for curtain applications comprises the following steps: inner yarn (11) is twisted in S or Z directions for 100-500 turns for increasing the strength, fixation process is carried out at 60-120°C for 30-120 minutes for fixing the twist, the internal yarn (11) is pulled from the creel with a tension apparatus between 5-25 cN, outer yarn (12) is passed through the spindle and wrapped over the inner yarn (11) in the S or Z direction at a number of 200-800 turns, resulting composite yarn (10) is pulled with a tension of 5-25 grams and wrapped around the bobbin, fixation process is conducted in a fixation machine at 60-120°C and in 30-120 minutes.

[0042] In these production steps, twisting is performed to increase the strength of the yarns (11 , 12) (plain twist) or to impart various characteristics (fancy twist). The amount of twist required to hold the yarns (11 , 12) together depends on the diameter, type, and length of the yarn (10). Fixing is performed on high-twist, multi-ply yarns (10) to stabilize the twist, add strength, prevent static electricity, and ensure the smooth operation of the yarn (10).

[0043] The invention concerns screen fabrics (20) produced with a bicomponent PET melting outer yarn (12) twisted with a certain number of turns onto the central inner yarn (11), preferably acrylic yarn. The fabric (20) prevents solar heat while transmitting solar light at a level that illuminates the environment.

[0044] The construction of the fabric (20) and the technical performance of the composite yarns (10) used are the most important factors affecting strength. The prepared composite yarns (10) are woven into raw fabric (20) by producing them according to the desired weft (21) and warp (22) densities, desired fabric widths, and fabric construction. The woven raw fabric (20) is then finished during the finishing process to become the finished product. Parameters such as fabric width, weight, and shrinkage can be easily adjusted.

[0045] The fabric (20) subject to invention is produced by drawing warp yarn (22) from the composite yarn (10) produced, weaving the warp yarn (22), and picking the weft yarn (21) in a weaving machine to weave fabric in different constructions (plain weave, panama, etc.). The details of the fabric (20) subject to invention are given in plain fabric weaving structure in Figure 2.1 and in panama fabric weaving structure in Figure 2.2. The warp (22) and weft (21) densities of fabric (20) to be produced should be 10-50 yarns per centimeter. The fabric (20) can be woven by producing the prepared threads (10) in the desired weft (21)-warp (22) densities, desired fabric (20) widths and fabric (20) construction. The fabric (20) of the invention can be obtained in all woven fabric constructions, especially in plain and panama constructions.

[0046] The woven fabric (20) is subjected to a thermal textile finishing process. The fabric (20) is subjected to the thermal textile finishing process on stender at a speed of 5-35 m / min at 110- 190°C. The melting outer yarn (12) in the composite yarn (10) structure of the woven screen fabric (20) melts with the heat applied during the heat treatment, then hardening, stabilizing, and shaping the screen fabric (20).

[0047] In our patent No. TR 2015 / 07441 having title of "Yarn, Fabric, and Their Production Method for Screening Applications", studies are conducted on a product and production method to improve the disadvantages of existing screen fabrics by changing their glass fiber and PVC content. This invention, by being PVC-free, achieves a natural appearance and provides a solution to existing technical problems. The composite yarn of our patent file No. 2015 / 07441 covers a bicomponent PET melt yarn wrapped around a textured PET yarn at the center and the production process. The textured yarn creates a grainy appearance on the screen fabric, which limits its aesthetic use. However, our invention addresses this appearance problem by using acrylic in the inner yarn (11). Furthermore, polyester (PET) yarns have lower UV resistance than acrylic fibers. This limits their use in outdoor conditions. Again, by using acrylic as the inner yarn (11), the solution to this technical problem is provided by the inventive composite yarn (10) and the fabric (20).

Claims

CLAIMS1. A composite yarn (10) for curtain applications; comprising an inner yarn (11) and an outer yarn (12) wrapped over the inner yarn (11) characterized by that the inner yarn (11) comprises a mixture of one or more acrylic, staple fiber, and filament components.

2. The composite yarn (10) according to Claim 1 , wherein the inner yarn (11) is an acrylic polymer formed from acrylonitrile and a comonomer.

3. The composite yarn (10) according to Claim 1 , wherein the outer yarn (12) is a melting bicomponent fiber.

4. The composite yarn (10) according to Claims 1 to 3, wherein the melting bicomponent fiber of the outer yarn (12) comprises at least one or more polymer components selected from thermoplastic polymers such as PTT, PET, PP, PA, and PE.

5. The composite yarn (10) according to Claims 1 to 4, wherein the outer yarn (12) comprises a meltable bicomponent fiber having conventional PET at its core and a low-melting co- PET at its outer surface.

6. The composite yarn (10) according to Claim 4, wherein the bicomponent fiber comprises 50-300 denier and 24-144 filaments.

7. A production method of a composite yarn (10) for curtaining applications comprising an inner yarn (11) and an outer yarn (12) wrapped over the inner yarn (11), characterized by the process steps of: twisting the inner yarn (11) 100-500 turns in the S or Z direction for increasing its strength, fixing the twist of the inner yarn (11) at 60-120°C for 35-120 minutes, drawing the fixed inner yarn (11) from the creel with a tension of 2-25 cN by means of a tensioning apparatus, passing the outer yarn (12) through a spindle and wrapping it over the inner yarn (11) 200-800 turns in the S or Z direction to obtain the composite yarn (10),winding the resulting composite yarn (10) onto a bobbin by drawing it with a tension of 5-25 g, completing the fixing processes in a fixing machine at 60-120°C for 30-120 minutes.

8. A curtaining fabric (20), characterized by comprising the composite yarn (10) of Claims 1 to 6 in woven form.

9. The curtaining fabric (20) according to Claim 8, wherein warp yarn (22) and weft yarn (21) densities in the fabric (20) are 10-50 yarns per centimeter.

10. A production method of a curtaining fabric (20), characterized by the process steps of- warping warp yarns (22) using a yarn (10), drawing-in of the warp (22),- weaving by inserting the weft (21) using the yarn (10), subjecting the woven fabric (20) to a thermal textile finishing process on stender at 110-190°C at 5-35 m / min, melting of the melting yarn (12) in the yarn (10) structure by means of the heat applied during thermal processing, hardening and stabilization of the woven fabric (20).

11. The production method of a curtain fabric (20) according to Claim 10, wherein the fabric (20) is woven on a weaving machine in different constructions such as plain weave or panama.

Images