A type of yarn and fabric made of this yarn

Abstract

The present invention relates to a bicomponent yarn that does not comprise polyvinyl chloride (PVC), which is specifically designed for indoor and outdoor textiles and curtaining applications, particularly allowing the transmission of solar light while blocking solar heat, and a fabric obtained from this yarn.

Description

[0001] A TYPE OF YARN AND FABRIC MADE OF THIS YARN Technical Area

[0002] The present invention relates to a yarn having multiple functional properties to be used in indoor and outdoor textiles and curtaining (screening) applications and related to a fabric produced from this yarn.

[0003] The invention specifically discloses a bicomponent yarn providing solar light transmission while blocking solar heat, being environmentally friendly by absence of polyvinyl chloride (PVC) or chemical substances, and discloses a fabric obtained from this yarn.

[0004] State of the Art

[0005] In the textile industry, it is becoming prominent for the yarn used and the fabric obtained from these yarns to have a sustainable and ecological approach. As a result, there is a rapidly increasing demand for recycled and eco-friendly products. Therefore, alternative solutions are being sought for materials used in indoor and outdoor textiles and curtaining applications that are harmful to health and the environment and cannot be recycled. Regulating heat and light transmission in products used in curtaining applications is of great importance. Fabrics for this use are generally produced from yarns blended with fiberglass and PVC. In the current technique, the yarns used in the product groups manufactured to date are coated with PVC material, which is known to be harmful to human health. In addition to the risk of the PVC material flaking off in fragments over time, the fact that the product is not suitable for recycling creates disadvantages. Furthermore, the dust generated when cutting the fabric made from fiberglass-comprising yarn during the curtain manufacturing process poses a health risk and creates challenges in operational processes. In the production method of PVC-coated yarns, yarn coating is performed by passing a carrier (core) yarn through a melt. While other synthetic yarns such as glass fiber (GF), polyester, nylon, and all kinds of natural, synthetic fibers or mixtures are used for 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 process of thefinal coated 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.

[0006] Yarns and fabrics of the aforementioned type are used in curtaining systems, particularly in outdoor spaces. These fabrics are expected to have a robust structure and be resistant to all environmental conditions. It is expected that the fabric has protection and shading properties in outdoor spaces. In addition, the fabric must be special and resistant to heat and UV rays.

[0007] In the current technique, fabrics used for transmitting solar light while blocking solar heat are produced from yarns blended with fiberglass and PVC. PVC-coated yarn and the fabric made of this yarn have an artificial appearance. Furthermore, PVC-coated fabric can change in shape and size over time. Fabrics used in known curtaining applications are particularly problematic in terms of weight, cost, and appearance features. The touch (texture) of the fabric has an artificial appearance, particularly because PVC is used. Moreover, the fact that PVC is exposed to environmental conditions and creates bad odors over time creates problems in the fabric.

[0008] As a result of these problems, some of the techniques developed are provided below. Patent document TR 2015 / 07441 is the applicant's previously registered patent. This invention relates to a yarn consisting of at least one polyester outer yarn wrapped around a polyester inner yarn, instead of using PVC as in the prior 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 as the inner yarn and a bicomponent PET melting 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 fabrics. This limits the aesthetic use of fabric.

[0009] In our invention, however, a bicomponent yarn manufactured from polymers is used instead of this textured PET yarn. With yarn usage in our invention, a clean appearance close to natural fiber can be achieved, and the uneven appearance that the previous invention could not overcome is eliminated. It has been determined by tests that the durability of the yarn and fabric created in our invention in indoor and outdoor curtaining is better than the invention disclosed in patent document TR 2015 / 07441.Utility model document No. TR 2018 / 17954 relates to the use of at least one PVC-coated yarn in narrow weaving produced for use in tarpaulins, greenhouses, tents, and ship sails. In the production method of PVC-coated yarns, yarn coating is performed by passing a carrier (core) yarn through a melt. While other synthetic yarns such as glass fiber (GF), polyester, and nylon, not limited to these, and all kinds of natural, synthetic fibers or mixtures including their combinations are used as the inner yarn, the outer coating melt is polyvinyl chloride (PVC). This yarn production method, unsuitable for a standard production facility, requires specialized machinery for weaving and processing PVC-coated yarns into finished products. Since the process of producing the final coated yarn is chemical, chemical waste is generated. Therefore, integrated production facilities for this yarn are of paramount importance.

[0010] On the other hand, the bicomponent yarn produced in our invention is an environmentally friendly and green product. Furthermore, our invention is recyclable as it does not comprise PVC and does not endanger human health.

[0011] In the light of the above explanations, the yarns used in indoor and outdoor curtains in the current technique are coated with PVC material, which is harmful to human health and cannot be recycled. Furthermore, the use of fiberglass as an inner yarn is also common in the current technique. The dust generated from the fiberglass during the cutting process of the fabric obtained from this inner yarn during the curtain manufacturing process also poses a health risk to human health. In summary, current applications cause the use of substances that are harmful to human health and the creation of non-recyclable products. Additionally, achieving an artificial appearance with the PVC used, the deformation of PVC in shape and size overtime, and the formation of bad odors are known technical problems. Therefore, due to the disadvantages described above and the insufficiency of current solutions regarding the subject, a need has arisen for development in the relevant technical field.

[0012] Objectives and Brief Description of the Invention

[0013] The main purpose of the present invention is to obtain a long-lasting, environmentally friendly, and recyclable yarn and fabric.Another purpose of the invention is to provide a bicomponent yarn that shows high performance for indoor-outdoor textiles that can adapt to harsh weather conditions and has the desired UV resistance, and to provide a fabric made of this yarn.

[0014] Another purpose of the invention is to obtain a bicomponent yarn with a natural appearance and a fabric made of this yarn. It is expected that the said fabric does not change shape and size over time, does not create a bad odor, has no uneven (thick and thin) in its appearance, and has a clean look.

[0015] To achieve the aforementioned objectives, the invention is a bicomponent yarn manufactured from combinations comprising two or more of PET (Polyethylene terephthalate), rPET (recycled PET), CoPET, PBT (Polybutylene terephthalate), PTT (Polytrimethylene terephthalate), PP (Polypropylene), and PA (Polyamide) polymers for curtaining applications. In the polymer combinations that comprise the bicomponent yarn described here, one of the polymers comprises at least 10% by weight.

[0016] The bicomponent yarn is preferably manufactured from filaments such as POY and FDY or staple fibers. The filament mentioned here can preferably be in the range of 20-5000 denier. The filament range is 2-1000. It is preferably produced with a fiber size of staple fiber in the range of 0-3.2 microns.

[0017] In a preferred embodiment, the bicomponent yarn is obtained by yarn formation techniques such as texturing, twisting, IMG, and has a twist of 20-3000 turns / m. Preferred cross-sectional shapes of the bicomponent yarn are islands-in-the-sea, side-by-side, sheath-core, and segmented pie.

[0018] The invention is also curtain fabric comprising the bicomponent yarn in all weaving constructions, preferably as plain weave and panama.

[0019] Brief Description of Figures

[0020] Figure 1 shows the cross-sectional views of bicomponent fibers according to their cross-sectional shapes.

[0021] Figure 1.1 shows the cross-sectional view of a side-by-side bicomponent fiber.

[0022] Figure 1.2 shows the cross-sectional view of a concentric bicomponent fiber.

[0023] Figure 1.3 shows a different cross-sectional view of a concentric bicomponent fiber. Figure 1.4 shows the cross-sectional view of an island-in-sea bicomponent fiber.Figure 1.5 shows the cross-sectional view of a segmented pie bicomponent fiber.

[0024] Detailed Description of the Invention

[0025] The invention subject to the application relates to multi-functional textile surfaces used in upholstery, awnings, tulle, backgrounds, outdoor textiles, indoor textiles, and curtaining (screen, roller blind) systems. The invention also relates to the textile product used in indoor and outdoor curtaining systems. The invention discloses a bicomponent yarn providing solar light transmission while blocking solar heat, being environmentally friendly by absence of polyvinyl chloride (PVC) or chemical substances, and discloses a fabric obtained from this yarn.

[0026] The bicomponent yarn (fiber) described in our invention is made of at least two or more polymer components. The polymers are selected from PET (Polyethylene terephthalate), rPET (recycled PET), CoPET, PBT (Polybutylene terephthalate), PTT (Polytrimethylene terephthalate), PP (Polypropylene), and PA (Polyamide). A synthetic fiber (bicomponent yarn) is produced by preparing a mixture using at least two or more different polymers and then extruding it.

[0027] These polymers can be used in example combinations such as PET+PBT, PET+PA, PET+PTT, PP+PET, rPET+PBT, rPET+PTT, rPET+PA, PP+rPET, PA+PP, PA+PBT, PP+PBT, CoPET+PBT, CoPET+PA, CoPET+PTT, PP+CoPET.

[0028] In the preferred bicomponent yarn; 20-5000 denier, 2-1000 filaments, and FDY, POY versions can be used. Yarn production can be carried out in form of filament (POY or FDY) or staple fiber. Production can be made from staple fiber with a fiber size in the range of 0-3.2 microns. In a preferred embodiment, yarn formation techniques such as texturing, twisting, img (permanent, soft, slight), twist (20-3000 turns / m), etc., are used.

[0029] The yarn obtained with these polymers can be produced in all bicomponent yarn crosssections (sheath-core, side-by-side, islands-in-the-sea, or segmented pie) known in the art. The production of the bicomponent yarn is carried out by flowing two different polymers that will form the same fiber through the same spinneret and drawing them together. Bicomponent fibers are shown in Figure 1 according to their cross-sectional shapes. As can be seen in Figure 1, bicomponent fibers are classified as side-by-side (Figure 1.1), concentric (Figures 1.2 and 1.3), island-in-sea (Figure 1.4), or segmented pie (Figure 1.5).For side-by-side fibers (Figure 1.1), there are generally two components in two or more separate regions longitudinally in one fiber. In concentric bicomponent fibers (Figures 1.2 and 1.3), there is one component at the center and another component surrounding it from the outside. In the island-in-the-sea (Figure 1.4) technique, the fibers are drawn from a mixture of two polymers in the necessary ratio, and one polymer remains suspended in the second melt in the form of droplets. In the segmented pie (Figure 1.5) technique, two different polymers that do not mix with each other are arranged in the fiber in the form of pie slices or triangular prisms. The difference of this method from the islands-in-the-sea method is that, instead of removing one polymer, both polymers are located within the fiber. With this method, two different and more properties can be imparted to the fibers. Masterbatch can also be added to the polymers before the extruder process to impart very different properties to the fibers. Thus, additional properties such as color, flame retardancy, antibacterial structure, full matte, matte can be imparted. Furthermore, yarns that are suitable for recycling, have reduced water usage with the masterbatch dyeing technique, are eco-friendly, and have properties that do not endanger human health are obtained.

[0030] The prepared yarns can be woven as fabric according to the desired weft-warp densities, desired fabric widths, and fabric construction. The fabric which is the subject of the invention is realized by the steps of warping from the produced bicomponent yarn, drawing-in the warp, and weaving the fabric in different constructions (plain weave, panama, etc.) on a weaving machine by picking weft yarn. The obtained fabric is woven in all constructions, preferably plain weave and panama constructions. The construction of the fabric and the technical performance of the bicomponent yarns used are the most important factors affecting strength.

[0031] The woven fabric is subjected to a thermal textile finishing process. This process is carried out at 110-190°C at a speed of 5-35 m / min. Parameters such as fabric width, weight, and shrinkage can be adjusted at this stage. While the fabric provides the blocking of solar heat, it can transmit solar light at a level that will provide the illumination of the environment.

[0032] In the known technique, an uneven appearance occurs on the surface of curtain fabrics woven by using textured yarn. In our invention, a clean and clear appearance is achieved instead of an uneven appearance by using bicomponent yarn. Therefore, the developedfabric and the curtain made of this fabric can be used for products that show high performance for indoor and outdoor textiles that can adapt to extreme weather conditions. Curtain fabrics can be divided into various groups as mechanism-based products such as curtaining, tulle, roller-screen, depending on the area of use. The fabric of the invention belongs to screen fabric. With the invention, it is intended to produce a PVC-free, UV-resistant curtain fabric in indoor and outdoor curtaining systems. Thanks to the developed bicomponent yarn structure, an odorless, user-friendly, environmentally friendly, and recyclable curtain fabric is provided as it does not compise harmful chemicals such as PVC, formaldehyde, halogen.

[0033] Screen curtains are quite successful in controlling the daylight intake of indoorand outdoor spaces thanks to their special fabric structure. Sunlight causes the fading of home textile products by directly affecting them in a short time, the easy heating of electronic devices, the deformation of parquet and furniture, and most importantly, reasons that bother people. Screen curtains break direct sunlight in the environments where they are used thanks to their features. While they provide a bright environment, they also eliminate the damage caused by UV rays to textile products, electronic devices, and people in the environment. Besides these features of screen curtains, they also have an aesthetic appearance advantage by allowing different patterns.

[0034] In addition to the curtain fabric produced within the scope of the invention being modern and aesthetic, it provides micro-ventilation to users. Thanks to the special texture of the fabric, various advantages such as air circulation, light control, and heat insulation; protection against UV, UVA, and UVB rays, and protection from the burning effect of the sun during sudden weather changes are provided.

Claims

CLAIMS1. A bicomponent yarn for indoor and outdoor textiles and curtaining applications, characterized in that it is made of combinations comprising two or more polymers of PET (Polyethylene terephthalate), rPET (recycled PET), CoPET, PBT (Polybutylene terephthalate), PTT (Polytrimethylene terephthalate), PP (Polypropylene), and PA (Polyamide).

2. The bicomponent yarn according to Claim 1, wherein one of the polymers in the polymer combinations is at least 10% by weight.

3. The bicomponent yarn according to Claim 1, wherein it is made of filament or staple fiber.

4. The bicomponent yarn according to Claim 3, wherein the filament is in the 20-5000 denier range.

5. The bicomponent yarn according to Claims 3 and 4, wherein the filament is in the 2-1000 filament range.

6. The bicomponent yarn according to Claim 3, wherein the staple fiber has a fiber size in the 0-3,2 micron range.

7. The bicomponent yarn according to the preceding claims, wherein the bicomponent yarn is obtained by yarn formation techniques such as texturing, twisting, IMG.

8. The bicomponent yarn according to Claims 3 and 4, wherein it is obtained with a twist of 20-3000 turns / m.

9. The bicomponent yarn according to the preceding claims, wherein it has a cross-section in the form of islands-in-the-sea, side-by-side, concentric, and segmented pie.

10. A curtain fabric characterized by comprising the bicomponent yarn mentioned in Claims 1 to 8 in woven form.

11. The fabric according to Claim 10, wherein the bicomponent yarn is in all weaving constructions, preferably plain weave or panama weaving.

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