Composite Yarn Blending for Cut Resistance and Comfort
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing yarns used in protective apparel are thick, heavy, stiff, and uncomfortable, failing to provide a balance between protective properties and comfort, particularly when in direct contact with the skin, and are often expensive.
Innovation Solution
A composite yarn is formed by blending high tenacity synthetic fibers with lower tenacity fibers, such as chain-extended polyolefin and aramid fibers, along with optional inorganic fibers, to create a flexible and comfortable yarn with enhanced protective properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick, heavy yarns with high denier are used to provide protective properties, then cut resistance and abrasion resistance are improved, but comfort and flexibility deteriorate
Solution Approach 1:
The patent applies composite materials by blending high tenacity fibers (providing cut and abrasion resistance) with softer, more flexible fibers (providing comfort and flexibility). This creates a composite yarn that combines the protective properties of stiff fibers with the comfort properties of softer fibers, resolving the contradiction between protection and comfort.
Solution Approach 2:
The patent applies local quality by creating yarns with non-uniform fiber distribution and varying fiber properties along the yarn length. Different regions of the yarn have different fiber compositions, allowing specific areas to provide protection while other areas provide comfort, particularly when fibers are stretch-broken to create varied lengths and distributions.
2Strength
If stiff materials such as steel or copper wire are incorporated into yarns to enhance protective properties, then cut resistance is improved, but flexibility and comfort deteriorate
Solution Approach 1:
The patent replaces stiff metal wires with composite yarns combining high tenacity synthetic fibers and softer fibers. This achieves cut resistance through the high tenacity fibers without incorporating rigid metal elements that would compromise flexibility and comfort.
Solution Approach 2:
The patent changes the physical parameters of the protective fibers by stretch-breaking them to reduce their length and alter their mechanical properties. This reduces the stiffness and rigidity of the high tenacity fibers while maintaining their cut resistance, allowing them to be blended with softer fibers to create flexible, comfortable yarns.
3Strength
If high tenacity fibers are used to provide protective properties, then cut resistance and abrasion resistance are improved, but cost increases
Solution Approach 1:
The patent applies local quality by using stretch-broken fibers of varying lengths and properties distributed throughout the yarn. This creates regions of different fiber concentrations and orientations, optimizing protection where needed while reducing overall material costs through efficient use of high tenacity fibers.
Solution Approach 2:
The patent blends expensive high tenacity fibers with more economical softer fibers to create a cost-effective composite yarn. This reduces the overall cost compared to using 100% high tenacity fibers while maintaining adequate protective properties through the synergistic combination of fiber types.
4Strength
If yarns with high denier are used to achieve required protective levels, then protection is improved, but yarn thickness and weight increase
Solution Approach 1:
The patent uses composite yarns combining high tenacity fibers with softer, lighter fibers to achieve the required protective properties at lower weights. The high tenacity fibers provide strength and protection, while the softer fibers contribute to comfort and reduce overall yarn density and weight.
Solution Approach 2:
The patent changes the structural parameters of the yarn by stretch-breaking fibers to create varied lengths and improving the spinning process to create more efficient fiber packing. This increases the protective efficiency per unit weight, allowing thinner, lighter yarns to achieve the same protective levels as heavier traditional yarns.
Data Source
AI summary
A composite yarn is disclosed herein having a plurality of first synthetic fibers having a tenacity of greater than or equal to 1 N/tex; and a plurality of second fibers having a tenacity of less than or equal to 0.95 N/tex; wherein each of the first synthetic fibers and the second fibers are stretch broken and/or cut; and wherein each of the first synthetic fibers and the second fibers have an average length from about 75 mm to about 150 mm. A method of making the composite yarn and articles formed from the composite yarn are also disclosed.