Composite Yarn Composition for Flexible Cut Protection
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Solution Overview
Problem
Existing yarns used in protective apparel are thick, heavy, stiff, and uncomfortable, compromising flexibility and comfort while providing high levels of protection, and are often expensive or incorporate irritating materials like steel or copper wire.
Innovation Solution
A composite yarn is formed by blending high tenacity synthetic fibers (≥1 N/tex) with lower tenacity fibers (≤0.95 N/tex), both stretch broken or cut to 75-150 mm lengths, optionally wrapped with a wrapping yarn, to create a flexible and comfortable yarn suitable for protective articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick, heavy yarns with high denier (e.g., higher than 600 denier) are used to provide high levels of protection, then cut resistance and abrasion resistance are improved, but flexibility and comfort deteriorate
Solution Approach 1:
The patent uses a composite yarn structure combining high tenacity fibers (≥1 N/tex) with softer fibers (≤0.95 N/tex) in a blended ratio. This composite approach allows the yarn to provide high cut resistance through the high tenacity fibers while maintaining flexibility and comfort through the softer fibers, resolving the contradiction between protection and ease of operation.
Solution Approach 2:
The patent applies local quality by having different fiber types within the same yarn serve different functions. The high tenacity fibers are distributed throughout to provide cut resistance where needed, while the softer fibers are interspersed to provide comfort and flexibility in contact with skin, allowing different regions of the yarn to have different properties.
2Strength
If stiff materials such as steel or copper wire are incorporated into yarns to augment protective properties, then cut resistance and abrasion resistance are improved, but comfort and flexibility deteriorate
Solution Approach 1:
The patent replaces expensive, irritating metal wires (steel or copper) with high tenacity synthetic fibers that provide equivalent or superior cut resistance without skin irritation. These synthetic fibers serve as a disposable-like alternative that achieves the same protective function without the harmful effects of metal materials.
Solution Approach 2:
The patent changes the material parameter from metal wires to high tenacity synthetic fibers, altering the chemical composition and physical properties of the yarn. This parameter change maintains cut resistance while eliminating skin irritation and improving flexibility, as the synthetic fibers have different mechanical and chemical characteristics compared to metal.
3Strength
If high tenacity fibers are used to provide protective properties, then cut resistance is improved, but cost increases
Solution Approach 1:
The patent applies partial action by using a blended mixture of high tenacity fibers and softer fibers rather than 100% high tenacity fibers. This partial use of high tenacity fibers provides sufficient cut resistance for protective apparel while reducing material costs compared to using only high tenacity fibers throughout the entire yarn.
Data Source
Figure 1
Figure 2A~2D
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 75 mm to 150 mm. A method of making the composite yarn and articles formed from the composite yarn are also disclosed.