Composite Cut-Resistant Yarn Structure for Flexible Protective Gloves
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Solution Overview
Problem
Existing cut-resistant yarns and fabrics do not effectively balance the properties of strength, flexibility, and resistance to cutting, particularly in garments like gloves and sleeves, necessitating improved manufacturing methods to enhance their protective capabilities.
Innovation Solution
A composite yarn structure is developed by combining core-spun yarns with covering layers, utilizing materials like basalt and polyester fibers, and securing them with additional layers to enhance cut resistance while maintaining flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single yarn structure is used to provide cut resistance, then the structure must be complex to achieve sufficient protection, but this increases manufacturing complexity and reduces flexibility
Solution Approach 1:
The cut-resistant garment is constructed from multiple separate yarn types (core-spun yarn with cut-resistant core and staple fibers, covering yarn with cut-resistant core and covering fibers) that are woven together in a specific pattern. This segmentation allows each yarn type to contribute specific properties (cut resistance, flexibility, coverage) without requiring a single complex yarn structure.
Solution Approach 2:
The invention uses composite yarn structures combining different fiber types (cut-resistant core filaments with staple fibers or covering fibers) to achieve multiple functions simultaneously. The core-spun yarn combines cut-resistant core with flexible staple fibers, while the covering yarn combines cut-resistant core with covering fibers, creating a composite material system that provides both protection and comfort.
2Strength
If more cut-resistant material is used to improve protection, then cut resistance increases, but the flexibility and comfort of the garment decreases
Solution Approach 1:
The cut-resistant core filaments are strategically positioned within the yarn structure and garment weave to provide protection only where needed, while the surrounding staple fibers and covering fibers provide flexibility and comfort in non-critical areas. The interlocking weave pattern ensures cut-resistant elements are concentrated at stress points while maintaining overall garment flexibility.
Solution Approach 2:
The invention varies the parameters of the yarn construction, including the ratio of cut-resistant core to covering fibers, the twist level, and the weave density, to optimize the balance between cut resistance and flexibility. Different yarn types with varying compositions are used in different locations of the garment to achieve local optimization of both protection and comfort.
Data Source
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AI summary
Embodiments relate generally to a cut-resistant composite yarn structure. The cut-resistant yarn structure comprises a core-spun yarn comprising a first cut-resistant core filament and staple fibers spun over the first cut-resistant core filament, a covering yarn comprising a second cut-resistant core filament and a first covering layer wound over the second cut-resistant core filament, where the first covering layer comprises a first filament, and a second covering layer wound over the core-spun yarn and the covering yarn, where the second covering layer comprises a second filament. The cut-resistant composite yarn structure can be used to manufacture cut-resistant cloth which may in turn be used to manufacture cut-resistant garments such as cut-resistant gloves, cut-resistant sleeves, and other cut-resistant garments.