U.S. patent application number 11/589210 was filed with the patent office on 2007-06-28 for method for coating fibers and yarns and the coated products formed therefrom.
This patent application is currently assigned to SUPREME CORPORATION. Invention is credited to Nathaniel H. Kolmes, James Threlkeld.
Application Number | 20070144135 11/589210 |
Document ID | / |
Family ID | 38006392 |
Filed Date | 2007-06-28 |
United States Patent
Application |
20070144135 |
Kind Code |
A1 |
Kolmes; Nathaniel H. ; et
al. |
June 28, 2007 |
Method for coating fibers and yarns and the coated products formed
therefrom
Abstract
A method for coating one or more yarn components, either
individually or in an assembled configuration, with a (co)polymer
coating is provided involving (i) immersing the one or more yarn
components, either individually or as an assembled unit of two or
more of said yarn components, in a treatment bath containing a
carrier medium and a (co)polymer that can be dissolved or dispersed
in the carrier medium; (ii) removing the one or more yarn
components from the treatment bath; and (iii) evaporating excess
carrier medium from the one or more yarn components to thereby form
a coating of the (co)polymer on a surface of the one or more yarn
components; and the coated yarn products formed thereby.
Inventors: |
Kolmes; Nathaniel H.;
(Hickory, NC) ; Threlkeld; James; (Indian Trail,
NC) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND, MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Assignee: |
SUPREME CORPORATION
Conover
NC
28613
|
Family ID: |
38006392 |
Appl. No.: |
11/589210 |
Filed: |
October 30, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60730829 |
Oct 28, 2005 |
|
|
|
Current U.S.
Class: |
57/232 |
Current CPC
Class: |
D02G 3/404 20130101;
D06M 15/564 20130101; D06M 15/333 20130101; D02G 3/38 20130101;
D06M 15/248 20130101 |
Class at
Publication: |
057/232 |
International
Class: |
D02G 3/36 20060101
D02G003/36 |
Claims
1. A composite yarn comprising: a. two or more yarn components; and
b. a (co)polymer coating on at least one of said two or more yarn
components.
2. The composite yarn of claim 1, wherein said two or more yarn
components form (i) a core comprising at least one of said two or
more yarn components, and (ii) one or more wrapping layers wrapped
around said core, wherein said (co)polymer coating coats at least
one of (i) said core, (ii) one or more of said wrapping layers, or
both.
3. The composite yarn of claim 2, wherein said core comprises two
or more yarn components, at least one of which is a
high-performance fiber.
4. The composite yarn of claim 1, wherein said two or more yarn
components are blended together and said (co)polymer coating forms
a coating around the resultant blended yarn.
5. The composite yarn of claim 1, wherein said (co)polymer is at
least one member selected from the group consisting of
polyvinylchloride, polyurethane polymers and copolymers, and
ethylene-vinyl acetate copolymers.
6. The composite yarn of claim 2, wherein said (co)polymer is at
least one member selected from the group consisting of
polyvinylchloride, polyurethane polymers and copolymers, and
ethylene-vinyl acetate copolymers.
7. The composite yarn of claim 2, wherein said (co)polymer forms a
coating on an exterior surface of the assembled composite yarn.
8. The composite yarn of claim 2, wherein said (co)polymer forms a
coating directly on said core.
9. The composite yarn of claim 2, wherein said core comprises two
or more yarns in an arrangement with respect to each other selected
from parallel, twisted around one another or one wrapped around the
other(s).
10. The composite yarn of claim 9, wherein said (co)polymer forms a
coating around at least one of said two or more yarns in said
core.
11. The composite yarn of claim 2, wherein said (co)polymer coating
coats said core and at least one of said wrapping layers.
12. The composite yarn of claim 11, wherein said (co)polymer
coating coats said core and each of said wrapping layers.
13. A method for coating one or more yarn components with a
(co)polymer, comprising: a. immersing said one or more yarn
components, either individually or as an assembled unit of two or
more of said yarn components, in a treatment bath comprising a
carrier medium and a (co)polymer that can be dissolved or dispersed
in said carrier medium; b. removing said one or more yarn
components from said treatment bath; and c. evaporating excess
carrier medium from said one or more yarn components to thereby
form a coating of said (co)polymer on a surface of said one or more
yarn components.
14. The method of claim 13, wherein said carrier medium is
water.
15. The method of claim 13, wherein said (co)polymer is at least
one member selected from the group consisting of polyvinylchloride,
polyurethane polymers and copolymers, and ethylene-vinyl acetate
copolymers.
16. The method of claim 13, wherein said one or more yarn
components are assembled to form a composite yarn prior to said
immersing step.
17. The method of claim 13, wherein said treatment bath further
comprises at least one member selected from the group consisting of
antimicrobial agents, antistatic agents, colorants, and
lubricants.
18. The method of claim 13, wherein said immersing step is
performed by passing said one or more yarn components continuously
through said treatment bath.
19. The method of claim 18, wherein said evaporating step is
performed by wrapping said one or more yarn components around a
heated roller a number of revolutions sufficient to permit
evaporation of substantially all of said carrier medium while in
contact with said heated roller at a given continuous throughput of
said one or more yarn components.
20. The method of claim 19, further comprising a step of collecting
said coated one or more yarn components on a bobbin or tube.
21. The method of claim 19, further comprising drying said coated
one or more yarn components by heating said coated one or more yarn
components at a temperature sufficient to remove the remainder of
said carrier medium.
22. The method of claim 21, wherein said drying step is performed
by passing said coated one or more yarn components through a heated
oven at a temperature and for a duration of time sufficient to
effect said drying.
23. The method of claim 19, further comprising drying the collected
coated one or more yarn components by placing the collected yarn
and the tube or bobbin on which the one or more yarn components are
collected into a heater at a temperature and for a duration of time
sufficient to effect said drying.
24. The method of claim 13, wherein said (co)polymer is present in
said treatment bath in an amount of from 1-15% by weight.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates generally to a method for
providing one or more types of coatings on a fiber or yarn to
enhance the properties of the fiber or yarn, and/or protect the
fiber or yarn from infiltration by contaminants, and the coated
fibers or yarns produced therefrom.
[0003] 2. Discussion of the Background
[0004] There are many types of fibers and yarns that are
conventionally produced, from monofilaments to multicomponent
composite yarns. However, often the yarns produced do not have a
good feel, or "hand" as it is called in the trade, or do not
possess good wear and durability characteristics. Further, in the
area of composite yarns, it can often be difficult to provide a
yarn of a single consistent color, due to the different types of
fibers making up the various constituents of the composite
yarn.
[0005] Many attempts have been made through the years to improve
the hand of fiber and yarn products, most often by application of
some sort of finish chemical. These are conventionally liquid
materials that coat the surface of the fibers, and provide better
processability and hand. Oftentimes, however, even application of a
finish does not avoid fuzziness of a final yarn product.
[0006] One method for dyeing multicomponent composite yarns has
been proposed in U.S. Ser. No. 10/972,332, filed Oct. 26, 2004, the
contents of which are incorporated herein by reference. However,
this method of dyeing, while providing consistent coloring of any
type of fiber and mixtures of fibers, does not provide improved
processability, durability and hand.
SUMMARY OF THE INVENTION
[0007] Accordingly, one object of the present invention is to
provide a method for coating a yarn component, or plurality of yarn
components individually or assembled into a single unit, with a
(co)polymer that is environmentally friendly, and efficient.
[0008] A further object of the present invention is to provide a
method for coating a yarn component, or plurality of yarn
components individually or assembled into a single unit, that can
also color the yarn component simultaneously and uniformly.
[0009] A further object of the present invention is to provide a
method for coating a composite yarn with a (co)polymer to improve
processing and durability of the resulting coated product, as well
as prevent infiltration of contaminants into the body of the
resulting coated yarn product.
[0010] A further object of the present invention is to provide a
coated yarn product prepared by the method of the present
invention.
[0011] These and other objects of the invention have been satisfied
by the discovery of a method for coating one or more yarn
components with a (co)polymer comprising: [0012] a. immersing said
one or more yarn components, either individually or as an assembled
unit of two or more of said yarn components, in a treatment bath
comprising a carrier medium and a (co)polymer that can be dissolved
or dispersed in said carrier medium; [0013] b. removing said one or
more yarn components from said treatment bath; and [0014] c.
evaporating excess carrier medium from said one or more yarn
components to thereby form a coating of said (co)polymer on a
surface of said one or more yarn components; and the coated
products made thereby.
BRIEF DESCRIPTION OF THE FIGURE
[0015] A more complete appreciation of the invention and many of
the attendant advantages thereof will be readily obtained as the
same becomes better understood by reference to the following
detailed description when considered in connection with the
accompanying drawings, wherein:
[0016] FIG. 1 represents a preferred embodiment of the process of
the present invention, wherein one or more yarn components (13) are
passed through a treatment bath (11) in which is contained a
treatment composition.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The term "fiber" as used herein refers to a fundamental
component used in the assembly of yarns and fabrics. Generally, a
fiber is a component which has a length dimension which is much
greater than its diameter or width. This term includes ribbon,
strip, staple, and other forms of chopped, cut or discontinuous
fiber and the like having a regular or irregular cross section.
"Fiber" also includes a plurality of any one of the above or a
combination of the above.
[0018] As used herein, the term "high performance fiber" means that
class of synthetic or natural non-glass fibers having high values
of tenacity greater than 10 g/denier, such that they lend
themselves for applications where high abrasion and/or cut
resistance is important. Typically, high performance fibers have a
very high degree of molecular orientation and crystallinity in the
final fiber structure.
[0019] The term "filament" as used herein refers to a fiber of
indefinite or extreme length such as found naturally in silk. This
term also refers to manufactured fibers produced by, among other
things, extrusion processes. Individual filaments making up a fiber
may have any one of a variety of cross sections to include round,
serrated or crenular, bean-shaped or others.
[0020] The term "yarn" as used herein refers to a continuous strand
of textile fibers, filaments or material in a form suitable for
knitting, weaving, or otherwise intertwining to form a textile
fabric. Yarn can occur in a variety of forms to include a spun yarn
consisting of staple fibers usually bound together by twist; a
multi filament yarn consisting of many continuous filaments or
strands; or a mono filament yarn which consist of a single
strand.
[0021] For convenience, the term "yarn component" as used herein,
encompasses fiber, monofilament, multifilament and yarn.
[0022] The term "composite yarn" refers to a yarn prepared from two
or more yarns, which can be the same or different. Composite yarn
can occur in a variety of forms wherein the two or more yarns are
in differing orientations relative to one another. The two or more
yarns can, for example, be blended, parallel, wrapped one around
the other(s), twisted together, or combinations of any or all of
these, as well as other orientations, depending on the properties
of the composite yarn desired. Examples of such composite yarns are
provided in U.S. Pat. Nos. 4,777,789; 5,177,948; 5,628,172;
5,845,476; 6,351,932; 6,363,703 and 6,367,290, the contents of
which are hereby incorporated by reference.
[0023] The term "air interlacing" as used herein refers to
subjecting multiple strands of yarn to an air jet to combine the
strands and thus form a single, intermittently commingled strand.
This treatment is sometimes referred to as "air tacking." This term
is not used to refer to the process of "intermingling" or
"entangling" which is understood in the art to refer to a method of
air compacting a multifilament yarn to facilitate its further
processing, particularly in weaving processes. A yarn strand that
has been intermingled typically is not combined with another yarn.
Rather, the individual multifilament strands are entangled with
each other within the confines of the single strand. This air
compacting is used as a substitute for yarn sizing and as a means
to provide improved pick resistance. This term also does not refer
to well known air texturizing performed to increase the bulk of
single yarn or multiple yarn strands. Methods of air interlacing in
composite yarns and suitable apparatus therefore are described in
U.S. Pat. Nos. 6,349,531; 6,341,483; and 6,212,914, the relevant
portions of which are hereby incorporated by reference.
[0024] The present invention is directed to a method for treating
or coating a yarn component that is quick, efficient, low-cost and
multi-dimensional. Within the context of the present invention, the
term "multi-dimensional" is used to denote the ability to provide
multiple fiber or yarn treatments in a single pass through a
treatment bath. In its broadest embodiment, the present method is
as depicted in FIG. 1. FIG. 1 shows one or more yarn components
(13) being passed through a treatment bath (11) in which is
contained a treatment composition. The treated yarn components are
then wound around a heated roller (12) one or more revolutions,
followed by takeup on tubes or bobbins (4).
[0025] The treatment composition can take any form, including but
not limited to solutions, dispersions and emulsions. The treatment
composition contains at least one (co)polymer suitable for coating
the yarn component. This at least one (co)polymer can be in
solution or present as a (co)polymer emulsion or dispersion. The
(co)polymer can be present in any desired amount in the treatment
composition, preferably from about 1-15% by weight of the
composition, more preferably from about 2-10% by weight, most
preferably from about 3-9% by weight. Preferred (co)polymers for
use as this component are polyvinylchloride (PVC), polyurethane
polymers and copolymers, and ethylene-vinyl acetate copolymers.
[0026] The treatment composition can optionally contain one or more
additional treatment components, including but not limited to
antimicrobial agents, antistatic agents, colorants, and lubricants.
Preferably, the treatment bath contains the one or more
(co)polymers and at least one of the additional components, more
preferably at least two of the additional components. In a most
preferred embodiment, the treatment composition comprises an
aqueous solution or dispersion of ethylene-vinyl acetate copolymer,
a colorant and an antimicrobial agent. Most preferably, the
components contained in the treatment composition are chemically
compatible (i.e. do not detrimentally react with one another; note
this does permit reaction or interaction between components, so
long as the reaction or interaction is not detrimental to the
formation of the (co)polymer coating, or other desired properties,
such as color, antimicrobial properties or anti-static properties,
etc.).
[0027] The treatment composition is preferably aqueous, although
non-aqueous compositions are also included within the present
invention. When non-aqueous compositions are used, proper
precautions must be taken for removal of organic vapors during the
drying step at the heated drying roller. The treatment composition
can be used at ambient or room temperature or can be heated or
cooled as desired.
[0028] The yarn component to be treated can be made of or contain
any natural or synthetic fiber, alone or in combinations or blends,
including, but not limited to, cotton, wool, nylons, polyesters,
polyethylenes, polypropylenes, aramids, glass, and metal fibers.
The component to be treated may be in the form of a monofilament
fiber, multifilament fiber, yarns made from these fibers, composite
yarns, or the components of composite yarns, such as the core or
individual sheath or wrap layers of the composite yarn.
[0029] In a preferred embodiment, the process is used to treat the
core of a composite yarn such as those disclosed in U.S. Pat. Nos.
5,177,948 (already incorporated by reference above). Most
preferably, the composite yarn being treated has a core that
contains no high performance fibers (in the present context, "high
performance fibers" is defined as fibers having a tenacity of at
least 10 g/den, such as glass, aramids, and extended-chain
polyethylene). In this embodiment, when the treatment composition
is applied and dried, the resulting core has surprisingly improved
resistance to cutting, compared to the same composition having no
treatment composition applied. This process permits the preparation
of composite yarns that are therefore cut-resistant or cut-proof,
without the costly inclusion of high-performance fibers. The
process further permits the introduction of color into the product,
as well as anti-microbial and or antistatic properties as desired,
all in a single treatment bath, thus lowering production costs
significantly.
[0030] In another preferred embodiment of the present process, the
composite yarn contains a low-melting encasing yarn in the core,
which has a softening point below the temperature of the heated
drying roll (4), such that during the drying process, the encasing
yarn softens and forms an encasing covering on the underlying fiber
or yarn. In doing so, the composite yarn that results has a coating
of (co)polymer on the exterior of the outer sheath or wrap layer,
with an additional coating of the encasing yarn forming a layer
between the core and innermost sheath or wrap layer. Suitable
encasing yarns include, but are not limited to, those disclosed in
U.S. Pat. Nos. 6,230,524 and 6,367,290, the contents of which are
hereby incorporated by reference.
[0031] The present process can be used to improve the
cut-resistance of a composite yarn, and can also improve the
appearance and/or hand of a composite yarn. In particular, in some
instances when preparing conventional composite yarns, the
resulting product has high levels of fuzz present on the exterior
surface of the yarn. Additionally, in some instances conventional
composite yarns have a problem with evenness of the exterior
surface properties, particularly in dyeing or coloring of the
composite yarn. Using the present process to coat the exterior of
the yarn with a coating containing a (co)polymer as described
herein, then passing the coated product over the heated drying
roll, results in significant reductions of fuzz level.
Additionally, when the treatment bath contains a colorant in
addition to the (co)polymer, the colorant is evenly distributed by
the treatment composition, and evenly colors the (co)polymer
coating. This is particularly effective in providing better
uniformity of color in the final product, as the surface layer is
all the same (co)polymer, and thus has more uniform dye or colorant
uptake compared to uptake of the dye with the surface of the
composite yarn itself, which may have multiple types of fibers
exposed at the surface.
[0032] Although the present invention has been described with
preferred embodiments and examples of those embodiments, it is to
be understood that modifications and variations may be utilized
without departing from the spirit and scope of this invention, as
those skilled in the art would readily understand. Such
modifications and variations are considered to be within the
purview and scope of the appended claims
* * * * *