U.S. patent application number 11/803699 was filed with the patent office on 2007-12-06 for uv and flame resistant textile polymer yarn.
Invention is credited to Charles A. Glew, Libby Kowalski.
Application Number | 20070281158 11/803699 |
Document ID | / |
Family ID | 38790611 |
Filed Date | 2007-12-06 |
United States Patent
Application |
20070281158 |
Kind Code |
A1 |
Glew; Charles A. ; et
al. |
December 6, 2007 |
UV and flame resistant textile polymer yarn
Abstract
The present invention describes a UV, flame-resistant, polymeric
coreless or hollow yarn or fiber, formed with either primary resins
or recycled or regrind thermoplastics that is useful for completing
a warp or weft in a woven or knitted web or mesh that can be used
for decorative wall coverings, window panels or shades, upholstery,
draperies, building panels, apparel and the like. The yarn may be
transparent, translucent, colored or multicolored.
Inventors: |
Glew; Charles A.;
(Pawcatusk, CT) ; Kowalski; Libby; (New York,
NY) |
Correspondence
Address: |
GUERRY LEONARD GRUNE
784 S VILLIER CT.
VIRGINIA BEACH
VA
23452
US
|
Family ID: |
38790611 |
Appl. No.: |
11/803699 |
Filed: |
May 15, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60800513 |
May 15, 2006 |
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Current U.S.
Class: |
428/375 |
Current CPC
Class: |
Y10T 428/2933 20150115;
D02G 3/443 20130101 |
Class at
Publication: |
428/375 |
International
Class: |
D02G 3/00 20060101
D02G003/00 |
Claims
1. A UV, flame resistant, polymer yarn comprising a hollow core
portion.
2. The polymer yarn of claim 1, wherein said polymer yarn comprises
polymers that may be poly-vinyl chlorides (PVC's), acrylates,
polycarbonates, or PETG resins and wherein said polymer yarn and
polymers comprising said yarn may comprise formed polymeric
sheets.
3. The polymer yarn of claim 2, wherein said polymer yarn is
comprised of either regrind polymer or recycled polymer.
4. The polymer yarn of claim 1, wherein said hollow portion is
located essentially concentrically within said polymer yarn.
5. The polymer yarn of claim 1, wherein said hollow portion may
vary in diameter from 0.001''-0.015'' longitudinally within said
polymer yarn and wherein a preferred diameter of 0.009''.
6. The polymer yarn of claim 1, wherein said polymer yarn provides
an outside diameter of 0.020''-0.125'' with preferred average
outside diameters of 0.060'', 0.040'', 0.024'' or 0.020''.
7. The polymer yarn of claim 1, wherein said polymer yarn includes
a wall thickness of at least 0.008'', preferably 0.010''.
8. The polymer yarn of claim 1, wherein said yarn is comprised of
coreless, solid filaments.
9. The polymer yarn of claim 6, wherein said outside diameter may
be non-uniform and either symmetrically or asymmetrically shaped
including flat, twisted, or irregular.
10. The polymer yarn of claim 1, wherein said polymer yarn may be
transparent, translucent, tinted, colored or opaque.
11. The polymer yarn of claim 1, wherein said polymer yarn may be
used coreless or constructed with a core material or with both said
coreless or said core material.
12. The polymer yarn of claim 1, wherein said polymer yarn may be
woven, non-woven or knitted with synthetic or natural materials as
warp or weft.
13. The polymer yarn of claim 12, wherein said polymer yarn is
woven, non-woven or knitted and may be a portion or the entirety of
a wall covering, window shade or panel track, upholstery, drapery
or encapsulated into a building panel.
14. The polymer yarn of claim 12, wherein said woven, non-woven, or
knitted polymer yarn may be open to the environment or encapsulated
between resin panels or translucent resin panels or translucent or
transparent laminate building materials of any composition such as
polycarbonate or acrylic resin and wherein said yarn may also be a
natural yarn.
15. The polymer yarn of claim 12, wherein said woven, non-woven, or
knitted polymer yarn is a structural mesh of said polymer yarn that
may be bonded by heat to said warp and weft or wherein each strand
of yarn may also be bonded to another strand of yarn.
16. The polymer yarn of claim 14, wherein said woven or knitted
polymer yarn complies with NFPA 701 large scale drapery test fire
ratings for woven or knitted polymer building or decorative
materials.
17. A method of producing UV, flame resistant, polymer yarn
comprising a hollow core portion, wherein producing of said polymer
yarn is by one of several methods including extrusion, spinning by
using a metering pump and spinneret assembly, or spinning and
drawing, or pultrusion, or a combination of any of these methods or
like methods.
18. The method according to claim 17, wherein said polymer yarn
comprises polymers that provide for UV and fire resistant
brominated and chlorinated polymers including flame resistant
polyvinyl chlorides (PVC's) or PETG resins and the like.
19. The method according to claim 17, wherein said hollow core
portion of said yarns is located essentially concentrically within
said polymer yarn.
20. The method according to claim 17, providing said hollow portion
may vary in diameter from 0.001''-0.015'' longitudinally within
said polymer yarn and wherein there is a preferred diameter of
0.009''.
21. The method according to claim 17, wherein said polymer yarn
provides an outside diameter of 0.020''-0.125'' with preferred
average outside diameters of 0.060'', 0.040'', 0.024'' or
0.020''.
22. The method according to claim 17, wherein said polymer yarn
provides a wall thickness of at least 0.008'', preferably
0.010''.
23. The method according to claim 21, wherein said outside diameter
provides a non-uniform and either symmetrically or asymmetrically
or irregular cross-sectional shape and wherein said outer diameter
along a horizontal length may include bumpy, thick or thin
sections.
24. The method according to claim 17, wherein said polymer yarn may
be transparent, translucent, tinted, colored or opaque.
25. The method according to claim 17, wherein said polymer yarn may
be used coreless, solid, or constructed with a core material or
with both said coreless or said core material.
26. The method according to claim 17, wherein said polymer yarn may
be woven, non-woven or knitted with synthetic or natural materials
as warp or weft.
27. The method according to claim 26, wherein said polymer yarn is
woven, non-woven or knitted and provides a portion or the entirety
of a wall covering, window shade or panel, upholstery, drapery or
building panel.
28. The method according to claim 27, wherein said woven or knitted
polymer yarn may be open to the environment or encapsulated between
transparent or translucent thermoplastic panels such as
polycarbonate or acrylic or translucent or transparent laminate
building materials of any composition and wherein said yarn may
also be a natural yarn.
29. The method according to claim 27, wherein said woven or knitted
polymer yarn may be bonded by heat to said warp and weft.
30. The method according to claim 27, wherein said woven or knitted
polymer yarn complies with NFPA 701 large scale drapery test fire
ratings and including ASTM E-84 regarding flammability and AATCC
16-1998 regarding light fastness for woven or knitted polymer
building materials.
31. The method according to claim 17, wherein said extruding
provides a UV, flame resistant, polymer yarn comprising a hollow
core portion comprising using a tubing die, a tip and die, a
spinnerette, or any other known satisfactory extrusion technique
known to be capable of producing said polymer yarn.
32. A UV, flame resistant, coreless polymer yarn comprising wherein
said polymer yarn comprises a hollow portion and may be used
coreless or constructed with a core material or with both said
coreless or said core material.
33. The polymer yarn of claim 32, wherein said polymer yarn
comprises polymers that may be brominated and chlorinated polymers
including flame resistant poly-vinyl chlorides (PVC's), acrylates,
or polycarbonates or PETG resins and the like.
34. The polymer yarn of claim 32, wherein said polymer yarn is
comprised of either regrind polymer or recycled polymer.
35. The polymer yarn of claim 32, wherein said hollow portion is
located essentially concentrically within said polymer yarn.
36. The polymer yarn of claim 32, wherein said hollow portion may
vary in diameter from 0.001''-0.015'' longitudinally within said
polymer yarn and wherein a preferred diameter of 0.009'' may be
utilized.
37. The polymer yarn of claim 32, wherein said polymer yarn
provides an outside diameter of 0.020''-0.125'' with preferred
average outside diameters of 0.060'', 0.040'', 0.024'' or
0.020''.
38. The polymer yarn of claim 32, wherein said polymer yarn
includes a wall thickness of at least 0.008'', preferably
0.010''.
39. The polymer yarn of claim 37, wherein said outside diameter may
be non-uniform and either symmetrically or asymmetrically shaped
including flat, twisted, or irregular.
40. The polymer yarn of claim 32, wherein said polymer yarn may be
transparent, translucent, tinted, colored or opaque.
41. The polymer yarn of claim 32, wherein said polymer yarn may be
used coreless or constructed with a core material or with both said
coreless or said core material.
42. The polymer yarn of claim 32, wherein said polymer yarn may be
woven, non-woven or knitted with synthetic or natural materials as
warp or weft.
43. The polymer yarn of claim 42, wherein said polymer yarn is
woven, non-woven or knitted and may be a portion or the entirety of
a wall covering, window shade or panel track, upholstery, drapery
or encapsulated into a building panel.
44. The web structure of the polymer yarn of claim 42, wherein said
woven, non-woven, or knitted polymer yarn may be open to the
environment or encapsulated between resin panels or translucent
resin panels or translucent or transparent laminate building
materials of compositions such as polycarbonate or acrylic resin
and wherein said yarn may also be a natural yarn.
45. The woven, non-woven, or knitted polymer yarn of claim 42,
wherein said woven, non-woven, or knitted polymer yarn is a
structural mesh of said polymer yarn that may be bonded by heat to
said warp and weft or wherein each strand of yarn may also be
bonded to another strand of yarn.
46. The polymer yarn of claim 42, wherein said woven or knitted
polymer yarn complies with NFPA 701 large scale drapery test fire
ratings for woven or knitted polymer building or decorative
materials and including ASTM E-84 regarding flammability and AATCC
16-1998 regarding light fastness for woven or knitted polymer
building materials
47. A method of producing UV, flame resistant, polymer yarn
comprising a hollow core portion, wherein said production is by one
of several methods including extrusion, spinning by using a
metering pump and spinneret assembly, or spinning and drawing, or
pultrusion, or a combination of any of these methods or like
methods.
Description
FIELD OF INVENTION
[0001] This invention relates to the weaving and application of
woven hollow polymer yarns for use in products requiring UV
(ultraviolet light) and flammability resistance while also
providing decorative art.
BACKGROUND OF INVENTION
[0002] Natural fibers have been used in the manufacture of
weavings, decorative wall hangings and fabric room dividers for
many centuries. The casual, informal, and artistic appearance of
textiles has made it especially popular for use in public places
such as museums, atria and office buildings and in informal
settings such as offices, hotels and other establishments. Natural
fibers, however, have limited use due to minimal resistance to fire
and smoke. Windows, walls and panel applications, space dividers,
screens as well as window panels upholstered walls and wall
hangings all can be decorated or enhanced with the use of such
fibers or yarns if UV (ultraviolet light) and flammability
protection could be incorporated into the properties of such fibers
and yarns.
[0003] Decorative textile hangings, window treatments, wall
covering and upholstery fabrics typically comprise a warp yarn,
i.e., a yarn running straight through the woven material, and a
weft yarn, i.e., a yarn that is woven back and forth through the
warp yarn. Numerous styles of weave or knit structures, interlaces,
meshes or webs are used in the manufacture of wall hangings, window
treatments, drapery, wall covering and upholsters in order to
achieve the decorative attributes sought by the designer. The
various styles of weave or knit result in a different look, feel,
strength and weight of the finished woven or knit product. In a
simple weave pattern, the warp yarns are spaced apart and arranged
parallel to each other. The weft yarns are woven over and under the
alternating warp yarns. Adjacent weft yarns pass on opposite sides
of a given warp yarn.
[0004] Polymer yarns have been used as well to manufacture
tapestries and textile hangings including draperies, window
treatments, upholstery and apparel. By way of example, a polymer
yarn is known which is constructed as an elongated body, such as of
indeterminate length, having a core surrounded by a sheath of
polyvinyl chloride (PVC). Foamed PVC material gives greater volume
with less material. The outer coating of these fibers or yarns may
be formed of other synthetic materials such as polyamides,
polyesters and the like. The yarn is typically made in a single
step using an extrusion, melt spinning, melt spinning and drawing,
or pultrusion or other similar or like process, as is known in the
art. Co-extrusion providing a skin or overcoating could also be
used to make these products.
[0005] Producing polymer yarns may be by one of several methods
including extrusion, spinning by using a metering pump and
spinneret assembly, or spinning and drawing, or pultrusion, or a
combination of any of these methods.
[0006] The inner core may include a single filament of polyester or
fiberglass, or may include a plurality of polyester or fiberglass
filaments bundled to form a single core. The core can also be
filled with a polymer to produce a coreless yarn with UV and flame
resistant properties.
[0007] A coreless yarn is defined as a yarn or thread that is not
wrapped around a core. It could be a single strand such as a
monofilament or several strands interwoven with no central core
yarn or support.
[0008] Yarns are fibers or filaments formed into a continuous
strand for use in weaving textiles or for the manufacture of
thread. A staple fiber such as cotton, linen, or wool, is made into
natural yarn by carding, combing (for fine, long staples only),
drawing out into roving, and subsequently spinning. Continuous
synthetic filaments, such as silk, rayon, and nylon, may be formed
directly into synthetic yarn or may be cut into short lengths and
prepared like staple fibers.
[0009] The polymer yarn being constructed from foamed PVC material,
for example, results in a lack of uniformity in the foaming of the
PVC material during the extrusion process. This produces a yarn
which lacks a uniform cylindrical exterior appearance. The yarn,
however, can also have a more uniform exterior shape, as well as
other shapes such as square, oval, flat, triangular and the like.
Polymer yarns as thus far described are known from U.S. Pat. Nos.
5,704,690, 5,845,970 and 6,179,382; as well as U.S. Design Pat.
Nos. 395,171, 474,614 and 409,001; the disclosures of which are
incorporated herein by reference.
[0010] It is therefore desirable to provide improvements in the
manufacture of polymer woven material for use in building
decorative and functional textile articles and accessories
including, for example, the use of coreless, hollow, fire and UV
resistant polymer yarns and complying to the recommended NFPA 701
small and large scale drapery test fire ratings for polymer
building materials and including other tests such as ASTM
E-84--flammability and AATCC 16-1998--lightfastness.
DESCRIPTION OF PRIOR ART
[0011] U.S. Pat. No. 5,141,542 to Fingeat, et. al., and assigned to
Filature de la Gosse, S A., describes a fire-resistant textile yarn
comprising a core formed from a ply yarn comprising
double-threaded-multiple-glass filaments, and fibers wound around
the core, wherein at least 33% by weight of said fibers are formed
from aramid resin, and the yarn count is between 30-55 tex, the
mass ratio of the core is between 10% and 26%, and the fibers are
spun without axial twisting around the core.
[0012] U.S. Pat. No. 4,967,548 to Fingeat, et. al., and assigned to
Filature de la Gosse, S A., describes a fire-resistant textile yarn
comprising an inorganic filament core surrounded by fibres formed
from at least 50% by weight of aramid resin, wherein the yarn count
is between 30-50 tex, the mass ratio of the core being between 10%
and 25%, the aramid fibres being spun without axial twisting around
this core.
[0013] U.S. Pat. No. 3,729,920 to Sayers, et. al., and assigned to
Courtaulds Ltd., describes a novelty core yarn consisting
essentially of a continuous filamentary glass core provided with a
sheath of a roving of modacrylic textile fibers having inherent,
built-in flame-resistance and composed of a copolymer selected from
the group consisting of acrylonitrile and vinylidene chloride,
acrylonitrile and vinyl chloride and acrylonitrile and vinylidene
chloride and vinyl chloride.
[0014] U.S. Pat. No. 4,670,327 to Weber, John W, and unassigned,
describes a yarn comprising a sheath of individually wrapped aramid
fibers surrounding and substantially covering a continuous filament
core of amorphous silica product containing at least 96% silica and
having the thermal performance of a refractory material.
[0015] U.S. Pat. No. 4,500,593 to Weber, John W, and unassigned,
describes a high temperature resistant fabric comprised of yarns,
having a core of high temperature resistant refractory material
silica and covering of a second high temperature resistant fiber
selected from the group consisting essentially of aramid, phenolic,
polyacrylonitrile and polybenzimidazole fibers, and a metallic
laminate.
[0016] U.S. Patent Application No. 2005/0191923A1 to Schwartz,
Larry, and unassigned, describes a woven panel comprising a
plurality of polymer first yarns each having an essential core
woven together with a plurality of polymer second yarns each having
a superficial core forming a woven panel therefrom.
[0017] U.S. Patent Application No. 2005/0106974A1 to Schwartz,
Larry, and unassigned, describes a woven panel comprising a
plurality of elongated first yarns, said first yarns including an
outer sheath of a first polymer material surrounding an elongated
core of a second material; and a plurality of elongated second
yarns, said second yarns including a body of a third polymer
material devoid of a region of a material different from said third
polymer material, said plurality of first yarns woven together with
said plurality of second yarns to form a woven panel. The woven
panel wherein said second yarns have an elongated hollow region.
The woven panel wherein said coreless yarns have a solid
cross-section.
[0018] U.S. Pat. No. 6,610,176 to Mauretti, Gerald J, and assigned
to Pascale Industries, Inc., describes a method of forming a yarn
comprising at least four filaments of a desired material wrapped
about one another said filaments drawn from spools in a series is
successively wrapped in opposite directions by a further filament
as the yarn precursor is drawn through the hollow core of each
spool in the series.
[0019] Japanese Application Number JP2000178824A2, to Shibuya et.
al., and assigned to Uniplas Shiga K K, describes an undrawn
monofilament yarn obtained by the quenching and solidification of a
thermoplastic synthetic resin extruded by an extrusion molding
means is successively and continuously subjected to a
water-removing treatment with a water-removing means, a heating and
drawing treatment with a heating and drawing means and a crimping
treatment with a crimping means to obtain a crimped monofilament
yarn having a thickness of 150-500 de.
[0020] Japanese Application Number JP2004183118A2, to Ikenaga
Hideo., and assigned to Asahi Kasei Fibers Corp., describes a solid
knit fabric is composed of a knitted fabric of two layers of the
face side and back side and connecting yarns connecting the two
layers of the knitted fabric and synthetic fiber monofilament yarns
of .gtoreq.110 dtex. The knitted fabric on the face side is a dense
knit texture formed of a multifilament yarn having .ltoreq.35%
opening ratio. The ratio of appearance area A of the monofilament
yarn of the knitted fabric on the face side to the appearance area
B of the multifilament yarn is represented by formula (1),
A/B.ltoreq.0.15 and the relationship between the diameter D of the
monofilament yarn and the apparent diameter MD of the multifilament
yarn in the same stitch is represented by formula (2),
MD/D.gtoreq.1.2.
[0021] Japanese Application Number JP2002105815A2, to Tsumura, et.
al., and assigned to Suminoe Textile Co. Ltd., describes a
three-dimensional solid knit sheet comprises a three-dimensional
solid knit cloth produced with a double raschel knitting machine of
6-18 gauges. The total thickness of yarns constituting the meshes
of the obverse and reverse knit cloths, is set at .gtoreq.550 dtex.
The linking yarn connecting the obverse knit cloth and the reverse
knit cloth consists of a monofilament yarn. At least the obverse
knit cloth is constituted with a coarse part 20 knitted into a lace
stitch texture such as mesh and a dense part knitted at a spatial
filling rate of 1.1-6 times that of the coarse part.
[0022] Japanese Application Number JP10034778A2, to Torii, et. al.,
and assigned to Taiyo Kogyo K K, describes a translucent heat
insulating material has a structure wherein on both surfaces being
coarse of a base fabric which is formed into a solid structure, a
synthetic resin film with high translucence, is affixed. The base
fabric has a structure wherein top and bottom ground weave which
are flat texture woven by making the density of, e.g. mock leno
weave or leno weave coarser, are integrated by binding them. by a
binding weave. The thickness is normally, e.g. approx. 3-10 mm.
Also, for the ground weave and the binding weave, if fire
resistance is not required, a monofilament thread made of a
synthetic resin with high rigidity, is used, and if fire resistance
is required, a vinyl chloride coated glass fiber is used.
[0023] Japanese Application Number JP2004232177A2, to Ohara
Hiroshi, and assigned to Ohara Hiroshi, describes a decorative
material is provided by interlacing a lame thread with a colored
assembly thread to be a decorative thread, directly and tightly
winding the decorative thread itself or a somewhat thicker
decorative thread made by twisting the decorative thread in
parallel on the surface of a base material of an article to be
decorated, subsequently enclosing and fixing the wound part with a
transparent synthetic resin to obtain a decorative material. Or,
after tightly winding the decorative thread in parallel on a base
material for working, the wound part is temporarily fixed with the
transparent synthetic resin to obtain a decorative surface which is
separated from the base material and cut into a proper shape. The
cut part is adhered to the surface of the base of the article to be
decorated; subsequently the adhered cut part is enclosed and fixed
with the transparent synthetic resin to form the decorative
material.
[0024] Japanese Application Number JP2002001853A2, to Kon, et. al.,
and assigned to Diatex Co Ltd, Toshin Sangyo K K, describes a
cloth-like body layer prepared by making flat yarns of a
thermoplastic resin intersect each other like warp and weft is
formed of a cloth-like body obtained by a method wherein the flat
yarns of the thermoplastic resin of a thickness 20-200 .mu.m and a
thread width 0.2-8 mm are made to intersect each other with a mesh
of 1.6-8 mm and wherein the points of intersection thereof are
fusion-bonded. A surface layer of film is fusion-bonded on one side
of the cloth-like body so that it is laminated thereon to form a
flat surface substantially, and a rear layer film is fusion-bonded
on the other side of the cloth-like body, while the part of the
mesh of the cloth-like body is brought into close contact with the
surface layer film and fusion-bonded thereon to be laminated so
that a recess is formed substantially. In this way, the
transparency of the whole laminated body is made 75% or above.
[0025] Japanese Application Number JP2001081642A2, to Sakai, et.
al, and assigned to Nakai Kinshi Kogyo K K, describes This
laminated sheet material is obtained by laminating a transparent
film assuming an iris pattern directly or through a transparent
resin film onto the outside of a resin layer containing a luminous
pigment. The laminated sheet is preferably a sheet material
prepared by laminating other films to both sides of the resin layer
containing the luminous pigment and the resin containing the
luminous pigment is preferably an adhesive. A twisted yarn for a
woven fabric is preferably obtained by mutually twisting a foil
yarn formed by slitting the laminated sheet into narrow width by
using a core yarn or without using the core yarn.
[0026] Japanese Application Number JP 1291418A2, to Matano, et.
al., and assigned to Hagiwara Kogyo K K, describes an ethylene
.alpha.-olefin copolymer is manufactured by the use of a
metallocene catalyst having properties of a melt-flow rate of
0.3-30 g/10 mn, a density of 0.90-0.94 g/cm3, a minimum peak
temperature of 80-125.degree. C. by DSC, a molecular weight
distribution (Mw/Nn) of 1.8-3.5, and a melt tension of 0.5-4 g.
After that, this is woven or knitted by 50-90 wt. % by the use of
flat yarn as warp and weft, which is made of resin composition
consisting of 10-50 wt. % high density polyethylene with a density
of 0.945 g/cm3 so as to form cloth, and finally, an ethylene
.alpha.-olefin copolymeric layer is laminated on one surface or
both surfaces thereof.
[0027] Japanese Application Number JP06062682A2, to Washino, et.
al., and unassigned, describes The agricultural film is obtained by
including an antifogging agent in flexible vinyl chloride resin
films in splitting a transparent stretched film into a tape like
form, crossing the resultant tapes in the form of lattice at a
suitable interval, laminating the crossed tapes between two layers
of the flexible vinyl chloride resin films and stretching the
laminate in an agricultural greenhouse. The lattice-like material
of the flat yarn includes a material having a structure in which
the flat yarn such as polyethylene crosses directly or through an
adhesive layer and there are parts of opened meshes without any
flat yarn and the flat yarn is in the form of the lattice through a
thin vinyl chloride film. This film sustains the antifogging
performance without sagging thereof during the time of
stretching.
[0028] Japanese Application Number JP06048785A2, to Yamashita
Kiyoaki, and assigned to Tatsumura Bijutsu Oirmono K K, describes a
threadlike body and low-melting fiber melting at a relatively low
temperature are employed and either is used as weft or warp yarn to
construct a woven fabric. The same resin films and as the
low-melting fiber are superposed and nipped between two plate
members and in the form of a sandwich and heated under a reduced
pressure. Thereby, the low-melting fiber and the resin films and
are melted while maintaining the pattern formed from the
lightweight threadlike body to completely bond the two plate
members.
[0029] Japanese Application Number JP06033671A2, to Okada Mizuo,
and assigned to Mitsubshi Rayon Co. Ltd, describes A curtain
texture is formed as a fiber sheet type double-sided lenticular, in
which an optical diffusive resin containing styrene bead spheres is
melted and spun to a transparent polycarbonate resin, and
inter-yarn welded in the outlet of a nozzle by a Barus effect, and
yarn having an approximately round cross section is arranged.
Consequently, a ray transmittance of the texture thus constituted
is improved, optical diffusivity in the horizontal direction is
also enhanced, and the whole indoors are irradiated efficiently
with mellow light. Accordingly, the directional properties of light
and the degree of diffusion can be controlled.
[0030] Japanese Application Number JP05057840A2 to Sumi Shozaburo,
and assigned to Sumi Shozaburo, describes Decorative knit sheet or
ribbon--comprises PET, PVC, or polypropylene resin having
evaporated metal membranes or color evaporated membranes formed on
both sides. On both sides of synthetic resin film, metallized film
is applied and, after that, tricot knitted fabric is also pasted
through adhesive so as to make into an integral body in order to
provide the decorative knitted fabric sheet concerned. Furthermore,
as the case may be, embossing such as sanitizing or the like is
applied onto the surface of the ribbon.
[0031] U.S. Pat. No. 3,884,754 to Kimura, et. al., and assigned to
Kanebo, LTD, describes a hollow filament comprising a filamentary
polymer composed of from 50% to 100% by weight of a flame-resistant
and anti-fusing cured novolak resin and up to 50% by weight of a
fiber-forming thermoplastic synthetic resin selected from at least
one of the group consisting of polyamides, polyesters,
polyesterethers, polyolefins and polyurethanes, characterized in
that the hollow structure continuously extends in the axial
direction of the filament, the degree of hollowness thereof being
in the range of 10-80%. The filament is described as being
partially cured novalak.
[0032] US Patent applications 2005016974A1 and 20060021668A1 to
Schwartz are for woven panels with or without a hollow core as a
strength member for upholstery. The second application
20060021668A1 provides an invention for shaping the polymer yarns
and twisting these same yarns followed by removing the heat in
order for the panel to retain its shape. The second application is
assigned to Sun Isle USA, LLC.
[0033] US Patent application 20050042447A1 to Conesa, et. al. ,
assigned to Chavanoz Industrie, describes coating a natural fiber
yarn with a polymer to make a composite yarn.
[0034] U.S. Pat. No. 6,673,444 to Yukki, et. al., assigned to Asahi
Kasei Kabushiki Kaisha describes a method and use for polymethylene
terephthalate monofilament yarns for toothbrushes and the like.
SUMMARY OF THE INVENTION
[0035] The present invention describes a UV, flame-resistant,
polymeric hollow polymer yarn or fiber useful for completing a
woven, knitted or non-woven structure or web that can be used for
decorative wall coverings, window shades, upholstery, draperies,
building panels, clothing, and the like. The yarn may also be solid
or coreless in nature.
[0036] This invention describes an improvement in polymer yarns for
enhancement of building materials including decorative arts,
specifically a transparent or translucent polymer yarn that has an
essentially concentrically, longitudinal hollow core or solid core
portion wherein the polymer yarn contains UV and fire resistant
properties that may be used as a coreless or a cored yarn and woven
or knitted with synthetic or natural yarns in a warp or weft-like
manner.
[0037] More specifically a hollow polymer yarn that complies with
NFPA 701 large-scale drapery test fire ratings for woven, non-woven
or knitted polymer building materials that may be transparent,
translucent, tinted, colored or opaque are the subject of this
invention. The applications for these yarns include incorporation
into building panels for decorative purposes both internal and
external to the buildings.
[0038] The hollow portion most preferably contains a hole diameter
of 0.009'', but may range from 0.001''-0.015'' with a wall
thickness of minimally 0.008'', preferably 0.010''.
[0039] The UV and flame resistant polymer yarn may be from
0.020''-0.125'' in outside diameter and may be non-uniform,
symmetrically or asymmetrically in outside diameter, preferably 60
mil, 40 mil, 24 mil or 20 mil average diameters for compatibility
with standard weaving and knitting machines.
[0040] The polymer yarn is woven or knitted and may be a portion or
the entirety of a wall covering, window shade, upholstery, drapery
or building panel.
[0041] The yarn may be encapsulated between
polyethyleneterephthalate glass (PETG), polycarbonate or acrylic
impregnated transparent resin panels or translucent laminate
building materials to provide decorative, UV and fire resistant
building panels for segregating floor spaces or for aligning with
walls or windows or just as decorative items in foyers, on
cabinetry, shower doors, and the like.
[0042] The woven or knitted yarn may additionally be bonded by
heating with synthetic or natural yarns as warp and weft sections
and the yarns may be left exposed to the environment.
[0043] The polymer yarn may also be solid to provide a similar or
same effects as the hollow fiber when placed in a woven, laminated,
or non-woven application.
[0044] The method of manufacture of yarn can include several
different extrusion methods including; [0045] a) the use of a
tubing die which allows for a standard extrusion instead of a
pressure-type extrusion to produce the hollow fibers [0046] b) the
use of a standard tip and die extrusion technique for a standard
extrusion process [0047] c) the use of a spinnerette designed to
manufacture hollow fibers that are circular or tubular in nature
and useful for woven or non-woven applications
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] FIG. 1 is an example of a woven or knitted polymer yarn.
[0049] FIG. 2 is an example of a woven polymer yarn encapsulated
between two clear resin panels.
DETAILED DESCRIPTION OF THE DRAWINGS
[0050] FIG. 1 is an example of a hollow polymer yarn [10] woven
between a synthetic yarn [20] or a combination of synthetic and
natural yarn [30].
[0051] FIG. 2 is an example of a hollow polymer yarn [10] woven
between a synthetic yarn [20] or natural yarn [30] encapsulated
between two clear panels [40].
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