U.S. patent application number 15/603737 was filed with the patent office on 2017-12-07 for multilayer coated multicolor yarn and manufacturing method thereof.
The applicant listed for this patent is Duksung Co., Ltd.. Invention is credited to Dal Rae JO, Sung Jin KIM, Young Chul LEE.
Application Number | 20170350045 15/603737 |
Document ID | / |
Family ID | 60477665 |
Filed Date | 2017-12-07 |
United States Patent
Application |
20170350045 |
Kind Code |
A1 |
KIM; Sung Jin ; et
al. |
December 7, 2017 |
MULTILAYER COATED MULTICOLOR YARN AND MANUFACTURING METHOD
THEREOF
Abstract
The multilayer coated multicolor yarn according to the present
invention is part-colored and exposes various colors on the surface
of the yarn, and, therefore, a fabric woven by the inventive yarn
gives a unique aesthetic feeling. In addition, due to the multiple
urethane coating layers, the yarn has excellent abrasion
resistance, mechanical properties, durability, thermoformability
and adhesion property.
Inventors: |
KIM; Sung Jin; (Incheon,
KR) ; LEE; Young Chul; (Gyeonggi-do, KR) ; JO;
Dal Rae; (Gyeonggi-do, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Duksung Co., Ltd. |
Gyeonggi-do |
|
KR |
|
|
Family ID: |
60477665 |
Appl. No.: |
15/603737 |
Filed: |
May 24, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D02G 3/404 20130101;
D02G 3/36 20130101 |
International
Class: |
D02G 3/36 20060101
D02G003/36 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 2, 2016 |
KR |
10-2016-0069055 |
Claims
1. A multilayer coated multicolor yarn comprising a core yarn, a
first coating layer formed on the core yarn and a second coating
layer formed on the first coating layer, wherein at least a part of
the first coating layer is not covered by the second coating layer
so that each colors of the first and second coating layers appear
at the surface of the multilayer coated multicolor yarn.
2. The multilayer coated multicolor yarn of claim 1, further
comprising a third coating layer formed on the second coating
layer, at least a part of the second coating layer is not covered
by the third coating layer and at least a part of the first coating
layer not covered by the second coating layer is not covered by the
third coating layer so that each colors of the first, the second
and third coating layers appear at the surface of the multilayer
coated multicolor yarn.
3. The multilayer coated multicolor yarn of claim 2, further
comprising an additional coating layer on the third coating layer,
wherein each colors of the coating layers appear at the surface of
the multilayer coated multicolor yarn.
4. The multilayer coated multicolor yarn of claim 1, wherein the
multilayer coated multicolor yarn color yarn is a twisted yarn
twisted with a rotational speed of 1,000 to 10,000 rpm.
5. A method for preparing the multilayer coated multicolor yarn of
claim 1, comprising the steps of coating a first resin composition
including a first pigment on the surface of the core yarn and
drying the first resin composition to form the first coating layer
on the core yarn; coating a second resin composition including a
second pigment on the first coating layer to form the second
coating layer; removing a part of the second coating layer so that
the first coating layer is partially exposed to the outside; and
drying the second coating layer.
6. The method of claim 5, further comprising coating a third resin
composition after drying the second coating layer; removing a part
of the third coating layer so that the first and second coating
layers are partially exposed to the outside; and drying the third
coating layer.
7. The method of claim 6, wherein a part of the second coating
layer or the third coating layer is removed by scraping a part of
the second or third coating layer before drying the second or third
coating layer.
8. The method of claim 7, wherein a part of the coating layer is
scraped by making a coated yarn discharging from an outlet of a
coater contact with an edge of the coater outlet at a predetermined
angle by using a roller.
9. The method of claim 8, wherein the roller is an eccentric roller
and the coated yarn contacts with the edge of the coater outlet at
different points.
10. The method of claim 8, wherein the roller is mounted on a
rotatable means which is rotatable at 360 degrees with respect to
the center axis of the coater outlet, the coated yarn discharging
from the coater is in contact with the circumference of the outlet
edge.
11. The method of claim 5, further comprising twisting finally
dried coated yarn.
12. The method of claim 6, further comprising twisting finally
dried coated yarn.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Korean patent
application 10-2016-0069055, filed on Jun. 2, 2017, incorporated
herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a coated yarn, and more
particularly, to a parti-colored yarn having multiple layers of
urethane coating for imparting strength and multicolor to a yarn by
exposing each color of each layer on the surface of the yarn, and a
method of manufacturing same.
BACKGROUND OF THE INVENTION
[0003] Generally, an industrial yarn is produced by coating a
thermoplastic resin such as PVC, PP, or thermoplastic polyurethane
(TPU) on the surface of a polyester or nylon yarn using an extruder
die in order to increase the strength of yarn.
[0004] However, it is hard to coating a small amount of coating
resin, and, therefore, it is difficult to fabricate a coated yarn
having a thickness of 1,000 denier or less. Otherwise, it is
difficult to improve the durability and abrasion resistance of a
coated yarn.
[0005] To solve such problem, Korean Patent No. 10-1318135
discloses a thermoplastic polyurethane compound composition for
producing a coated yarn, which comprises thermoplastic
polyurethane, a thickener and an olefin-based coupling agent.
[0006] Further, Korean Patent No. 10-1341055 entitled "A
composition of thermoplastic polyurethane yarn and a method for
producing same" describes a method for producing a multi-layered
thermoplastic polyurethane yarn comprising the steps of mixing
thermoplastic polyurethane, a thickener and a processing lubricant;
melting and kneading the mixture; drying and aging to prepare a
resin compound; and introducing the resin compound into a
co-extruder to form a core yarn while introducing another resin
selected from thermoplastic polyurethane, polyester, nylon and
acryl into the co-extruder to form a shell layer.
[0007] However, although a coated yarn having a relatively thin
coating layer can be produced by the above-mentioned methods, it is
hard to realize a light weight since the density of the coated yarn
is high. Further, it is difficult to implement a coated yarn having
various colors, textures and functionalities, e.g., metallic
feeling, thermochromic property, phosphorescent property, shifting
colors, etc.
[0008] Hence, Korean Patent No. 10-1561890 filed and owned by the
applicant provides an aqueous thermosetting urethane composition
for coating yarns capable of realizing multi-layered yarn having a
low density, i.e., light weight and improved physical properties
including elasticity and textures.
DISCLOSURE OF INVENTION
Technical Problem
[0009] It is an object of the present invention to provide a
multilayered multicolor yarn which can embody various colors in a
single yarn.
[0010] It is another object of the present invention to provide a
method for producing the multilayered multicolor yarn.
Solution to Problem
[0011] In a first aspect, the subject invention provides a
multilayer coated multicolor yarn comprising a core yarn, a first
coating layer formed on the core yarn and a second coating layer
formed on the first coating layer, wherein at least a part of the
first coating layer is not covered by the second coating layer so
that each colors of the first and second coating layers appear at
the surface of the multilayer coated multicolor yarn.
[0012] In another aspect, the multilayer coated multicolor yarn may
further comprise a third coating layer formed on the second coating
layer, wherein at least a part of the second coating layer is not
covered by the third coating layer and at least a part of the first
coating layer not covered by the second coating layer is not
covered by the third coating layer so that each colors of the
first, the second and third coating layers appear at the surface of
the multilayer coated multicolor yarn.
[0013] In a further aspect, the multilayer coated multicolor yarn
may further comprise an additional coating layer on the third
coating layer, wherein each color of each coating layer appears at
the surface of the multilayer coated multicolor yarn.
[0014] In an additional aspect, the multilayer coated multicolor
yarn may be a twisted yarn twisted with a rotational speed of 1,000
to 10,000 rpm.
[0015] In an additional aspect, the multilayer coated multicolor
yarn may by prepared by a method comprising the steps of coating a
first resin composition including a first pigment on the surface of
a core yarn and drying the first resin composition to form a first
coating layer on the core yarn; coating a second resin composition
including a second pigment on the first coating layer to form a
second coating layer; removing a part of the second coating layer
so that the first coating layer is partially exposed to the
outside; and drying the second coating layer.
[0016] In an additional aspect, the method for preparing a
multilayer coated multicolor yarn may further comprise the steps of
coating a third resin composition including a third pigment after
drying the second coating layer to form a third coating layer;
removing a part of the third coating layer so that the first and
second coating layers are partially exposed to the outside; and
drying the third coating layer.
[0017] In an additional aspect, a part of the second coating layer
or the third coating layer may be removed by scraping a part of the
second or third coating layer before drying.
[0018] In an additional aspect, a part of the coating layer may be
scraped by making a coated yarn discharging from an outlet of a
coater contact with an edge of the outlet at a predetermined
discharge angle by using a roller.
[0019] In an additional aspect, the roller may be an eccentric
roller and the coated yarn contacts with the edge of the coater
outlet at different points.
[0020] In an additional aspect, the roller may be mounted on a
rotatable means which rotates at 360 degrees with respect to the
center axis of the coater outlet so that the coated yarn discharge
from the coater outlet may contact with the circumference of the
outlet edge.
[0021] In an additional aspect, the method may further comprise
twisting finally dried coated yarn to obtain twisted yarn.
Advantageous Effects of the Invention
[0022] The multilayer coated multicolor yarn according to the
present invention is parti-colored, i.e., exposes various colors on
the surface of the yarn, and, therefore, a fabric woven by the
inventive yarn gives a unique aesthetic feeling. In addition, due
to the multiple coating layers, the yarn has excellent abrasion
resistance, mechanical properties, durability, thermoformability
and adhesion property.
BRIEF DESCRIPTION OF DRAWINGS
[0023] FIG. 1 is a schematic cross-sectional view of a two-layer
coated multicolor yarn according to one embodiment of the present
invention.
[0024] FIG. 2 is a schematic cross-sectional view of a three-layer
coated multicolor yarn according to another embodiment of the
present invention.
[0025] FIG. 3 is a schematic diagram of a process for fabricating a
multi-layer coated multicolor yarn according to an embodiment of
the present invention.
[0026] FIGS. 4A to 4C are schematic diagrams of apparatus for
fabricating a multilayer coated multicolor yarn according to
various embodiments of the present invention.
[0027] FIGS. 5 and 6 are schematic side views of multilayer coated
multicolor yarns fabricated according to various embodiments of the
present invention.
[0028] FIG. 7 is a photograph showing the appearance of different
multilayer coated multicolor yarns produced according to various
embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Hereinafter, the present invention will be described in
detail with reference to the accompanying drawings.
[0030] FIG. 1 is a schematic cross-sectional view of a two-layer
coated multicolor yarn according to one embodiment of the present
invention. The two-layer coated multicolor yarn comprises a core
yarn 1, a first coating layer 10 formed on the core yarn 1, and a
second coating layer 20 formed on the first coating layer 10. The
color of the first coating layer 10 is exposed at a part 11 which
is not covered by the second coating layer.20.
[0031] FIG. 2 shows a three-layer coated multicolor yarn according
to another embodiment, which further comprises a third coating
layer 30. The three-layer coated multicolor yarn comprises a core
yarn 1, a first coating layer 10 and a second coating layer 20,
wherein at least a part 11 of the first coating layer 10 is not
covered by the second coating layer 20 and the third coating layer
30, and at least a part 21 of the second coating layer 20 is not
covered by the third coating layer. Thereby, each color of the
first, the second and the third coating layers can be observed at
the surface of the coated yarn.
[0032] According to the present invention, it is possible to form a
desired number of coating layer without limitation. That is, an
additional layer can be formed on the third coating layer 30 such
that each color of each layer can appears at the surface of the
coated yarn.
[0033] FIG. 1 and FIG. 2 are schematic cross-sectional views
showing a simplified structure of a multi-layered multicolor yarn
according to the present invention. In practice, each coating layer
can be randomly exposed and covered.
[0034] FIG. 3 shows a manufacturing process of a multilayer coated
multicolor yarn according to one embodiment of the present
invention. The process comprises the steps of:
[0035] coating a first resin composition including a first pigment
on the surface of a core yarn and drying the first resin
composition to form a first coating layer on the core yarn;
[0036] coating a second resin composition including a second
pigment on the first coating layer to form the second coating
layer;
[0037] removing a part of the second coating layer so that the
first coating layer is partially exposed to the outside (R);
and
[0038] drying the second coating layer.
[0039] FIG. 3 shows an example of a two-layer coating as an
example, but not limited thereto. In the case of a three-layer
coating, the steps of forming a third coating layer after the
second coating layer is dried, a removing a part of the third
coating layer, and drying the third coating layer may be further
performed.
[0040] That is, the method for preparing a three-layer coated
multicolor yarn may further comprise the steps of coating a third
resin composition including a third pigment after drying the second
resin composition to form a third coating layer; removing a part of
the third coating layer so that the first and second coating layers
are partially exposed to the outside; and drying the third coating
layer.
[0041] In the case of a multilayer coating having four or more
layers, the process can be repeated with the same principle.
[0042] According to a preferred embodiment of the present
invention, the step of removing (R) a part of a coating layer is
performed by scraping off a part of the coating layer before
drying.
[0043] In the process of scraping off a part of the coating layer,
the coating process may be followed by a process of scraping off a
part of the coating layer using a separate scraper.
[0044] Otherwise, as shown in FIGS. 4A to 4C, the coated yarn
discharging from a coater is brought into contact with an edge of
the coater outlet at a predetermined angle by using a roller.
[0045] According to one embodiment, the roller 41a may be
positioned at an angle to the coater outlet, as shown in FIG. 4A,
so that the coating layer of the coated yarn can be scratched by
the edge of the coater outlet.
[0046] According to another embodiment, the roller 41a may be an
eccentric roller 42a, and the path of the coated yarn discharged
from the coater outlet is changed so that the coated yarn
discharged from the coater comes into contact with the edge of the
coater outlet edge at different position.
[0047] According to another embodiment, a set of rollers 43a, 43b,
43c is installed into an apparatus 50 which is capable of rotating
360 degrees, thereby the coated yarn being contact with the entire
circumference of the edge of the coater outlet.
[0048] FIG. 5 is a schematic side view of a two-layer coated yarn
produced according to one embodiment. Scratches of the coating
layer may appear spirally on the yarn surface. FIG. 5 shows a
two-layer coated yarn wherein the exposed portion 11 of the first
coating layer is spirally uncovered by the second coating layer
20.
[0049] FIG. 6 is a schematic side view of a three-layer coating, in
which each colors of three layers are exposed by the part of second
coating layer 21 spirally uncovered by the third coating layer 30
and the part of the first coating layer 11 spirally uncovered by
both of the second and third coating layers.
[0050] FIGS. 5 and 6 assume that the spiral scratching occurs
regularly to some extent. However, in practice, the spiral shape
may be random, and the exposed part of the lower layer may be also
irregular.
[0051] According to one embodiment of the present invention, if the
finally formed coated yarn is twisted, the exposed part becomes
denser, and more colorful and vivid color contrast can be obtained.
In addition, the strength of the coated yarn greatly increases when
twisted.
[0052] Thus, the process for fabricating the multilayer coating
multicolor yarn according to the present invention may further
comprise twisting the finally dried coated yarn. The multi-layer
coated multicolor yarn may be twisted by rotating with a rotational
speed of 1,000 to 10,000 rpm, preferably 2,000 to 5,000 rpm.
[0053] In the present invention, the conventional resin composition
for coating the core yarn can be used without limitation as long as
it is generally used for imparting color to a yarn in this field.
For example, the resin composition is a urethane based resin
composition.
[0054] In addition to the resin composition for imparting color,
other additives can be additionally added to obtain various
functions. For example, a water-based thermosetting urethane
composition for yarn coating may comprise 100 parts by weight of an
aqueous thermosetting urethane resin, 1.5 to 2.5 parts by weight of
a thickener, 8 to 15 parts by weight of a pigment, and 2.5 to 3.5
parts by weight of a matting agent.
[0055] That is, an aqueous thermosetting urethane composition for
coating a yarn according to the present invention is formed by
mixing a predetermined amount of a thickener, a processing
lubricant and a pigment with a water-based thermosetting urethane
resin, and coating a core yarn such as polyester or nylon yarn with
the aqueous thermosetting urethane composition in a desired number
of layers, i.e., single or multi-layer.
[0056] Since the aqueous thermosetting urethane resin is
water-based, there is no need for an organic solvent, and the
desired viscosity can be easily controlled by adding a thickener
while maintaining the required solid content.
[0057] In the present invention, the aqueous thermosetting urethane
resin is selected from the group consisting of aqueous
thermosetting silicone modified urethane, aqueous thermosetting
polyurethane, aqueous thermosetting polyacryl urethane or a mixture
thereof. The thickening agent is preferably polyacrylate.
[0058] A thickener is used to control the viscosity of the aqueous
thermosetting urethane composition, and a predetermined amount of
the thickener is added to obtain a desired thickness of the coating
layer.
[0059] The thickener is preferably used in an amount of 1.5 to 2.5
parts by weight (PHR) based on 100 parts by weight of the aqueous
thermosetting urethane resin. When the viscosity is higher than the
above range, the resin composition may not be uniformly coated, and
if it is lower than the above range, the viscosity may be too low
to form an appropriate thickness of coating layer and the coating
is not properly performed.
[0060] The processing lubricant may comprise a matting agent, a
foam stabilizer, a dispersant, and a crosslinking agent.
[0061] The matting agent is preferably silica and may be added,
preferably, in an amount of 2.5 to 3.5 parts by weight based on 100
parts by weight of the aqueous thermosetting urethane resin.
[0062] The matting agent is used for scattering incident or
reflected light at the surface of the coated yarn. For example,
amorphous inorganic silica having an average particle diameter of
20 .mu.m or less can be used to provide a roughened surface to
scatter incident light, thereby providing good surface gloss.
[0063] Thus, a water-based thermosetting urethane resin composition
may be prepared by mixing an aqueous thermosetting urethane resin
with an appropriate amount of a thickener and a processing
lubricant.
[0064] In the present invention, a foam stabilizer, a dispersant,
and a crosslinking agent which can be used to prepare the inventive
yarn are not specially limited as long as they are generally used
for fabricating a coated yarn.
[0065] As shown in FIG. 3, a first aqueous thermosetting urethane
composition is supplied to the hopper and the core yarn is first
coated with the aqueous thermosetting urethane composition, and
then the coated yarn is discharged through a nozzle and then dried.
Then, a second aqueous thermosetting urethane composition is coated
on the coated yarn as the secondary coating, and a part of the
second coating layer is removed by scraping, followed by drying,
cooling, and winding to provide a multilayer coated multicolor
yarn.
[0066] FIG. 7 is a photograph showing the appearances of various
types of multilayer coated multicolor yarns produced according to
the present invention.
[0067] In FIG. 7, (A) is an external view of a multicolor yarn
having two coating layers according to one embodiment of the
present invention; (B) is a multicolor yarn produced by twisting
the yarn (A) with a rotational speed of about 3,000 rpm; and (C) is
an external view of a multicolor yarn having three layers of
coating.
[0068] As shown in FIG. 7, the multilayer coated multicolor yarn
according to the present invention exposes various colors on the
surface of the yarn, and, therefore, a fabric woven by the
inventive yarn gives a unique aesthetic feeling. In addition, due
to the multiple urethane coating layers, the yarn has excellent
abrasion resistance, mechanical properties, durability,
thermoformability and adhesion property.
* * * * *