U.S. patent application number 16/991879 was filed with the patent office on 2021-02-18 for composite yarns.
The applicant listed for this patent is Allbirds, Inc.. Invention is credited to Justin Cleveland, Thomas Jad Finck, Joseph Zwillinger.
Application Number | 20210047757 16/991879 |
Document ID | / |
Family ID | 1000005022746 |
Filed Date | 2021-02-18 |
United States Patent
Application |
20210047757 |
Kind Code |
A1 |
Cleveland; Justin ; et
al. |
February 18, 2021 |
COMPOSITE YARNS
Abstract
Composite yarns including a cellulose-based filament are
disclosed. The cellulose-based filament may be wrapped around a
staple fiber core of the yarn or may be included in a core of the
yarn and at least partially surrounded by a staple fiber sheath.
Such composite yarns can combine the strength of the regenerated
cellulose filament with the "feel" and other properties of the
organic fiber. Textiles formed from the composite yarns and
articles including the textiles are also disclosed.
Inventors: |
Cleveland; Justin; (Concord,
CA) ; Finck; Thomas Jad; (San Francisco, CA) ;
Zwillinger; Joseph; (Mill Valley, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Allbirds, Inc. |
San Francisco |
CA |
US |
|
|
Family ID: |
1000005022746 |
Appl. No.: |
16/991879 |
Filed: |
August 12, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62886310 |
Aug 13, 2019 |
|
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63022175 |
May 8, 2020 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D02G 3/32 20130101; A41B
11/00 20130101; D02G 3/36 20130101; A41B 9/001 20130101; A41B
2500/10 20130101; A41D 2500/10 20130101; D10B 2201/01 20130101;
D02G 3/04 20130101; A41C 3/00 20130101; D10B 2211/02 20130101; A41D
17/02 20130101; D10B 2331/04 20130101 |
International
Class: |
D02G 3/36 20060101
D02G003/36; A41D 17/02 20060101 A41D017/02; A41B 11/00 20060101
A41B011/00; D02G 3/04 20060101 D02G003/04 |
Claims
1. A composite yarn comprising: a core including a wool fiber, a
regenerated cellulose staple fiber, a bast fiber, a recycled
synthetic fiber, or a combination thereof; and a regenerated
cellulose filament at least partially surrounding the core.
2. The composite yarn of claim 1, wherein the regenerated cellulose
filament is a lyocell filament and the composite yarn comprises:
from about 60% to about 85% by weight of the wool fiber; and from
about 15% to about 40% by weight of the lyocell filament.
3. The composite yarn of claim 1, wherein the wool fiber has an
average diameter less than 20 microns.
4. The composite yarn of claim 1, wherein the regenerated cellulose
filament is a lyocell filament and the composite yarn comprises:
from about 40% to about 60% by weight of the regenerated cellulose
staple fiber, the bast fiber, or a combination thereof; and from
about 60% to about 40% by weight of the lyocell filament.
5. The composite yarn of claim 4, wherein the composite yarn
comprises a lyocell staple fiber.
6. The composite yarn of claim 1, wherein the regenerated cellulose
filament is a lyocell filament and the composite yarn comprises:
from about 40% to about 60% by weight of a recycled polyester
staple fiber; and from about 60% to about 40% by weight of the
lyocell filament.
7. The composite yarn of claim 1, wherein: the composite yarn
comprises a filament strand including multiple lyocell filaments
wrapped around the core; and the filament strand has a linear
density from 25 dTex to 160 dTex.
8. The composite yarn of claim 7, wherein the filament strand
includes from 25 to 100 filaments.
9. The composite yarn of claim 1, having a metric yarn number from
about 25 to about 100.
10. A textile comprising the composite yarn of claim 1.
11. An article comprising the textile of claim 10 and selected from
a clothing article, a footwear article, or an accessory
article.
12. The article of claim 11, wherein: the textile has a knitted
structure; and the article is selected from a sock, an
undergarment, or a pair of leggings.
13. A composite yarn comprising: a core including at least one
regenerated cellulose filament; and a sheath at least partially
surrounding the core and including an organic fiber.
14. The composite yarn of claim 13, wherein the organic fiber is a
wool fiber having an average diameter less than 20 microns.
15. The composite yarn of claim 14, wherein the sheath comprises at
least 70% by weight of the wool fiber.
16. The composite yarn of claim 13, wherein the at least one
regenerated cellulose filament is a lyocell filament.
17. The composite yarn of claim 13, wherein the core has a linear
density from 25 dTex to 100 dTex.
18. A textile comprising the composite yarn of claim 13.
19. An article comprising the textile of claim 18 and selected from
a clothing article, a footwear article, or an accessory
article.
20. The article of claim 19, wherein: the textile has a knitted
structure; and the article is selected from a sock, an
undergarment, or a pair of leggings.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/886,310, filed Aug. 13, 2019, titled"
Composite Yarns" and U.S. Provisional Patent Application No.
63/022,175, filed May 8, 2020, titled "Composite Yarns," the
disclosure of each of which is hereby incorporated by reference in
its entirety.
FIELD
[0002] The described embodiments relate generally to composite
yarns and textiles and articles including the composite yarns and
textiles. More particularly, the present embodiments relate to
composite yarns including a cellulose-based filament.
BACKGROUND
[0003] A composite yarn may combine a staple fiber component and a
filament component. Some conventional composite yarns include
filaments which are synthetic in nature, such as nylon or an
elastomer. In one configuration, the staple fiber may form a core
of the composite yarn and a conventional synthetic filament may be
wrapped around the core. In another configuration, a conventional
synthetic filament may form the core of the composite yarn and the
staple fiber may form a sheath around the core.
SUMMARY
[0004] The present disclosure provides a composite yarn which
combines a cellulose-based filament with an organic and/or a
recycled synthetic fiber. As examples, the cellulose-based filament
may be wrapped around a staple fiber core of the yarn or may be
included in a core of the yarn and at least partially surrounded by
a staple fiber sheath. The composite yarns disclosed herein can
have a reduced environmental impact as compared to composite yarns
including conventional synthetic filaments. For example,
cellulose-based filaments and organic fibers can be obtained from
renewable natural sources and can be biodegradable. Recycled
synthetic fibers can help divert plastic from landfills and oceans
and their production can be less energy intensive than production
of virgin synthetic fibers.
[0005] In some cases the composite yarn comprises a core including
an organic fiber, a recycled synthetic fiber, or a combination
thereof and a cellulose-based filament at least partially
surrounding the core. The cellulose-based filament or a strand
comprising multiple cellulose-based filaments may be wrapped around
the core. In other cases, the cellulose based filament and the
organic fiber and/or recycled synthetic fiber are twisted together.
The cellulose-based filament may be a regenerated cellulose
filament, such as a lyocell filament. The organic fiber and/or the
recycled synthetic fiber is typically in staple form. These
composite yarns can have higher strength than comparably sized
yarns spun solely from the staple fiber(s).
[0006] The organic fiber of the core may be a fiber of plant origin
or a fiber of animal origin and is typically in staple form. For
example, the organic fiber may be a wool fiber or a cellulose-based
fiber. The cellulose-based fiber may include one or more of a
regenerated cellulose fiber such as a lyocell staple fiber or a
bast fiber such as a hemp staple fiber. The core may include more
than one type of organic fiber. For example, the core may include a
combination of a wool fiber and a cellulose-based staple fiber or a
combination of cellulose-based staple fibers. Further, the core may
also include a synthetic fiber, such as a recycled synthetic fiber,
alone or in combination with an organic fiber. The recycled
synthetic fiber is typically in staple form and may be a recycled
polyester fiber, a recycled nylon fiber, or the like.
[0007] In additional cases, the composite yarn comprises a core
including at least one cellulose-based filament and a sheath at
least partially surrounding the core and including an organic
fiber. The cellulose-based filament may be a regenerated cellulose
filament, such as a lyocell filament. The organic fiber of the core
is typically in staple form. The composite yarns disclosed herein
can provide yarns with the appearance and "feel" of the organic
fiber but with higher strength than comparably sized yarns spun
from the organic staple fiber.
[0008] The organic fiber may be a fiber of plant origin or a fiber
of animal origin. For example, the organic fiber may be a wool
fiber or a cellulose-based fiber. The sheath may include more than
one type of organic fiber. For example, the sheath may include a
combination of a wool fiber and a cellulose-based staple fiber.
Further, the sheath may predominantly include organic fibers but
may also include a synthetic fiber.
[0009] In addition, the composite yarns disclosed herein can be
used to make knitted or woven textiles. These textiles can be used
in variety of articles including clothing, footwear, and accessory
articles. For example, a clothing article may include a textile
having a knitted structure, the textile including a composite yarn
of the present disclosure. Clothing articles such as shirts,
leggings, socks, undergarments, and the like can be produced from
the finely knit textiles disclosed herein. These articles may have
a reduced environmental impact as compared to conventional articles
having a higher synthetic content.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The disclosure will be readily understood by the following
detailed description in conjunction with the accompanying drawings,
wherein like reference numerals designate like elements.
[0011] FIG. 1 shows an example of composite yarn having a filament
wrapped core structure.
[0012] FIG. 2 shows an additional example of a composite yarn
having a filament wrapped core structure.
[0013] FIG. 3 schematically shows a composite yarn having a
core-sheath structure.
[0014] FIG. 4 shows a detail view of a region of the composite yarn
of FIG. 3.
[0015] FIG. 5 shows the composite yarn of FIG. 3, with a portion of
the yarn cut away to show the core.
[0016] FIG. 6 shows an additional example of a composite yarn
having a core-sheath structure.
[0017] FIG. 7 shows an example of a shoe including a composite
yarn.
[0018] FIG. 8 shows an example of a pair of leggings including a
composite yarn.
[0019] FIG. 9A shows a first example of a sock made, at least
partially, from a composite yarn.
[0020] FIG. 9B shows a second example of a sock made, at least
partially, from a composite yarn.
[0021] The use of cross-hatching or shading in the accompanying
figures is generally provided to clarify the boundaries between
adjacent elements and also to facilitate legibility of the figures.
Accordingly, neither the presence nor the absence of cross-hatching
or shading conveys or indicates any preference or requirement for
particular materials, material properties, element proportions,
element dimensions, commonalities of similarly illustrated
elements, or any other characteristic, attribute, or property for
any element illustrated in the accompanying figures.
[0022] Additionally, it should be understood that the proportions
and dimensions (either relative or absolute) of the various
features and elements (and collections and groupings thereof) and
the boundaries, separations, and positional relationships presented
therebetween, are provided in the accompanying figures merely to
facilitate an understanding of the various embodiments described
herein and, accordingly, may not necessarily be presented or
illustrated to scale, and are not intended to indicate any
preference or requirement for an illustrated embodiment to the
exclusion of embodiments described with reference thereto.
DETAILED DESCRIPTION
[0023] Reference will now be made in detail to representative
embodiments illustrated in the accompanying drawings. It should be
understood that the following descriptions are not intended to
limit the embodiments to one preferred implementation. To the
contrary, the described embodiments are intended to cover
alternatives, modifications, and equivalents as can be included
within the spirit and scope of the disclosure and as defined by the
appended claims.
[0024] The following disclosure relates to composite yarns
including at least one cellulose-based filament. The
cellulose-based filament may be wrapped around a staple fiber core
of the yarn or may be included in a core of the yarn and at least
partially surrounded by a staple fiber sheath. Recent advances have
allowed production of cellulose-based filaments, such as lyocell
filaments, having good mechanical properties. Composite yarns
including renewably sourced cellulose-based filaments can have a
reduced environmental impact as compared to conventional composite
yarns having a staple fiber core wrapped with synthetic filaments
or having a core consisting of synthetic filaments.
[0025] In some cases, the composite yarn includes a cellulose-based
filament wrapped around a core including an organic fiber, a
recycled synthetic fiber, or a combination thereof. The
cellulose-based filament may be a regenerated cellulose filament,
such as a lyocell filament. The organic fiber and the recycled
synthetic fiber may be in staple form. When the core includes an
organic fiber, the composite yarn may include at least 40%, 50%,
60%, or 70% and up to about 85% by weight of the organic fiber. In
some cases, the composite yarn may include from about 40% to about
60% by weight of the organic fiber. When the core includes a
recycled synthetic fiber, the composite yarn may include 30% to 70%
or 40% to 60% by weight of the recycled synthetic fiber. In some
cases, the core may predominantly include one or more of an organic
fiber or a recycled synthetic fiber, but may also include a virgin
synthetic fiber. The composite yarn may include from about 15% to
about 40% or from about 40% to about 60% of the cellulose-based
filament.
[0026] In some examples, the composite yarn includes a core
including a wool fiber, a regenerated cellulose staple fiber, a
bast fiber, a recycled synthetic fiber, or a combination thereof
and a lyocell filament wrapped around the core. When the core
includes a fine wool fiber, the fine wool fiber can contribute
softness and moisture wicking properties to the composite yarn. A
core including a moisture-wicking recycled synthetic fiber such as
polyester may also contribute moisture wicking properties to the
composite yarn. Bast and regenerated cellulose staple fibers can be
renewably sourced are also biodegradable. Therefore yarns including
these fibers can have a reduced environmental impact as compared to
yarns including fibers which are not renewably sourced and/or
biodegradable.
[0027] In additional cases, the composite yarn includes a
cellulose-based filament twisted with a strand including an organic
fiber, a recycled synthetic fiber, or a combination thereof. When
the strand includes an organic fiber, the composite yarn may
include at least 40%, 50%, 60%, or 70% and up to about 85% by
weight of the organic fiber. In some cases, the strand may include
from about 40% to about 60% by weight of the organic fiber. When
the strand includes a recycled synthetic fiber, the composite yarn
may include 30% to 70% or 40% to 60% by weight of the recycled
synthetic fiber. The strand may be a staple fiber strand. In some
cases, the staple fiber strand may predominantly include one or
more of an organic fiber or a recycled synthetic fiber, but may
also include a virgin synthetic fiber. The composite yarn may
include from about 15% to about 40% or from about 40% to about 60%
of the cellulose-based filament.
[0028] In some examples, the composite yarn includes a lyocell
filament twisted with a strand including any of a wool fiber, a
bast fiber, a regenerated cellulose staple fiber, a recycled
synthetic fiber, or a combination thereof. These composite yarns
can have similar benefits to those in which the lyocell filament is
wrapped around the core.
[0029] In further cases, a composite yarn has a core-sheath
structure and includes at least one cellulose-based filament in the
core. The cellulose-based filament may be a regenerated cellulose
filament, such as a lyocell filament. The sheath typically includes
an organic fiber, such as a wool fiber and/or a cellulose-based
fiber. The sheath may also include a synthetic fiber. The
filament(s) of the core may provide at least 2% and up to 5%, 10%,
or 15% of the yarn while the fibers of the sheath may make up the
remainder of the yarn.
[0030] Including an organic fiber in the sheath in combination with
the cellulose-based filament of the core can give the composite
yarn a high content of renewably sourced materials and a low
environmental impact. When the sheath predominantly includes one or
more organic fibers, the composite yarns can have the appearance
and "feel" of the organic fiber(s) but have a higher strength than
a comparably sized yarn spun from the organic fiber(s). For
example, when the sheath includes a fine wool fiber, the fine wool
fiber can contribute softness and moisture wicking properties to
the composite yarn. In some embodiments, the sheath may be wholly
formed from organic fibers.
[0031] Textiles knitted or woven from these composite yarns can be
incorporated into articles such as clothing, footwear, or accessory
articles. Finely knit textiles suitable for activewear and
undergarments are also provided by the disclosure herein.
[0032] These and other embodiments are discussed below with
reference to FIGS. 1 to 9B. However, those skilled in the art will
readily appreciate that the detailed description given herein with
respect to these figures is for explanatory purposes only and
should not be construed as limiting.
[0033] FIG. 1 shows an example of a composite yarn 100 having a
filament wrapped core structure. The composite yarn 100 includes
multiple filament fibers 118 wrapped around a core 115 including
the fibers 112. The fibers 112 are typically staple fibers. The
example of FIG. 1 is not limiting and in some cases, a greater or a
lesser number filament fibers may be wrapped around the core
115.
[0034] As shown in FIG. 1, the filament fibers 118 need not
completely cover the core. The yarn 100 may also be described as
having a wrapped structure in which the filament fibers 118 and the
fibers 112 of the core 115 alternate at the surface of the yarn.
Such a structure allows the fibers 112 of the core to contribute to
the "feel" of the composite yarn. A composite yarn having a
filament wrapped core structure may be produced by a process such
as a siro-fil or embeddable and locatable spinning process.
[0035] In some cases, the composite yarn 100 may predominantly
include the fibers 112 of the core 115. For example, the fibers of
the core may make up at least 50%, 60%, or 70% and up to about 85%
by weight of the composite yarn. In additional cases, the fibers of
the core may make up from 30% to 70% or 40% to 60% by weight of the
composite yarn. The amount of the filament fibers and the amount of
the core fibers together may make up greater than 50%, at least
60%, at least 70%, at least 80%, at least 90%, at least 95%, or
even up to 100% by weight of the composite yarn.
[0036] The yarn 100 may be characterized by a yarn number. The
metric yarn number (Nm) is a measure of the number of meters per
gram of the yarn. In some cases, the metric yarn number is from 25
to 100, from 25 to 75, from 25 to 50 or from 50 to 100 for a single
strand. A standard method test method, such as an ASTM test method
(e.g., ASTM D1059), may be used to determine the yarn number of the
yarns described herein.
[0037] In the example of FIG. 1, the filament fibers 118 define a
filament strand 117. In some cases, the filament fibers 118 in the
filament strand 117 may be twisted. When the filament fibers are
relatively fine and have a relatively low linear density, the
filament strand may include from 10 to 100 filaments. When the
filament fibers have a higher linear density the filament strand
may include fewer filaments. In some cases, a single filament may
be wrapped around the core. One measure of the wrapping of the
filament strand 117 around the core 115 is the number of turns per
unit distance. In some cases, the number of turns per meter is from
100 turns to 10,000 turns per meter.
[0038] In some cases, each of the filament fibers 118 is a
regenerated cellulose-based filament, also referred to herein as a
regenerated cellulose filament. Regenerated cellulose fibers and
filaments include, but are not limited to, rayon, viscose, and
lyocell fibers and filaments. In some embodiments, the regenerated
cellulose-based filament is a lyocell filament. Lyocell filaments
and fibers are produced using the lyocell process. The lyocell
process can have reduced environmental impacts as compared to some
other fiber production processes due to its use of renewable source
materials, a non-toxic solvent, and a high efficiency of solvent
recycling. The lyocell filament may have a strength approaching
that of a synthetic filament such as polyester or nylon filament.
For example, the lyocell filament may have a tensile strength from
500 MPa to 800 MPa, from 600 MPa to 900 MPa, or from 600 MPa to 700
MPa. The tensile strength of cellulose-based filaments may be
determined using standard methods, such as ASTM methods.
[0039] The filament strand 117 may have a linear density from 25
dTex to 175 dTex, from 25 dTex to 160 dTex, from 30 dTex to 75
dTex, or from 50 dTex to 160 dTex. The individual filaments 118,
such as lyocell filaments, may have a linear density from 1 dTex to
10 dTex, from 1 dTex to 5 dTex, from 1 dTex to 3 dTex, from 5 dTex
to 25 dTex, from 10 dTex to 30 dTex, or 10 dTex to 50 dTex. When
each filament has a linear density from about 1 dTex to about 5
dTex, the filament strand may include from 25 to 100 filaments. The
filament strand may include a fewer number of fibers when each
filament has a higher linear density. A standard method test
method, such as an ASTM test method or an ISO test method (e.g.,
ISO 1973:1995), may be used to determine the linear density of the
fibers, strands, and yarns described herein.
[0040] In additional cases, the filament strand may include
includes one or more synthetic filaments. The synthetic filament
may include at least a portion of recycled material. For example,
when the synthetic filament is a nylon filament, the nylon fiber
may include at least a portion of recycled nylon.
[0041] In some embodiments, the core 115 includes a single type of
fiber 112. For example, the core may comprise or consist
essentially of an organic fiber or a recycled synthetic fiber. The
organic fiber may be of animal origin, such as from sheep, goats,
silkworms, and the like. Fibers of animal origin include, but are
not limited to, wool, cashmere, and silk fibers. The organic fibers
may also be of plant origin, such as from trees (e.g., eucalyptus,
beech), bamboo, cotton plants, flax plants, and the like. Fibers of
plant origin include, but are not limited to, cellulose-based
fibers (also referred to as cellulosic fibers). Cellulose-based
fibers include seed fibers such as cotton, bast fibers such as hemp
or linen, and regenerated cellulose fibers such as rayon fibers.
Regenerated cellulose fibers include, but are not limited to,
viscose, modal, and lyocell fibers and can be made from wood pulp
and other plant sources such as bamboo and hemp. The recycled
synthetic fiber may be a recycled polyester staple fiber, a
recycled nylon staple fiber, or the like. In some cases, the fibers
112 may be provided in a staple fiber strand, which may or may not
be twisted.
[0042] In some cases, the core 115 includes a wool fiber. Fine wool
fibers, such as fibers having a mean or an average diameter less
than 24 microns, less than 20 microns or even less than or equal to
17.5 microns, may be used to provide a soft "handle" to the
resulting textile. The wool fiber may be a merino wool fiber. A
test method established by the International Wool Testing
Organization (IWTO) or the American Society for Testing and
Materials (ASTM) may be used to determine the average diameter of
wool fibers. IWTO standards include IWTO-8-2011, IWTO-12-2012, and
IWTO-47-2013. ASTM standards include D3991, D6466, and D6500. For
example, the wool fiber may make up from 50% to 85%, from 60% to
85%, greater than 65% to 85%, or from 70% to 85% by weight of the
composite yarn. The amount of the filament fiber and the amount of
the wool fiber together may make up greater than 50%, at least 60%,
at least 70%, at least 80%, at least 90%, at least 95%, or even up
to 100% by weight of the composite yarn. It is to be understood
that reference in the present disclosure and claims to a type of
fiber in the singular form (e.g., "a wool fiber") typically
includes reference to one or more fibers of that type (e.g.,
multiple wool fibers).
[0043] In additional cases, the core 115 includes a cellulose-based
fiber. The core may include one or more of a regenerated cellulose
staple fiber or a bast staple fiber. As examples, the core may
include a lyocell staple fiber, a hemp staple fiber, a linen/flax
staple fiber, or a combination of these. In some embodiments, the
regenerated cellulose staple fiber or a bast staple fiber has a
linear density from 1 dTex to 50 dTex, from 2 dTex to 30 dTex, from
2 dTex to 20 dTex, from 1 dTex to 10 dTex, or from 1 dTex to 5
dTex. The staple length may be from 20 mm to 40 mm or from 25 mm to
50 mm.
[0044] In further cases, the core 115 includes a recycled synthetic
polymer fiber also referred to herein simply as a recycled
synthetic fiber. The recycled synthetic fiber may be a recycled
polyester fiber, a recycled nylon fiber, or the like. In some
embodiments, the synthetic fiber has a linear density from 1 dTex
to 5 dTex. In other embodiments, the synthetic fiber may have a
linear density less than or equal to 1 dTex, such from 0.1 dTex to
1 dTex, from 0.1 dTex to 0.5 dTex, from 0.1 dTex to 0.3 dTex, or
from 0.3 dTex to less than 1 dTex.
[0045] The yarn may include from 30% to 70%, 40% to 60%, or greater
than 50% to 70% by weight of the synthetic fiber; and from 30% to
70%, 40% to about 60%, or 30% to less than 50% by weight of the
filament fiber. The amount of the filament fiber and the amount of
the synthetic fiber together may make up greater than 50%, at least
60%, at least 70%, at least 80%, at least 90%, at least 95%, or
even up to 100% by weight of the composite yarn.
[0046] The recycled synthetic fiber includes at least a portion of
recycled polymer. In some cases the synthetic fiber includes from
50% to 100%, from 60% to 100%, from 60% to 100%, from 70% to 100%,
from 80% to 100%, or from 90% to 100% by weight of the recycled
polymer. When the synthetic fiber includes less than 100% by weight
of the recycled polymer, the recycled polymer may be blended with
virgin polymer. For example, a polyester fiber such as polyethylene
terephthalate (PET) may include at least a portion of recycled PET
(also referred to as R-PET). When the polyester fiber includes less
than 100% by weight R-PET, the R-PET may be blended with virgin PET
(also referred to as V-PET). Polymers may be recycled by a physical
process involving pellet forming and extrusion. Polymers may also
be recycled by a chemical process in which the polymer is
decomposed into depolymerized oligomers.
[0047] FIG. 2 shows an additional example of a composite yarn 200
having a filament wrapped core structure. The composite yarn 200
includes multiple filament fibers 218 wrapped around a core 215. In
the example of FIG. 2, the core 215 includes a fiber blend 210
which includes two different types of staple fiber, a fiber 212 and
a fiber 216. The composite yarn 200 may have a linear density and
other physical properties similar to those described for the
composite yarn 100 and the filament fibers 218 and the filament
strand 217 may have compositions and physical properties similar to
those described for the filament fibers 118 and the filament strand
117. For brevity, those details are not repeated here.
[0048] As shown in FIG. 2, the core 215 of the yarn 200 includes a
fiber blend 210 including two different types of fibers, a first
fiber 212, which is an organic fiber, and a second fiber 216, which
is different from the first fiber; the second fiber may also be
organic in many embodiments. The first fiber 212 and second fiber
216 may be in staple form.
[0049] For example, the first fiber 212 may include a wool fiber,
such as a merino wool fiber. The wool fiber may have similar
physical properties to the wool fiber previously described with
respect to the core 115 and, for brevity, that description is not
repeated here. In some embodiments, the second fiber 216 may be an
organic staple fiber different from the first fiber 212. As an
example, the second fiber 216 may be a cellulose-based staple fiber
such as a lyocell staple fiber. In some embodiments, the
cellulose-based fiber has a linear density from 1 dTex to 3 dTex.
For example, the amount of the wool fiber may be at least 40%, 50%,
60%, or 70% by weight of the core 215. In some embodiments, the
amount of the wool fiber is greater than or equal to the amount of
the cellulose-based staple fiber and the composite yarn 200 may
predominantly include the wool fiber. The amount of the wool fiber
and the amount of the cellulose-based staple fiber together may
make up at least 80%, 90%, or 95% by weight of the core 215.
[0050] Alternately, the second fiber 216 may be a synthetic fiber
in staple form. For example, the synthetic fiber may include one or
more of a nylon fiber, a polyester fiber, an acrylic fiber, and the
like. The synthetic fiber may be a recycled polyester fiber, a
recycled nylon fiber, and the like or may be a virgin synthetic
fiber. The synthetic fiber (recycled or virgin) may have a
composition and/or a physical property that is similar to that of
the recycled synthetic fiber previously described with respect to
the core 115 and, for brevity, that description is not repeated
here. For example, the amount of the wool fiber may be at least
40%, 50%, 60%, or 70% by weight of the core 215 and in some cases
the amount of the wool fiber may be greater than or equal to the
amount of the synthetic fiber. As another example, the amount of
the synthetic fiber may be at least 40%, 50%, 60%, or 70% by weight
of the core 215. The amount of the wool fiber and the amount of the
synthetic fiber together may make up at least 80%, 90%, or 95% by
weight of the core 215.
[0051] In additional cases, the first fiber 212 may include a
cellulose-based fiber and the second fiber 216 may include a
different cellulose-based fiber or a synthetic fiber. For example,
the first fiber 212 may be a regenerated cellulose-based fiber,
such as a lyocell staple fiber, and the second fiber 216 may be a
bast fiber, such as a hemp staple fiber or a linen staple fiber (or
vice versa). The cellulose-based fibers may have a composition
and/or a physical property that is similar to that of the
cellulose-based fibers previously described with respect to the
core 115 and, for brevity, that description is not repeated
here.
[0052] The example of FIG. 2 shows a core 215 including two
different types of fiber. In additional examples, the core may
include a blend of more than two types of fiber. For example, the
core may include a blend of a wool fiber, a cellulose-based staple
fiber, and a synthetic fiber. The amount of the synthetic fiber may
be less than that of the wool fiber and the cellulose-based fiber.
In a further example, the core may have an interior region
including an elastomeric filament, such as a spandex filament, in a
similar fashion as described with respect to FIG. 3. For brevity,
that description is not repeated here.
[0053] In some embodiments, the yarn may be made of the following
fibers: 48% lyocell; 21% wool; 15% nylon (including recycled
nylon); 7% polyester (including recycled polyester); and 2%
spandex. In other embodiments, the yarn may be made of the
following fibers: 47% lyocell; 21% wool, 18% nylon (including
recycled nylon, such as 17% recycled nylon and 1% unrecycled
nylon); 12% polyester (including recycled polyester, such as 6%
recycled polyester and 6% unrecycled polyester); and 2% spandex. In
still other embodiments, the yarn may be made of the following
fibers: 50% lyocell; 22% wool; 18% nylon (including recycled nylon,
such as 17% recycled nylon and 1% unrecycled nylon); 8% polyester
(including unrecycled polyester, such as 4% recycled polyester and
4% unrecycled polyester); and 2% spandex. It should be appreciated
that the percentages given may be by weight, density, volume, or
any other appropriate characteristic (as may any set of percentages
discussed herein). Further, although particular percentages have
been provided, it should be understood that any or all of the above
percentages, with respect to any of the embodiments, may vary by as
much as 3% in either direction in absolute terms, or by as much as
20% in relative terms. "Absolute terms" refers to the percentage as
a portion of the full makeup of the yarn; thus, if a fiber is given
as 21% of a fiber in one example and varies by 3% in absolute
terms, it may be as little as 18% or as much as 24% of a yarn in
various embodiments. "Relative terms" refers to a percentage of the
material making up the yarn; thus, given the same fiber that is 21%
of a yarn, it may be as little as 16.8% or as much as 25.2% of the
yarn in relative terms (e.g., 80% or 21% or 120% of 21%).
Variations in percentages may occur during manufacturing, or may be
a result of changing a fiber's constituent elements to provide
different material properties, such as stretch, tensile strength,
resistance to damage, breathability, and so on.
[0054] It should be appreciated that the ranges disclosed herein,
as well as the combination of various fibers in a yarn, provide
unique and unusual benefits for yarns. For example, the use of
recycled fibers in yarns (and, in particular, in yarns for
clothing, shoes, and the like) in the amounts shown is unusual and
difficult to achieve. The percentages and ranges given for the
combination of organic fibers (such as wool) and other fibers (such
as lyocell, nylon, polyester, spandex, and the like) may result in
a recyclable fiber and/or a fiber that is relatively durable,
breathable, and/or resistant to wear while not being brittle,
shearable, or separable, as opposed to other fiber blends used to
form yarns.
[0055] In some cases the composite yarn includes a cellulose-based
filament or filament twisted with a strand including an organic
fiber, a recycled synthetic fiber, or a combination thereof. The
cellulose-based filament or cellulose-based filament strand may
have one or more properties which are similar to those of the
cellulose-based filament or cellulose-based filament strands
described with respect to FIGS. 1 and 2. The strand including an
organic fiber, a recycled synthetic fiber, or a combination thereof
may have one or more properties which are similar to those of
strand(s) used to form the cores described with respect to FIGS. 1
and 2. For brevity, the description provided with respect to FIGS.
1 and 2 is not repeated here.
[0056] FIG. 3 schematically shows a composite yarn 300. The
composite yarn 300 has a core-sheath structure including a core 310
and a sheath 320. In some embodiments, the composite yarn has a
linear density from 50 dTex to 1000 dTex (100 Tex), from 50 dTex to
200 dTex, from 100 dTex to 500 dTex, or from 250 dTex to 1000 dTex.
A standard method test method, such as an ASTM test method, may be
used to determine the linear density of the fibers and the yarns
described herein.
[0057] In the example of FIG. 3, the core 310 includes a
cellulose-based filament. The cellulose-based filament may be a
regenerated cellulose filament, such as a lyocell filament. The
core may include a single cellulose-based filament or multiple
cellulose-based filaments. The individual filaments of the core
310, such as lyocell filaments, may have a linear density from 1
dTex to 10 dTex, from 1 dTex to 5 dTex, from 1 dTex to 3 dTex, from
5 dTex to 25 dTex, from 10 dTex to 30 dTex, or 10 dTex to 50 dTex.
The core may include a fewer number of fibers when each filament
has a higher linear density. The filament(s) of the core 310 may
provide at least 2% and up to 5%, 10%, or 15% of the yarn while the
fibers of the sheath 320 may make up the remainder of the yarn.
[0058] In some cases, the core 310 may also include a synthetic
filament, such as a recycled synthetic filament or an elastomer
fiber (recycled or virgin). For example, the core 310 may include
one or more synthetic elastomer fibers, such as spandex or elastane
filament fibers. The elastomer fiber may be a polyurethane
elastomer (e.g., a segmented polyurethane elastomer), a
cross-linked polyacrylate, or a combination of a polyurethane
elastomer with another polymer, such as nylon. In some cases, the
spandex fiber may be a bio-based spandex or a post-industrial
recycled spandex. The amount of the elastomer filament may be from
1% to less than 10% by weight, from 1% to 8% by weight, or from 2%
to 7% by weight of the core or of the yarn. The core may also
include a recycled synthetic filament which is not substantially
elastomeric, such as a recycled nylon filament.
[0059] Typically, the sheath 320 includes fibers in staple form
which are intimately mixed and interlocked. Typically, the staple
fibers are twisted around the core 310. When the filaments in the
core are twisted, the staple fibers may be twisted in the opposite
direction. The sheath may be formed around the core using a core
spinning technique, such as a ring spinning technique or a friction
spinning technique. However, other spinning techniques, such as
rotor spinning techniques, air jet techniques, and the like may
also be used.
[0060] The sheath 320 typically includes one or more organic
fibers. The sheath may also include a synthetic fiber in staple
form, although this is not necessary nor present in all
embodiments. In some embodiments, the amount of the synthetic
fiber(s) in the sheath is less than that of the organic fiber(s),
so that the sheath predominantly includes organic fibers. For
example, the amount of the synthetic fiber may be less than or
equal to 40%, 30%, 20%, 10%, or 5% by weight of the sheath fibers.
As examples, the synthetic fiber may include one or more of nylon,
polyester, acrylic, and the like.
[0061] FIG. 3 shows composite yarn 300 as having a single ply. In
additional examples, the composite yarns include multiple plies.
For example, multiple plies may be twisted together to obtain a
desired yarn thickness, linear density, and/or mechanical property.
The yarn 300 may be used to form a textile by a weaving or knitting
operation and the yarn properties may be adjusted for the
particular weaving or knitting operation.
[0062] FIG. 4 shows a detail view of the sheath 420 of the yarn
400, which is an example of detail region 1-1 of the yarn 300 of
FIG. 3. As shown in FIG. 4, the sheath 420 of the yarn 400 includes
a blend of two different types of fibers, a first fiber 412, which
is an organic fiber, and a second fiber 416, which is different
from the first fiber; the second fiber may also be organic in many
embodiments. The first fiber 412 and second fiber 416 may be in
staple form.
[0063] For example, the first fiber 412 may include a wool fiber,
such as a merino wool fiber. The wool fiber may have an average
diameter less than 24 microns, less than 20 microns, or even less
than or equal to 17.5 microns.
[0064] In some embodiments, the second fiber 416 may be an organic
staple fiber different from the first fiber 412. As an example, the
second fiber 416 may be a cellulose-based staple fiber such as a
lyocell staple fiber. In some embodiments, the cellulose-based
fibers have a linear density from 1 dTex to 3 dTex. For example,
the amount of a wool fiber may be at least 40%, 50%, 60%, or 70% by
weight of the sheath 420. The amount of the wool fiber may be
greater than or equal to the amount of the cellulose-based staple
fiber or the amount of the cellulose-based staple fiber may be
greater than or equal to the amount of the wool staple fiber. The
amount of the wool fiber and the amount of the cellulose-based
staple fiber together may make up at least 80%, 90%, or 95% by
weight of the sheath.
[0065] Alternately, the second fiber 416 may be a synthetic fiber
in staple form. For example, the synthetic fiber may include one or
more of a nylon fiber, a polyester fiber, an acrylic fiber, and the
like. The synthetic fiber may be a recycled synthetic fiber. In
some embodiments, the synthetic fiber has a linear density from 1
dTex to 5 dTex. For example, the amount of the wool fiber may be at
least 40%, 50%, 60%, or 70% by weight of the sheath. In some cases,
the amount of the wool fiber may be greater than or equal to the
amount of the synthetic fiber. The amount of the wool fiber and the
amount of the synthetic fiber together make up at least 80%, 90%,
or 95% by weight of the sheath.
[0066] In some embodiments, the yarn may be made of the following
fibers: 48% lyocell; 21% wool; 15% nylon (including recycled
nylon); 7% polyester (including recycled polyester); and 2%
spandex. In other embodiments, the yarn may be made of the
following fibers: 47% lyocell; 21% wool, 18% nylon (including
recycled nylon, such as 17% recycled nylon and 1% unrecycled
nylon); 12% polyester (including recycled polyester, such as 6%
recycled polyester and 6% unrecycled polyester); and 2% spandex. In
still other embodiments, the yarn may be made of the following
fibers: 50% lyocell; 22% wool; 18% nylon (including recycled nylon,
such as 17% recycled nylon and 1% unrecycled nylon); 8% polyester
(including unrecycled polyester, such as 4% recycled polyester and
4% unrecycled polyester); and 2% spandex. It should be appreciated
that the percentages given may be by weight, density, volume, or
any other appropriate characteristic (as may any set of percentages
discussed herein).
[0067] FIG. 5 shows an example of the composite yarn of FIG. 3,
with a portion of the yarn 500 cut away to show the core 510 and
the sheath 520. For the purposes of illustration, the core 510 is
shown as forming a substantial portion of the composite yarn.
However, the example of FIG. 5 is not limiting and the core may
form 50% or less, 40% or less, 30% or less, 25% or less, 20% or
less, 15% or less, or 10% or less by weight of the yarn.
[0068] As shown in FIG. 5, the sheath 520 substantially covers the
core 510. However, it is not necessary that the sheath completely
cover the core. For example, the coverage of the core by the sheath
may be from 70% to 100%, from 80% to 100%, or from 90% to 100%. The
level of coverage may be determined using an image analysis
technique. Substantially central placement of the core 510 within
the sheath 520, as shown in FIG. 5, can facilitate coverage of the
core 510 by the sheath 520.
[0069] The core 510 may include a cellulose-based filament as
previously described with respect to FIG. 3. In some embodiments,
the core 510 may have a linear density from 25 dTex to 150 dTex and
may include multiple cellulose-based filaments. The individual
filaments, such as lyocell filaments, may have a linear density
from 1 dTex to 10 dTex, from 1 dTex to 5 dTex, from 1 dTex to 3
dTex, from 5 dTex to 25 dTex, from 10 dTex to 30 dTex, or 10 dTex
to 50 dTex. The cellulose-based filaments in the core may be
twisted together.
[0070] In some cases, the core 510 may include a synthetic
filament, such as a recycled synthetic filament or an elastomer
fiber (recycled or virgin). The discussion of recycled synthetic
filaments and elastomer fibers provided with respect to FIG. 3 is
generally applicable herein and, for brevity, is not repeated
here.
[0071] FIG. 6 shows an additional example of composite yarn 600
having a core-sheath structure. The core 610 includes multiple
cellulose-based filaments 618. The sheath 620 includes organic
fibers 622, such as wool fibers. As schematically shown in FIG. 6,
the organic fibers 622 are generally twisted around the core 610
but some of the ends of the organic fibers 622 may project outward
from a central portion of the core. The organic fibers 622 may be
staple fibers. As previously discussed, in some cases the sheath
may include at least two different types of fibers, with the first
type of fiber being a wool fiber and the second type of fiber being
a different organic fiber or a synthetic fiber. The cellulose-based
filaments 618 of core 610 and the organic fibers 622 of the sheath
620 may be similar in composition, linear density, and other
physical properties to the cellulose based filaments and the
organic fibers previously described with respect to FIGS. 4 and 5
and, for brevity, that description is not repeated here.
[0072] The composite yarns described herein can be used to form
woven or knitted textiles. The textile may be formed solely from
the composite yarns of the present disclosure or may be formed from
a combination of the composite yarns with one or more additional
yarns. In some embodiments, the additional yarn may have a size
comparable to or less than that of the composite yarn. Knitted (or
knit) textiles have a knitted (or knit) structure which includes
intermeshed loops.
[0073] As previously discussed, the composite yarns described
herein may allow the production of finely knit textiles. For
example, these composite yarns can be knitted on knitting machines
having at least 30 needles per inch (30 gauge) and up to and
including 48 needles per inch (48 gauge). The knitted structure (or
knit structure) of the textile may be described by the gauge (e.g.,
30 gauge to 48 gauge) or alternately by the stitch density. The
knit textile may be formed by a weft knitting or by a warp knitting
process.
[0074] The knitted textiles may have a stretch property such as
two-way stretch (extending in one direction), four-way stretch
(extending in crosswise and lengthwise directions), or equal
stretch in all directions. For example, the textile may have a
stretch property due to the knitted structure, such as in a single
or double jersey. In addition, the textile may have a stretch
property due to incorporation of elastomeric yarns in the textile.
The elastomeric yarn may include one or more synthetic elastomer
filaments, such as spandex or elastane filaments. The elastomer
filament may be a polyurethane elastomer (e.g., a segmented
polyurethane elastomer), a cross-linked polyacrylate, or a
combination of a polyurethane elastomer with another polymer, such
as nylon. In some embodiments, the elastomeric yarn may be a "bare"
elastomer yarn, such as a spandex yarn. In additional embodiments,
the elastomeric yarn may be a covered yarn having a core including
an elastomeric filament and a sheath including an organic fiber, a
synthetic fiber, or a combination thereof.
[0075] In some embodiments, all or a portion of the textile may be
made of the following fibers: 48% lyocell; 21% wool; 15% nylon
(including recycled nylon); 7% polyester (including recycled
polyester); and 2% spandex. In other embodiments, all or a portion
of the textile may be made of the following fibers: 47% lyocell;
21% wool, 18% nylon (including recycled nylon, such as 17% recycled
nylon and 1% unrecycled nylon); 12% polyester (including recycled
polyester, such as 6% recycled polyester and 6% unrecycled
polyester); and 2% spandex. In still other embodiments, all or a
portion of the textile may be made of the following fibers: 50%
lyocell; 22% wool; 18% nylon (including recycled nylon, such as 17%
recycled nylon and 1% unrecycled nylon); 8% polyester (including
unrecycled polyester, such as 4% recycled polyester and 4%
unrecycled polyester); and 2% spandex. It should be appreciated
that the percentages given may be by weight, density, volume, or
any other appropriate characteristic (as may any set of percentages
discussed herein).
[0076] The disclosure also provides articles formed from the
textiles disclosed herein. For example, the textiles may be
included in a clothing article. A clothing article may be a
garment, such as a shirt, a pair of pants, a pair of leggings, a
sweatshirt, a jacket, socks, and the like. A clothing article may
also be an undergarment, such as a pair of underwear or a bra.
Clothing articles, such as garments or undergarments, may be
suitable for use as activewear or sportswear. The textiles may also
be included in a footwear article, such as a shoe.
[0077] The textiles disclosed herein may also be included in other
types of articles. For example, the textile may be included in an
accessory, such as a tote bag, handbag, or drawstring bag. Further,
the textile may be included in a household good, such as a sheet, a
bath towel, a dish towel, a tablecloth, an upholstered furniture
article, and the like.
[0078] FIG. 7 shows an example of a shoe 700 including a composite
yarn as described herein. The composite yarn is included in knitted
textile 760. Shoe 700 can have a greater percentage of renewably
sourced materials than some conventional shoes due to the high
percentage of organic fibers and filaments in the composite yarn.
In addition, the shoe 700 can have a desirable appearance, "feel,"
and so forth due to the organic fiber(s) in the sheath of the
composite yarn.
[0079] As shown in FIG. 7, the knitted textile 760 is included in
the upper 710 of the shoe 700. In additional examples, the knitted
textile 760 may be included in other parts of the shoe 700, such as
the tongue 730 or the liner 770. As shown in FIG. 7, the shoe 700
also includes a sole 720, eyelets 740, and a lace 750.
[0080] FIG. 8 shows an example of a pair of leggings 800 which
includes a composite yarn as described herein. The composite yarn
is included in a textile 860 having a knitted structure. The
textile 860 has a stretch property due to the knitted structure. In
some embodiments, the knitted structure includes an elastomeric
yarn in addition to the composite yarn.
[0081] The textile 860 may be finely knit and may have a fine
gauge. The knitted structure of textile 860 can help provide
durability to the leggings 800. In addition, the knitted structure
of textile 860 can maintain opacity (e.g., prevent "show-through")
in areas which may be stressed by the movement or position of a
wearer, such as the knees or the seat of the leggings 800.
[0082] Leggings including the composite yarns disclosed herein can
have a greater percentage of renewably sourced materials than some
conventional leggings which are knit wholly from synthetic yarns.
Therefore, leggings including the textiles disclosed herein can
have a reduced environmental impact as compared to some
conventional leggings. In addition, the leggings 800 can have the
desirable appearance, "feel," and so forth due to the organic
fiber(s) in the sheath of the composite yarn. For example, wool
fibers in the sheath of the composite yarn can give moisture
wicking properties to the leggings.
[0083] FIGS. 9A and 9B illustrate sample garments formed from
composite yarns as disclosed herein. In particular, FIGS. 9A and 9B
illustrate socks that may be formed from any of the yarns described
herein, including combinations of various yarns described herein
and/or more conventional yarns (such as cotton or wool).
[0084] FIG. 9A illustrates a low-rise sock 900 including a heel
retaining feature 905, a front retaining feature 910, and an
elastic feature 915. Any or all of the body 916 of the sock 900
(e.g., the portion of the sock excluding the heel retaining feature
905 and front retaining feature 910), the front retaining feature
910, and the heel retaining feature 905 may be formed from any yarn
described herein. Further, different parts of the sock 910 may be
formed from different yarns. As one non-limiting example, the
elastic feature 915 may be formed from a yarn including lyocell and
wool, but having a greater percentage of spandex than the rest of
the sock 900. Likewise, the heel retaining feature 905 and/or the
front retaining feature 910 may be formed from a yarn having
lyocell and wool fibers, but in different percentages, or including
polyester and/or nylon (whether virgin or recycled) in different
percentages, than another portion of the sock 900. In this fashion
the heel retaining feature 905 and front retaining feature 910 may
be more durable, less (or more) stretchable, or otherwise have
different material properties than other parts of the sock 900. As
yet another example, portions of the sock may have different knit
or weave patterns than other parts of the sock. Different numbers
of ends, densities, stitches, or the like may be used to vary
material properties even if the same yarn is used throughout the
sock 900 (or throughout different portions of the sock, including
the retaining features 905, 910 and/or elastic feature 915). As one
non-limiting example, the knit or weave of the sock may vary in the
elastic feature 915 as opposed to the rest of the sock in order to
increase stretch in the elastic feature, thereby enhancing the
ability of the sock to remain in place on a wearer's foot without
unduly shifting.
[0085] FIG. 9B illustrates another example sock 920 that may be
formed from any suitable yarn described herein, or a combination of
yarns described herein, or one or more yarns described herein and
one or more of wool, cotton, and/or lyocell yarns. The sock 920
includes a calf retaining feature 925, a heel 930, and an elastic
portion 935. Here, the calf retaining feature 925 may be similar in
composition, structure, and/or other facets of construction as
either the front retaining feature 910 and/or heel retaining
feature 905 of the sock 900 illustrated in FIG. 9A Likewise, the
body 940 of the sock 920 may be made of the same or similar yarn as
the body 916 of the sock 900 and the elastic portion 935 may be
similar in composition, structure, or the like to the elastic
portion 915 of FIG. 9A.
[0086] The calf retaining feature 925 may be knitted, woven, or
otherwise formed in such a fashion that an elasticity of the
feature 925 is enhanced as compared to a body of the sock 920,
thereby permitting the sock 920 to stay "up" while worn. The yarn
used to form the calf retaining feature 925 may likewise be the
same as that of the body of the sock 920, or it may be made of the
same or similar fibers in different proportions. Typically,
however, the yarn itself is the same throughout the sock 920 (and,
for that matter, the sock 900) while the weave or knit pattern
varies and/or different yarns are added in particular areas such as
the retaining feature(s).
[0087] Likewise, the heel 930 may be reinforced or may be formed
from a yarn that is made from the same fibers as the rest of the
sock 920 but in different percentages to strengthen the heel
relative to the rest of the sock. In some embodiments, however,
this is not the case.
[0088] In certain embodiments, the yarn used to form the sock 900,
920 may vary with a shape, height, or structure of the sock 900,
920. For example, the sock 900 shown in FIG. 9A may be formed from
a yarn having the following fibers in the following percentages:
48% lyocell; 21% wool; 15% nylon (including recycled nylon); 8%
polyester (including recycled polyester); and 2% spandex. With
respect to the sock 920 shown in FIG. 9B, the yarn may be made of
the following fibers: 50% lyocell; 22% wool; 18% nylon (including
recycled nylon, such as 17% recycled nylon and 1% unrecycled
nylon); 8% polyester (including unrecycled polyester, such as 4%
recycled polyester and 4% unrecycled polyester); and 2% spandex. A
low-rise sock may be formed from a yarn made of the following
fibers: 47% lyocell; 21% wool, 18% nylon (including recycled nylon,
such as 17% recycled nylon and 1% unrecycled nylon); 12% polyester
(including recycled polyester, such as 6% recycled polyester and 6%
unrecycled polyester); and 2% spandex. As mentioned above, the
specific percentages given here may be by weight, density, volume,
or any other suitable measurement. Likewise, although particular
percentages have been provided, it should be understood that any or
all of the above percentages, with respect to any of the
embodiments, may vary by as much as 3% in either direction in
absolute terms, or by as much as 20% in relative terms.
[0089] Although some of the foregoing embodiments are discussed
with respect to compositions by weight, it should be understood
that the same percentages and ranges may apply to compositions by
volume, number, or density in other embodiments. This applies to
any and all of the embodiments, percentages, and/or ranges
disclosed herein.
[0090] As used herein, the term "substantially" or "about" is used
to account for relatively small variations, such as a variation of
+/-10%, +/-5%, +/-2%, or +/-1%. The term "substantially free" may
indicate an amount of 10% or less, 5% or less, 2% or less, or 1% or
less of the element specified. In addition, the singular forms "a,"
"an," and "the" include the plural form unless the context dictates
otherwise.
[0091] As used herein, the phrase "one or more of" preceding a
series of items, with the term "and" or "or" to separate any of the
items, modifies the list as a whole, rather than each member of the
list. The phrase "one or more of" does not require selection of at
least one of each item listed; rather, the phrase allows a meaning
that includes at a minimum one of any of the items, and/or at a
minimum one of any combination of the items, and/or at a minimum
one of each of the items. By way of example, the phrases "one or
more of A, B, and C" or "one or more of A, B, or C" each refer to
only A, only B, or only C; any combination of A, B, and C; and/or
one or more of each of A, B, and C. Similarly, it may be
appreciated that an order of elements presented for a conjunctive
or disjunctive list provided herein should not be construed as
limiting the disclosure to only that order provided.
[0092] The foregoing description, for purposes of explanation, used
specific nomenclature to provide a thorough understanding of the
described embodiments. However, it will be apparent to one skilled
in the art that the specific details are not required in order to
practice the described embodiments. Thus, the foregoing
descriptions of the specific embodiments described herein are
presented for purposes of illustration and description. They are
not intended to be exhaustive or to limit the embodiments to the
precise forms disclosed. It will be apparent to one of ordinary
skill in the art that many modifications and variations are
possible in view of the above teachings.
* * * * *