Note: Descriptions are shown in the official language in which they were submitted.
CA 02940707 2016-08-29
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COMPOSITE YARN WITH GLASS CORE
FIELD OF THE APPLICATION
pooq The present application relates to composite yarns
used in textiles and fabrics.
BACKGROUND OF THE ART
PM Textiles have evolved drastically for uses in
various applications, in which the textiles have technical
features enabling them to perform different protective
functions. For instance, textiles may be fire resistant, may
protect against electric arc, may be waterproof yet
breathable, may be puncture proof or rip proof, among numerous
other possible characteristics. Oftentimes, the textiles gain
their characteristics from the yarns or fibers that constitute
them.
NOM The challenge remains to offer textiles with such
protective features, while preserving other characteristics.
For example, garments made with textiles having such
protective features must remain as lightweight and flexible as
possible and thus not hamper free movements of the wearer.
Other characteristics apply to other applications as well. On
the other hand, the cost must also be factored in as an
important design factor in the choice of a yarn for protective
textile.
SUMMARY OF THE APPLICATION
[0004] It is therefore an aim of the present invention to
provide composite yarn having a glass core.
poq Therefore, in accordance with the present
application, there is provided a composite yarn comprising: a
glass core having a linear weight ranging between 50 to 400
deniers and composing from 15 to 60A of a total linear weight
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of the composite yarn; and a sheath surrounding the glass
core, the sheath constituted at least of fibers of meta-
aramid, the sheath constituting a remainder of the total
linear weight of the composite yarn; wherein the composite
yarn has a yarn count between 10 tex and 80 tex.
DESCRIPTION OF THE DRAWINGS
[0006] Fig. 1 is a cross section view of a composite yarn
with glass core according to the present disclosure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0007] Referring to Fig. 1,
there is illustrated a
composite yarn 10 in accordance with the present disclosure.
The composite yarn 10 is a composite textile yarn made of a
glass filament inside and various blend of fibers that will
provide cut-resistance, protect the integrity of the fabric
structure under flash fire, increase electric arc protection
compared to actual protective fabrics, while allowing the
yarn, or fabric to be dyed similarly to regular textile yarns.
The composite yarn 10 may be used as part of textiles and
fabrics, for any appropriate application, including non-
exhaustively clothing, protective garment, accessories,
upholstery, furniture material (e.g., plane seat covers) to
name but a few. The composite yarn 10 has a glass core 12 and
a sheath 14 surrounding the glass core 12. The sheath 14 may
also be referred to as wrapping, sleeve, cover, cladding, etc.
[0008] The glass core 12 serves as the structure or
backbone of the composite yarn 10. The glass core 12, by its
inherent properties, provides electrical arc protection, and
cut protection.
[0009] The sheath 14 covers the glass core 12, and serves a
different function than the glass core 12. In the embodiment
described below, the sheath 14 may be used for its flash fire
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resistance, and to provide the visual characteristics to the
composite yarn 10, for instance by being colored.
[0olo]
According to an embodiment, in order to provide
suitable electrical arc protection and tear resistance, the
glass core 12 is made of glass fiber filament of approximately
2.50 g/cm3 density + 0.45 g/cm3, with a linear weight ranging
between 50-400 deniers, such as E-glass (e.g., low alkali
alumino-borosilicate glass). The table below provides
examples of contemplated linear weight for the glass core 12,
along with yarn count minimum for the composite yarn 10:
GLASS FIBER FILAMENT
100 150 200 300 400
Linear weight (deniers) 50 deniers deniers deniers deniers
deniers deniers
Linear weight (tex) 5.5 11.0 16.5 22.0 33.0 44.0
Diameter -+1-53 urn +/-75 um +1-91 urn +/- 105 um
+/- 130 urn +/- 150 um
Yarn count minimum (tex) 9 18 27 36 55 73
Yam count minimum (Ne) 65.6 32.8 21.9 16.4 10.7 8.1
polq The
glass fiber filament as selected from the
parameters of the table will act as an electrical insulator
within the composite yarn 10. The linear weight ratio of the
glass core 12 in the composite yarn 10 is between 15%-60%,
relative to the sheath 14. This linear weight ratio is
selected to preserve the fabric integrity if a textile
composed of the composite yarn 10 is submitted to flames
during a flash fire and/or electrical arc discharge. The
proportion of 60% maximum for the core filament is to allow
enough staple fibers in the sheath 14 to cover the glass
filament of the core 12 inside for comfort and to preserve the
color shade of the fabric if applicable. The glass fiber
filament of the glass core 12 will help holding the blend of
fibers of the sheath 14 within the textile once the textile is
exposed to flames, due to its higher softening point, as
detailed below.
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[0012] The
sheath 14 is constituted of meta-aramid, and may
also incorporate additional different types of fibers, such as
para-aramid and/or modacrylic, among other possibilities,
which possibilities also include viscose (e.g., FR grade),
lyocell, etc, in addition to the meta-aramid. The
constitution of the sheath 14 depends on the desired
properties of the composite yarn 10.
[0013] The sheath 14 spun around the glass core 12 may contain
between 35% to 100% meta-aramid fibers, with or without para-
aramid fibers or blend of any ratio of meta-aramid/para-
aramid. The proportion of meta-aramid and glass content
combined must be above 45% of the total linear weight of the
yarn to provide sufficient flame resistance to the fabric.
Therefore, in a yarn with the lowest proportion of glass core,
i.e. 15% and the wrapping 14 of a blend of staple fiber
containing 35% meta-aramid, by calculation, a combined
proportion of glass and meta-aramid of approximately 45%
(44.75%), i.e., above 44%. Any other combination will provide
a higher proportion of the combination of meta-aramid and
glass. The meta-aramid (e.g., Nomexe, Conexe) is used for its
thermal resistance and chemical resistance. If
used, the
para-aramid (e.g., Kevlare, Twaron ) would increase the
tensile strength of the sheath 14.
Both the para-aramid
fibers and meta-aramid fibers could be greige (dyeable) fibers
or dope dyed fibers. It is also considered to use bale dyed
fiber, solution dyed fibers, dope dying before extrusion, or
greige fibers.
[0014]
According to an embodiment, modacrylic fibers or
other dyeable fibers such as FR viscose and lyocell are added
to the sheath 14 and provided at the surface of the composite
yarn 10, so as to allow the dyeing of the yarn 10, for example
in a high visibility color. The
modacrylic fiber has good
dyeing capability, but may start to degrade quicker than
aramid. However, the presence of glass filament as the glass
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core 12 compensates for the lower strength of the modacrylic
fiber, such that the presence of modacrylic may have little or
no effect on the fabric integrity when constructed as in
Fig. 1. The mix of fiber spun around the filament may contain
between 5% to 30% modacrylic fiber with an LOI (Limited Oxygen
Index) of 22 or more.
[0015] For
example, by combining a given proportion of
modacrylic fiber to the meta-aramid fibers in the sheath 14 of
the composite yarn 10, high-visibility color may be attained
while preserving fire resistance, which color cannot be
obtained with regular yarn made of aramid or aramid/modacrylic
that will withstand similar performance in a flash
fire/electrical arc discharge. The dyeing could be done in
yarn form or in fabric form. Both methods may work with the
composite yarn 10.
[0016] As
yet other possibilities, the mix of fibers of the
sheath 14 around the glass core 12 may contain between 0% to
10% antistatic fiber, such as carbon in a polyester or nylon
matrix (e.g., Beltrone).
poln The
presence of the glass core 12, with its
softening point generally above 700 Celsius (1292
Fahrenheit) remains its integrity when fibers of the sheath 14
may start softening.
Moreover, if E-glass type filament is
used as glass core 12, the softening point may be at
approximately at 846 Celsius (1555 Fahrenheit) For example,
a blend of aramid fibers starts decomposing between 427-482
Celsius (800-900 F), while modacrylic fibers start decomposing
at 250 Celsius (482 F). Accordingly, the glass core 12 holds
up the integrity of a textile of the composite yarn 10 and may
therefore protect the wearer for a longer time than fire-
resistant fabrics made mostly of aramid fibers.
gmlq The
yarn count for the composite yarn 10 constituted
of the glass core 12 and sheath 14 as described above may be
between 10 tex and 80 tex. The
composite yarn 10 could be
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,
plied in normal twisting textile processing to create coarser
and stronger yarns counts, as desired. It is to be noted that
the splicing of two ends of core glass yarn could be
problematic and could result in a weak spot. Hence, the sheath
14 around the core 12 will strengthen the splice of glass core
12. The yarn integrity will also have to be monitored so that
the sheath 14 of staple fiber becomes intermingled with the
glass core 12 to avoid any undesirable slip of the sheath 14
over the glass core 12. This may result in an undesired
exposure of the glass core 12.
[0019]
An example of a composite yarn 10 composition of the
type that can be dyed is provided below, for a 26.8 Ne yarn
count/2 ply composite yarn 10, or for a 13.4 Ne yarn count/1
ply composite yarn 10. The sheath 14 is constituted of 56.3%
meta-aramid, 3.7% para-aramid, and 15% modacrylic with orange
dye, while the 50 deniers glass core 12 represents 25% of
composite yarn 10.
[0020]
Further examples are provided below, to illustrate
the proportion of the constituents of the composite yarn 10
for different yarn counts.
It is possible to select the
constituents of the composite yarn 10 so that certain
characteristics of the textile or fabric would be enhanced,
based on the contemplated use of the garment featuring the
textile. For example, to increase the cut-resistance of the
fabric, the mass of glass in the core 12 may be increased. For
example, the composite yarn 10 may include a 100 deniers glass
filament instead of a SO deniers glass filament, effectively
doubling the linear weight of the glass in the fabric. As a
result, the increased liner weight of glass may improve the
cut-resistance performance of a fabric with such glass
filament. In a similar fashion, the ratio of constituents of
the composite yarn 10 could be adjust to improve the
electrical arc performance, as an example. The electrical arm
performance may be improved by increasing the linear weight of
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glass into the yarn 10, and/or adding to the sheath 14 a
portion of modacrylic fiber. If
the time required for the
textile of composite yarn 10 to self-extinguish is critical, a
blend could be selected to increase the level of meta-aramid
in the sheath 14. Hence, the proportion of constituents of
the composite yarn 10 may be chosen to hit specific
performance standards, or to optimize the performance of the
garment depending the contemplated use or need.
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Example 1 Exemple 2
If yarn is 22tex (26.8Ne) and a 5.5 tex Glass filament is If yarn
is 44tex (13.4Ne) and a 11 tex Glass filament is
used used
Yarn count 22 tex Yarn count 44 tex
Mix of fibers Mix of fibers
In the finalIn the final
Description before core glass Description before core glass
yarnyarn
spinning spinning
Glass filament 5.5tex- 25.0% Glass filament 11tex - 25.0%
M-Aramid 75.0% 56.3% M-Aramid 75.0% 56.3%
P-Aramid 5.0% 3.8% P-Aramid 5.0% 3.8%
_
Modacrylic 20.0% 15.0% Modacrylic 20.0% 15.0%
Antistatic 0.0% 0.0% Antistatic 0.0% 0.0%
TOTAL 100.0% 100.0% TOTAL 100.0% 100.0%
Example 3 Example 4
If yarn is 25tex (24Ne) and a 11 tex Glass filament is used If yarn
is 50tex (11.8Ne) and a 22 tex Glass filament is
Yarn count 25 tex Yarn count 50 tex
Mix of fibers Mix of fibers
In the finalIn the final
Description before core glass Description before core glass
yarnyarn
spinning spinning
Glass filament lltex - 44.0% Glass filament 22tex
- 44.0%
M-Aramid 74.0% 41.4% M-Aramid 74.0% 41.4%
P-Aramid 5.0% 2.8% P-Aramid 5.0% 2.8%
Modacrylic 20.0% 11.2% Modacrylic 20.0% 11.2%
Antistatic 1.0% 0.6% Antistatic 1.0% 0.6%
TOTAL 100.0% 100.0% TOTAL 100.0%
100.0%
Example 5 Example 6
If yarn is 25tex (24Ne) and all tex Glass filament is used If yarn
is 50tex (11.8Ne) and a 22 tex Glass filament is
Yarn count 25 tex Yarn count 50 tex
Mix of fibers Mix of fibers
In the finalIn the final
Description before core glass yarn Description before core
glass
yarn
spinning spinning
Glass filament lltex - 44.0% Glass filament 22tex
- 44.0%
M-Aramid 70.0% 39.2% M-Aramid 70.0% 39.2%
P-Aramid 0.0% 0.0% P-Aramid 0.0% 0.0%
Modacrylic 30.0% 16.8% Modacrylic 30.0% 16.8%
Antistatic 0.0% 0.0% Antistatic 0.0% 0.0%
TOTAL 100.0% 100.0% TOTAL 100.0%
100.0%
Example 7 Example 8
If yarn is 25tex (24Ne) and all tex Glass filament is used If yarn
is 50tex (11.8Ne) and a 22 tex Glass filament is
Yarn count 25 tex Yarn count 50 tex
Mix of fibers Mix of fibers
In the finalIn the final
Description before core glass Description before core glass
yarnyarn
spinning spinning
Glass filament 11tex - 44.0% Glass filament 22tex
- 44.0%
M-Aramid 100.0% 56.0% M-Aramid 100.0% 56.0%
P-Aramid 0.0% 0.0% P-Aramid 0.0% 0.0%
Modacrylic 0.0% 0.0% Modacrylic 0.0% 0.0%
Antistatic 0.0% 0.0% Antistatic 0.0% 0.0%
TOTAL 100.0% 100.0% TOTAL 100.0%
100.0%
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